Dt a level edexcel- Machining processes - Sheet1

Question 1

Name all 5 processes

Answer 1

Milling/routing, drilling, stamping, pressing, turning

Question 2

What is the process for drilling?

Answer 2

Making holes using a rotating cutting tool, often a twist drill, in a hand-operated drill or drilling machine.

Question 3

What are the applications of milling/routing?

Answer 3

Cutting slots in materials.

Question 4

What are the characteristics in milling/routing?

Answer 4

Precision cutting with a rotating cutter.

Question 5

What are the advantages and disadvantages of milling/routing?

Answer 5

+Versatile for various materials.
- Limited to specific materials.
- Requires different cutters.

Question 6

What are the applications of drilling?

Answer 6

Creating holes in various materials.

Question 7

What are the characteristics of drilling?

Answer 7

Uses a rotating cutting tool secured in a drill or machine.

Question 8

What are the advantages and disadvantages of using a drilling process?

Answer 8

+Efficient hole creation in different materials.
- Limited to hole-making.
- May not suit all shapes.

Question 9

What is the process of turning?

Answer 9

Performed on a metalworking or woodturning lathe. Mark on the centre of the wood so that the inside spindle and the tailstock can hold the timber. Dead centre is positioned right on the points marked. Headstock spins the timber. Chisel and roughing tools are used and held (using the tool rest to support it) by the operator close to the wood to chisel away wood, forming its desired shape.

Question 10

What are the applications of turning?

Answer 10

Smoothing material ends and reduces material diameter.

Question 11

What are the characteristics of turning?

Answer 11

Rotational movement shapes material.

Question 12

What are the advantages and disadvantages of turning?

Answer 12

+Versatility in shaping.
+ Applicable to metal and wood.
- Limited to rotational symmetrical shapes.

Question 13

What is the process of stamping?

Answer 13

Uses a die with a stamping press to cut, emboss, or bend sheet metal into blanks or nets.

Question 14

What are the applications of stamping?

Answer 14

Producing items from flat blanks of aluminum, stainless steel, copper, and zinc.

Question 15

What are the characteristics of stamping?

Answer 15

Die-based metal manipulation.

Question 16

What are the advantages and disadvantages of stamping?

Answer 16

+Efficient for mass production.
- Limited to sheet metal.
- Setup costs for dies.

Question 17

What is the process of pressing?

Answer 17

Linked with stamping, forming flat metal pieces into more complex products.

Question 18

What are the applications of pressing?

Answer 18

Creating complex metal shapes such as pans or car panels.

Question 19

What are the characteristics of pressing?

Answer 19

Transformation of flat pieces into three-dimensional forms.

Question 20

What are the advantages and disadvantages of pressing?

Answer 20

+Enables production of complex shapes.
- Thickness of the metal sheet limits the process.

Question 21

Tips on how to tell which process should be used?

Answer 21

Understand a material’s compatibility, precision requirements, and shape complexity.

Question 22

Choose the appropriate process for each material:

Answer 22

Choose milling for metal cutting, routing for wood/plastics, drilling for holes, turning for rotational symmetry, stamping for flat blanks, pressing for complex shapes.

Question 23

What should be evaluated when choosing a process?

Answer 23

Evaluate based on material, production volume, and required precision to make informed choices.