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FINAL DESIGN > Exam metal processes > Flashcards

Exam metal processes Flashcards

1
Q

types of stamping or pressing

A

piercing
blanking
notching
croppig
hending
forming

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2
Q

what piecing

A

where suitable punch shears a whoole in piece of metal

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3
Q

what is blaking

A

where punch shears the required shape from metla

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4
Q

what is cropping

A

where pucnh shears a plain or shaped length

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5
Q

what is bedning

A

where shit bent

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6
Q

what formig

A

where metal ks forced into the shape of the surface contous of a die

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7
Q

hwo press formign etc etc work

A

hydralich press just stamps whoels into shit
or forces into a shape
or forces around a jig, which bends it

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8
Q

formign step by step

A

sheet prepped
sheet stamped, formed , with hydralich press

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9
Q

how bendign work

A

aroudna die

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10
Q

when a sheet has a whoel or shape in it what is it called

A

piecing

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11
Q

when a sheet has a hole or bit fo metal taken out what is it called

A

blanking

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12
Q

what are majroity fo press related oepartings confiend to

A

large batch production

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13
Q

why majority fo press related shit left to large batch prod

A

high costs
length tool settign up involbed

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14
Q

what can be used to maxamsisie and economies press formign

A

cnc to work out best nesting of shapes etc

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15
Q

types of preses

A

arbor press
fly press

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16
Q

what is arbor pressing

A

hand operated shit

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17
Q

what is fly press

A

heavy iron frame
square ram
big release
boom

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18
Q

pros of balankign and peircing

A

many sahpes
any metal
high accuracy

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19
Q

cons fo blankign and peircing

A

restrcite to metal sheets
limited to size of stcok meteriasl
can be high waste

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20
Q

what press forming (booklet)

A

sheet metals loaded into press
clamped togheter
inblank holder
pucnh forces metal throguh die to take shape of punch

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21
Q

pros of pres formign (bookelt)

A

3d shapes
icn stiffness
carried otu at room temo
high to med vol
seamless sheets in one go

22
Q

cons of press formign (booklet)

A

high tooling costs
high levels of force needed

23
Q

what sand castin

A

low cost method of castign emtal in sand mould
s

24
Q

scale of sand cast

A

one off or low volume production

25
Q

step by step of sand castin

A

pattern palced in box
box filled with sand
sand solidifies
sprue channels are made
pattern rremoved
top mould half doen same process
moulds put on top of eahcother, lcoator pins for alignment
molten metalin
finish

26
Q

what to ensure there is on sand cast diargam

A

vents
sprue channels
parting pwoder between the moulds
slightly larger pattern than required

27
Q

adv of sand castign

A

low cost
easy to opertate
intircate parts
flexibel levels of production

28
Q

cons fo sand casting

A

moudl remade for every part
overall accuracy is poor
parts need finising

29
Q

is high pressure diecastign economical

A

yes

30
Q

how die castign work

A

molten metal poured into champer
piston or plunger forces metal at high pressure into caviy
pressure kept utnilshti solidifies
inejctor pins push out compoenents

31
Q

what die castign diragam look lie

A

inj mould
put instead of scre its plunger that pushs metal into die

32
Q

pros of die castign

A

re use moulds
no finsihign really
accurate
fast
small thin parts

33
Q

cons of die castign

A

expensive
can have weak strcutrue in parts
can nneed soem extra finsiing

34
Q

why steels and ferrous metals nto used in die castign

A

need high temp to metl them , whcih can damage moudls and accuracy leveels

35
Q

what gravity die castign

A

permanent metl die
metal poured in
let gravty do its thing

36
Q

why pressure die castign give better quality than gravity

A

presssure contstantl pushign emanign good contact with the die costantl

37
Q

what to make sure on die cast drawing

A

soem form fo coolign system

38
Q

what millign

A

removal of material using mutli tooth cuttign shit

work piece is secured to the bachine and then fed udner the cutter

39
Q

what moves on milling machien

A

the bed

40
Q

what millign allow for

A

rapid removal fo material

slots
steps

41
Q

what plasma cuttign

A

stream of ionisied gase which ebcomes so hot it vaporises metal cut

42
Q

materials used in palsma cutting

A

any electrically conductive etal
commonely stainelss steel or alimiunm

43
Q

pros of plasma cutting

A

good for small natches
clean cuts

44
Q

cons of palsma cutting

A

nto good for thin metals
very enegery intesive
high wastage when hand hel

45
Q

how sinterign work

A

material curshed to pwoeder
powder comapcted in die
compacted shape then heated
partciles bond

46
Q

brazign step by step

A

metal cleaned
flux brushed along joint to prevent oxidisation
pressures gas fed through nozzle and lighted
joint heated with flame until piping
rod pushed aginst until melted

47
Q

addv of brazing

A

low cost
not effect that host mateiral really
strong bond
no need for 2ndary finishig
complex and itnricate joitns achieved
shit can eb dismantled and rejoine d
all scales of production

48
Q

cons of brazing

A

cna be time consuming

49
Q

maetriasl sued in brazing

A

copper
steel
silver rod

50
Q

how tig welding work

A

tig generates heat via an arc of electicity jumping from tunsgtene metal electrode to metal you intned to world

heat melts edges

flux is used

51
Q

adv of tig welding

A

uses electric current
reduces sparks and shit
less contamination
no toolign costs

52
Q

dis adv fo tig

A

high set up tiem
skilled process
expensive
complex

FINAL DESIGN (43 decks)

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