Forming processes

Question 1

Press forming

Answer 1

used to shape metal into 3D forms. Metals such as medium carbon steel and aluminium as they are more ductile and malleable. Only used in mass or large scale production.

Question 2

Spinning

Answer 2

Used tor shaping products such as the body of stainless steel kettles, sauce pans or other product with radial symmetry. Involves spinning the sheet of metal at high speed as it is pushed over a former or mandrel. Typically used in mass and large scale production. can be set up using computer controlled design to create identical products.

Question 3

Cupping and deep drawing

Answer 3

Process used to form tube like shapes such as fire extinguishers and aerosol cans. The punch has rounded corners to stretch the metal rather than shear it.

Question 4

Drop forging

Answer 4

Used to shape hot metal into finished products. Manufacturers use this process when the finished products needs to be tough and hard. Spanners and screwdrivers are common products made using this process. Drop foreign allows for the metal to maintain the internal grain allowing it to keep its toughnesses and hardiness. Commonly used in mass production to high set up costs.

Question 5

Wrought iron forging

Answer 5

Iron with a low carbon content of < 0.8% making ir more malleable, suitable for hammering into shapes. Wrought iron is heated in gas or coke-fired forge. t is then shaped by hammering over an anvil or using other tools such as scroll formers or twisting bars.

Question 6

Bending

Answer 6

Bending sheet or plate metal. Desired bends are achieved by clamping the stock metal between matching punch and die. Modern press brakes use a device known as a back gauge to accurately position the metal. It can be used for one-off production but generally used in large scale production.