Forming

Question 1

Drop forging

Answer 1

For metals
For complex shapes-greater strength and toughness than casting
High tooling cost, high speed, low unit cost

Question 2

Sand casting

Answer 2

Metals with a high melting point-cast iron
Large components with complex shapes, poor surface finish
Low tooling cost, low speed, medium unit cost

Question 3

Die casting

Answer 3

Metals with low melting points-brass, aluminum
Small to medium sized complex shapes, good surface finish, good dimensional accuracy
High tooling cost, high speed, low unit cost

Question 4

Investment casting

Answer 4

Metals with high melting point- titanium
Small to medium sized highly complex shapes, excellent surface finish and dimensional accuracy
Medium tooling cost, low speed, medium unit cost

Question 5

Extruding

Answer 5

Metals with high ductility (aluminum), thermoplastic polymers
Used for forming long lengths with constant cross sectional area
Medium tooling cost, high speed, low unit cost

Question 6

Injection moulding

Answer 6

Thermoplastic polymers- ABS
Small to medium sized highly complex shapes, excellent surface finish and dimensional accuracy
High tooling cost, high speed, low unit cost

Question 7

Compression moulding

Answer 7

Thermosetting polymers (UF)
Small to medium sized complex shapes, good surface finish, good dimensional accuracy
Medium tooling cost, medium speed, medium unit cost

Question 8

Folding

Answer 8

Sheets of thin ductile metals- aluminum/mild steel
Simple folds using block and blade press tooling
No special tooling cost, medium speed, medium unit cost

Question 9

Bending

Answer 9

Bars/rods of ductile metals- mild steel, aluminum
Simple bends achieved on roll bender using general purpose tooling
No special tooling cost, medium speed, medium unit cost