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A Level Product Design > 3 Processes, Techniques and Specialist Tools > Flashcards

3 Processes, Techniques and Specialist Tools Flashcards

1
Q

What is heat treatment?

A

Heat treatment is the controlled heating and cooling of metals in order to alter their physical and mechanical properties without changing the products shape.

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2
Q

Why are heat treatments carried out?

A

In general, heat treatments are carried out to: Increase the strength of the material, allow the material to be machined and help to increase ductility

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3
Q

Describe the hardening process.

A

The hardening process takes place by heating the metal to the required temperature and then cooling it rapidly by placing the hot metal into a liquid, such as oil or water. The hardening process increases the hardness and strength of the metal but also increases its brittleness.

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4
Q

What are the applications of hardened materials?

A

Machine cutting tools, Construction materials, Knife blades, Armour plating

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5
Q

What is tempering and when does it occur?

A

Tempering occurs after the metal has been hardened as this process relieves the internal stresses and reduces the brittleness in the metal. After the metal has been hardened, tempering consists of heating the metal to a specific temperature and then cooling the metal in still air.The higher the tempering temperature, the softer the metal.

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6
Q

Advantages of tempering.

A
  1. Tempering can be used to alter the physical properties of the metal, e.g. decrease hardness whilst increasing toughness.
  2. Removes brittleness from materials
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7
Q

Disadvantages of hardening.

A
  1. Tempering is required after most processes of hardening.
  2. The product has to be cleaned so that the colours can be seen.
  3. If the metal has a carbon content below 0.4%, it cannot be hardened.
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8
Q

What is case hardening?

A

Case hardening is the process of hardening the surface of a metal, often low-carbon steel, by infusing elements into the material’s surface, forming a thin layer of a harder alloy.

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9
Q

What are the applications of case hardened metals?

A
  • Components that are subjected to severe impact and high pressures
  • Firearms
  • Drill parts
  • Gears
  • Screws
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10
Q

Advantages of case hardening.

A

Only the external surface can be hardened, leaving the centre core quite soft in comparison to the ‘case’. This helps to reduce the brittleness of the part, whilst retaining its hardness.

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11
Q

Disadvantages of case hardening.

A

Process has to be repeated several times in order to make a significant difference. This therefore takes up a lot of time and increases the cost for the process.

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12
Q

What is work hardening and when does it occur?

A
  • Work hardening is when a non-ferrous metal is bent, hit or shaped over a period of time, also known as cold worked. This results in the metal becoming extremely hard and brittle, increasing the risks of the material fracturing.
  • Work hardening can also occur where metal is cold rolled or cold drawn.
  • Heat treatments are usually required when work hardening occurs unless it is used for decorative purpose
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13
Q

Why are metals annealed?

A

Metals are annealed to reduce internal stress, increase ductility and reduce hardness.

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14
Q

How are metals annealed?

A

Metal is annealed by heating it to a certain temperature and then holding it at that temperature for the required time. The material is then cooled back to room temperature. The rate at which metal is cooled from the annealing temperature can vary due to different materials that require different annealing processes.

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15
Q

What are the applications of annealed metals?

A
  • Metal wire drawn into a smaller size
  • Sheet metal that has been work hardened
  • Machining operations that have been exposed to high temperatures
  • Welded components
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16
Q

Advantages of annealing.

A
  • Annealing restores ductility which allows additional processing to take place without cracking the material.
  • Releases mechanical stresses that can occur from machining, which prevents distortion during higher temperature heat treatments.
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17
Q

Disadvantages of annealing.

A
  • Surface produces a scale when being heated and cooled, which is difficult to clean.
  • Long cooling times
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18
Q

The process of annealing aluminium.

A
  • Aluminium has a low melting point and does not change colour
  • Danger of metal melting
    apply soap as temperature indicator
  • Heat aluminium until soap turns black
  • Remove aluminium from heat source
  • Cool under running cold water
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19
Q

The process of annealing copper.

A
  • Heat until a dull red
  • Remove copper from heat source
  • Allow copper to cool down in air or quench
  • Place in acid bath to remove oxides
  • Remove acid from work by placing in cold running water
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20
Q

Why are metals normalised?

A

Metals are normalised to relieve the internal stresses that have been produced by machining, forging or welding.

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21
Q

How are metals normalised?

