16-Metal Processes Flashcards

1
Q

What are the three types of metal processes?

A
  • Forming
  • Redistribution
  • Wasting
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2
Q

Metal Processes - Press Forming

A
  • Metal sheet placed over die
  • Press will be lowered to form the sheet to the die
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3
Q

Metal Processes - Spinning

A
  • Used to form sheet metal into round objects such as a kettle
  • Sheet metal is spun while rollers push the sheet metal to form around the shape of the mandrel
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4
Q

Metal Processes - Cupping and Deep Drawing

A
  • Forms Tube shaped shapes for example a fire extinguisher
  • Uses metal blank stock form
  • This is held over a cavity and pressed down by a deep drawing punch to form the shape
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5
Q

Metal Processes - Drop Forging

A
  • A lower die placed on top of an anvil and an upper die on the end of the Ram
  • A heated metal billet will be placed onto the lower die, it will be heated to just above its recrystallisation temperature
  • Ram will lower onto the billet to form the metal to the desired shape
  • Makes products like spanners
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6
Q

Metal Processes - Wrought Iron Forging

A
  • Metal is heated and then hammered, bent, and rolled into its correct shape
  • Only works for Iron with a carbon content of less than 0.08%
  • Will usually use a bar stock form
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7
Q

Metal Processes - Bending

A
  • Sheet metal placed over a V shaped die
  • Punch will then lower to push the sheet metal into the V forming an edge
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8
Q

Metal Processes - Rolling

A
  • Thicker metal will go through rollers which will compact and thin out the metal
  • This can be done hot or cold
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9
Q

Metal Processes - Sand Casting

A
  • Mould created in sand
  • Molten metal will be poured into the mould and left to cool
  • Used on metals with high melting points
  • Labour intensive and doesn’t produce a high quality finish on the metal
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10
Q

Metal Processes - Die Casting

A
  • Molten metal from a billet is poured into a die
  • This will usually rely on gravity for the metal to take the shape
  • Used with metals with lower melting point like aluminium
  • Often used to make door knobs
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10
Q

Metal Processes - Investment casting

A
  • exact replica of model is made in wax
  • This is then submerged in refectory clay, and placed in a kiln
  • This melts the wax, leaving a perfect mould within the clay
  • Molten metal is then poured into the mould and left to cool
  • This is mainly used for intricate designs like jewellery
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11
Q

Metal Processes - Low Temperature Casting (Pewter)

A
  • Two piece mould made out of MDF usually will be clamped together
  • Molten pewter then poured into the mould and left to dry
  • Used mainly in schools for one off production
  • Used to make small decorative items
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