forming processes

Question 1

lamination (clamp)

Answer 1

bonding materials together which are typically wood veneers like 3mm plywood
glued together and bent over a former
held in place while drying

Question 2

lamination (vacuum bagging)

Answer 2

vacuum bagging the former and veneers are placed under a polythene sheet
the edges of the sheet are taped down to the table a valve is fitted to the polymer and a vacuum pump sucks out the air = pressure

Question 3

steam bending

Answer 3

combined heat and steam enables strips of timber to be made pliable so they can be shaped over a former held in
putting timber into a steam box where the timber will absorb the steam then bent over.
quicker

Question 4

sandcasting

Answer 4

form high melting point metals into components and products
normally carried out in foundries
one off or batch production
not a high quality finish

Question 5

sandcasting process

Answer 5

1. pattern is made from wood
2. drag is turned over and a second box called the cops is clamped into position over the top of the drag sprue and runner is added
3. sand is packed into the cops around the runner riser and pattern a small depression is made on the surface around the sprue to make a pouring basin
4. cope and drag are separated, stakes and patterns are carefully removed, connecting channels are cut to join
   cope and drag reassembled
   5 vent holes
   6 metal poured into pouring basin down the runner
   once cooled removed

Question 6

die casting

Answer 6

lower melting point metals like aluminium uses tool steel moulds which are reusable only used in large and mass production
high quality surface finish

Question 7

gravity die casting

Answer 7

melting the metal and then pouring into the mould which relies of gravity with a runner and a riser
thicker or heavier sections

Question 8

pressure die casting

Answer 8

produce cast items quickly and in high volumes

Question 9

hot chamber pressure die casting

Answer 9

morels metal is stored in a chamber which is part of the machine a pneumatic and hydraulic pinger forces a shot of molten metal through the neck into the die all filled allowing fine detail
aluminium not used

Question 10

cold chamber pressure die casting

Answer 10

molten metal is kept separetly in a melting crucible and then ladled into the shot chamber a ram forces the metal into the mould

Question 11

investment casting
lost wax casting

Answer 11

cast items that are intricate or awkward shapes
difficult to mould in other places
cast jewellery
stainless steel brass aluminium

Question 12

investement casting process

Answer 12

1 excellent replica of cast is made in wax
2 wax pattern is dip coated with a refractory clay then fired in a kiln to bake the clay wax is burned leaving hollow
3 molten is poured in
4 cooled and broken away

Question 13

pewter casting process

Answer 13

1 mould is made from mdfwith the laser cutter with sprue and runner
2 mould is sandwiched and clamped
3 pewter is ladled in
4 removed
5 hacksaw off runner and riser
6 casting filed
7 polished

Question 14

vacuum forming

Answer 14

1 mould is placed on the bed of the machine (platen)
2 polymer sheet is clamped and heater is pulled over
3 when polymer sheet is soft platen rises and heater is removed
4 pump switches on and sucks polymer to mould
5 removed and cut

Question 15

thermoforming

Answer 15

industrial
baths
extra detail
slow - detailed and embossed
same as vacuum just additional mould presented into the surface
traps the polymer

Question 16

calendering

Answer 16

smoothing and rolling process
thin polymer sheets
heating pellets of thermoplastics so that it melts and then extruded through heated rollers
industrial
continuous

Question 17

line bending

Answer 17

produce bends in sheet thermoplastic like acrylic
one off of limited
slow and labour intensive
melted and bent

Question 18

lamination

Answer 18

3d products from fibre based composites like GRP
boats yachts kayaks

1 mould or former in shape
2 coated with release agent like wax
3 top layer of gel coat is applied - polyester resin
4 fibreglass is laid over resin is rolled over (stippling)
5 repeated until desired thickness
6 sets

Question 19

injection moulding

Answer 19

1 thermoplastics granules poured into hopper
2 screw thread is rotated by a motor
3 heaters melt
4 hydraulic ram forces screw thread forward
5 mould is water cooled
6 removed
7 trimmed

Question 20

blowmoulding

Answer 20

1 polymer fed into hopper
2 archimedean screw pulls the polymer through the heated section
3 melted polymer extruded as a tube
4 air is injected forming to sides
5 ejected

Question 21

rotational moulding

Answer 21

heavy duty seamless hollow objects that need a large wall thickness like traffic cones
1 granules into mould
2 transferred to oven at about 270degrees
3 rotated slowly less than 20 times per min
4 when at thickness it’s cooled
5 removed

Question 22

extrusion

Answer 22

solid rod or hollow tube or I and T sections
1 granules in hopper
2 moved the polymer granules past the heaters
3 heaters soften polymer
4 ram pushes the screw through the steel die making shape
5 may be supported by rollers
6 cooled and cut

Question 23

compression moulding

Answer 23

urea or melamine formaldehyde
electrical light fittings

1 slug of thermoset is inserted into moulds
2 closed with hydraulic pressure making it take shape of mould
3 cross linking to allow it to cure
4 opens and removed
5 flash removed

Question 24

mig welding

Answer 24

weld thin gauge metal or aluminium
heat generated is localised will not burn or distort
joining tubular steel in products like climbing frames
one off fabrication
electric arc to produce heat melting the joint area
uses inert gas likr co2 to form flux shield
helps prevent oxidisation

Question 25

tig welding

Answer 25

used to weld metals like stainless steel aswell as aluminium and copper
electric arc welding process
electrode doesn’t melt in the process
separate filled rod used gas shield of argon to protect from oxidisation
allows for greater control by the operator
so high levels of skill needed and slow

swimming pool ladders

Question 26

oxyacetylene welding

Answer 26

low carbon steel sheet, tube or plate where arc welding processes aren’t available
useful for quick repair jobs

mixture of oxygen and acytylene to form an intense flame that can burn at temps of 3500 degrees stored in separate bottles and moxed in a blow torch

1 metal prepared by grinding an angle on the edges of the two edges forming a V shape
2 joint area heating to form a melt pool steel filler rod is introduced
form a continuous bead along joint

Question 27

riveting

Answer 27

join sheet metal or plate
head at one end and shaft at other
overlapped and drilled
rivet shaft is inserted into hole
the end is hammered in squeezing the two pieces together

Question 28

pop riveting

Answer 28

thin sheet of metal
rivet and pin
rivet head pushed through hole drilled through the two pieces of metal being joined
head squashes pulling together
when underside of joint is inaccessible

Question 29

self tapping screws

Answer 29

joining thin sheet metal
pilot hole is drilled through the metal parts to be joined
has a course thread
when screwed in cuts it’s own hole
when panels needs to be removed for maintenance

children’s toys

Question 30

machine screws

Answer 30

thicker pieces of metal together
inspection covers on motor or gear housings or parts that need to be removed for maintenance
they have a thread the entire length of the shaft

Question 31

nut and bolt

Answer 31

put all the way through both pieces of metal and then a nut is tightened on to the end of the bolt to keep pieces together
nyloc nuts= nylon to deform to the bolts shape