A

The normalising process takes place by heating the metal to a specific temperature and then soaking the metal until the entire material is at an equal heat, and then left to cool in still air.
Undertaken on non ferrous metals that have become hardened in order to return them to unhardened state

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22
Q

What are the differences between annealing and normalising?

A

The main difference between the annealing and normalising process is that normalised products are much harder and stronger, whereas the annealing process aims to get the metal as soft as possible.

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23
Q

What are the applications of normalised metals?

A
  • Automotive industry
  • Nuclear industry
  • Normalising can take place on iron or nickel-based alloys, copper, brass or aluminium.
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24
Q

Advantages of normalising.

A
  • Refines the grain, which results in a harder metal with added strength
  • Higher surface quality is achieved after normalising process
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25
Q

Disadvantages of normalising.

A

The cooling rates may vary at different depths meaning the structure will be dependent on the thickness of the metal.

26
Q

What is an alloy?

A
  • Alloys are made up of 2 or more metals and occasionally other elements in order to produce a metal with enhanced properties.
  • In order to create an alloy, the metals and elements are melted down in a precise combination to form a specific material.
27
Q

What are the benefits of alloying?

A

Alloying can give a material enhancements like making a material more rigid (different elements have different sizes of molecules meaning that the layers of atoms can’t slide over each other as easily when being bent) or electric conductivity (done by adding copper to the material to carry charge) just to name a few.

28
Q

What is an example of an alloy?

A

An example of an alloy is stainless steel which is a combination of steel mixed with chromium, nickel, molybdenum, silicon, aluminum, and carbon. This creates a material that is very hard and scratch resistant, thus the name stainless steel.

29
Q

What is sand casting?

A

When molten metal is poured into a sand mould. Once the metal is solid the sand is broken away

30
Q

Describe the process of sand casting.

A
  1. A mould is made using sand set around a MDF model of the eventual product (Bigger than the final metal product due to contraction of metal) and once set the MDF is carefully removed, not breaking the sand
  2. The sand mould can be either left to dry and harden or coated in a varnish to seal and protect it
  3. Gates and channels are created into the sand so the molten metal can reach the mould
  4. The metal is heated and any impurities are removed before its slowly poured into the mould
  5. Once the metal cools and set its taken from creases and runners are removed using a hacksaw
31
Q

What are the applications of sand casting?

A

It’s often used for applications such as Garden furniture and parts in engines

32
Q

What is die casting and when can it be used?

A

An efficient method used to produce a wide range of metal (usually non-ferrous) shapes to a high accuracy and with a good finish. Die castings are used often in many different products, including toy cars or parts in real vehicles.

33
Q

The process of pressure die casting.

A
  1. The mould is sprayed with a lubricant to help control the temperature of the die and to remove the finished casting.
  2. Molten metal is shot into the die under high pressure.
  3. Pressure is maintained when the die is filled and the metal is solidified
  4. Once solid, the die is opened and the product is removed by ejector pins.
34
Q

The process of gravity die casting.

A

Mostly follows the same steps as pressure die casting, however the molten metal is poured into the mould and gravity helps it to flow around the mould.

35
Q

The process of using resin in casting.

A
  1. A silicone mould is made of the product.
  2. A two-part resin is mixed and poured into the mould.
  3. The simplest method is to use gravity to pulled down the resin into all the parts of the mould.
  4. Shake the mould to eliminate air bubbles.
  5. Once set the solidified resin is removed from the mould to give the finished product.
36
Q

What are the uses of resin?

A

It is often used for small-scale production such as industrial prototypes and dentistry as it enables the casting of intricate designs.

37
Q

What is Plaster of Paris?

A

A hard white substance made by adding water to gypsum (powered and dehydrated). It can set at up to 60ºC.

38
Q

What are the uses of Plaster of Paris?

A

Used for casts when you break a bone and sculptures. It is also used as a protective layer on ceilings and walls & to give aesthetic finishing touches to buildings.

39
Q

Advantages of Plaster of Paris.

A
  • Lightweight
  • More durable
  • Low thermal conductivity
  • Good heat insulating material
  • Doesn’t shrink whilst setting
  • Easily moulded into any shape
  • Colours can easily settle in it
40
Q

Disadvantages of Plaster of Paris.

