manufacturing - forming

Question 1

Name some common Forming Processes.

Answer 1

1. Rolling
2. Extrusion
3. Forging
4. Coining
5. Closed-Die
6. Drawing

Question 2

What is Rolling?

Answer 2

• passing metal through two rollers to reduce thickness
• can be done hot or cold

Question 3

Pros and Cons of Rolling?

Answer 3

Pros:
1. uniform / precise
2. efficient
3. cost effective
4. material versatility
5. low labour costs - all done by machines
Cons:
1. high set up costs
2.ideal for large scale
3. not cost effective for small scale operations

Question 4

What is Extrusion?

Answer 4

• metal is pushed through die hole to achieve certain cross sectional shape.
• uses high pressure
• can work materials that are brittle

Question 5

Pros and Cons of Extrusion?

Answer 5

Pros:
1. ideal for high production
2. complex shapes
3. material versatility
4. low cost per part
5. flexible
Cons:
1. high compressive force required
2. high set up costs
3. only one type of cross section can be created at a time
4.loose tolerances
5. die wear out
6.not good for thermosets

Question 6

what is additive manufacturing?
pros and cons?

Answer 6

Process of creating object one layer at a time.
pros:
1. multiple parts can be combined to one
2. improved part properties
3. lightweight
4. quick
5. easily customisable
cons:
1. limited materials
2. can have bad surface finish
3. can have size limitations

Question 7

Name some common post - processing methods.

Answer 7

1. Filing
2. Sanding
3. Grinding

Question 8

Pros and Cons of: Filing

Answer 8

PROS:
1. precise
2. vers
CONS:
1. time consuming
2. limited material removal
3. risk of damaging part

Question 9

Pros and Cons of: Sanding

Answer 9

PROS:
1. efficient
2. smooth finish
3. preps surface for other post processing activities
CONS:
1. lots of dust - PPE / Ventilation
2. limited precision
3. risk of surface damage

Question 10

Pros and Cons of: Grinding

Answer 10

PROS:
1. rapid removal
2. great for sharpening
3. ideal for achieving certain finishes
CONS:
1. can be expensive
2. careful handling required
3. only good for small removal jobs

Question 11

What is Forging?
What is hot forge and cold forge?

Answer 11

Using localised compressive forces to shape a metal.
Hot forge: Heats material to improve DUCTILITY
Cold forge: Room temp. better SURFACE FINISH and dimension control.
Warm: balance of the two.

Question 12

What are the pros and cons of forging?

Answer 12

PROS:
1. increases strength
2. increases durability
3. cost effective
4. vers
CONS:
1. high set up costs
2. complex
3. limited on materials
4. bad surface finish

Question 13

What is Drawing?

Answer 13

-pulling metal stock (wire of rod) through a die to reduce its diameter and increase length

Question 14

Pros and Cons of Drawing

Answer 14

PROS:
- high precision
- improved mechanical properties (strength, hardness)
- good surface finish
-minimal waste
CONS:
- limited shapes
- high start up costs
-sometimes bad surface finish
- mainly for ductile materials

Question 15

What is 2.5D manufacturing?

Answer 15

• creating parts with 2 moving axis at a time.
• 3rd axis can move if it wants to

1. Milling
2. Cutting (laser, plasma, water)
3. Engraving