A
  • Not suitable for exterior use as slightly soluble in water
  • More expensive than cement
  • Can’t be used in a humid environment
  • Labour costs are high
41
Q

What is a CNC router?

A

A CNC router is a computer-controlled cutting machine used for cutting materials, such as wood, composites, aluminium, steel, plastics, glass, and foams. … Instead of routing by hand, tool paths are controlled via computer numerical control.

42
Q

What are the uses of a CNC router?

A

-Used for block modelling (styrofoam)
-Can cut 3d shapes.

43
Q

Handheld router vs a CNC router?

A

A handheld router is a more cost effective option compared to the CNC router however, as it controlled by a human rather than being controlled a computer there is a higher chance of inaccuracy.

44
Q

What is a CNC Milling Machine?

A

A CNC milling machine can be fitted with tools and drill holes and work in a similar way to a router.It is a tool to do rotary motion, so it is suitable for processing some linear motion of the workpiece. Milling is the process of cutting away metal by feeding a piece of work through a rotating cutter.
Routing is a similar process but usually associated with wood, composites and plastics. Both of these process are used to cut slots into a material.
There are 2 types of milling machines - vertical and horizontal

45
Q

How does a vertical milling machine work?

A

Vertical is similar to a pillar drill but instead has a rotating cutter that can be raised and lowered. Work is clamped into the table below cutter which can move in order for metal to be cut along or across and at a desired depth.

46
Q

How does a horizontal milling machine work?

A

Horizontally, the work is clamped into the table that can move in 2 directions. Work must be moved in opposite direction to rotation of cutter. Work must also be securely fastened and lined up to cutters.

47
Q

What is a wood lathe and how does it work?

A

It is a tool used to form a piece of wood into a desired shape.

A piece of wood is attached to a spinning arm and tools are used to shape the piece of wood

48
Q

What precautions need to be taken during the set-up and use of a wood lathe?

A

Wood working lathe - set up
- Secure wood in chuck
- Ensure timber is free of knots

Wood working lathe - use
- Tool is hand held
- Ensure cutting tool is positioned on top of the tool rest
- Carefully move along the work

49
Q

What are the two basic processes of turning in lathe work?

A
  1. Facing off - Smoothing the end of a piece of material
  2. Turning down - Reducing the diameter of a piece of material
50
Q

What are the two types of chuck in lathe work?

A
  1. 3 jaw self centering - used for round or hexagonal bars
  2. 4 jaw - used for any cross sections
51
Q

What precautions need to be taken during the set-up and use of a metal working lathe?

A

Metal working lathe - set up
- Work secured in chuck
- Align tool with work
a. If too high - cuts inefficiently and tool will snap, become dull quickly or damage
b. If too low - will attempt to ride up the tool and will snap the tip of the tool

Metal working lathe - use
- Cutting tool is attached to tool post
- Tool post moved by hand wheels

52
Q

What is metal stamping?

A

Metal stamping is a manufacturing process used to convert flat metal sheets into specific shapes.

53
Q

What techniques are used in metal stamping?

A
  • Blanking
  • Punching
  • Bending
  • Piercing
54
Q

Advantages of metal stamping?

A
  • High quality
  • Low cost
  • Fast production time
55
Q

What is pressing?

A

Pressing is used to alter the shape of a metal sheet without breaking the metal, unlike stamping which involves piercing, banking and punching the metal.

56
Q

Pressing vs Stamping - Uses

A

Stamping is generally used if an entire sheet is being shaped while pressing is used mainly on individual pieces.

57
Q

What are the two types of drill bit and their uses?

A
  • Parallel shank and Taper shank
  • Parallel shanks are held into the drill by a chuck
  • Whereas, taper shanks are placed directly into drill and held by friction
58
Q

What is a twist drill bit used for?

A

Used to drill accurate holes into wood, metals, and plastic

59
Q

What is a forester drill bit used for?

A
  • Used to drill flat bottomed holes into wood
  • Used with a pillar drill
60
Q

What is a hole drill bit used for?

A
  • Used to create round holes
  • They are more efficient than traditional drill bits.
61
Q

What is a countersink drill bit used for?

A

Used to make sloping (conical) holes to hide the head of the of wood screws.

62
Q

What is a flat drill bit used for?

A
  • Used to cut deep holes in wood.
  • This drill bit removes the wood chips quickly

A Level Product Design (4 decks)

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