Manufacturing with metals.

Question 1

Press forming process.

Answer 1

1.Sheet metal is clamped over a die of the product that will determine the final shape of the pressing.
2.A hydraulic press pushes the die into the sheet metal, cutting blades may be included to punch holes into the sheet metal and trim excess.
3.The die is lowered and pressed sheet then the component is removed.
4.The sheet may be placed into the further press forming machines for additional pressing, where the shape is complex.

Question 2

What is press forming used for?

Answer 2

Turning sheet metal into 3D forms. Such as metal seats, car body panels, boxes and containers.
Mass or continuous production, due to high cost of dies.

Question 3

Metal spinning process.

Answer 3

1.A former called a mandrel is put into the chuck, the sheet metal blank is held in place between the mandrel and the tail stock.
2,The roller tool is moved into the blank and rotated with the mandrel. This starts to stretch the metal over the mandrel.
3.The roller tool is moved along the mandrel as pressure is maintained against the rotating blank.
4.The roller tool is moved to the end of the mandrel, while still maintaining contact with the blank. This finishes the shape of the product.
5.The finished product is removed from the mandrel.
*Excess material is trimmed off following the spinning process.

Question 4

What is metal spinning used for?

Answer 4

Spinning is an alternative process to press forming objects such as saucepans and steel kettles.

Question 5

Sand casting process?

Answer 5

1.Create a mould for the casting by packing sand into each half of the mould. The sand is packed around a pattern in the shape of the casting. When the pattern is removes it leaves a cavity in the shape of the casting (top=cope bottom=drag).
2.Once the mould is made it is prepared for the molten metal with lubricant to help with the removal of the casting. The two halves and joined and clamped.
3.Pour molten metal into the mould through a gap leading to the casting cavity.
4.Allow the metal to cool and solidify before removing from the mould.
*remove casting sand through vibration or shot blasting and trim excess metal.

Question 6

What is sand casting used for?

Answer 6

Railway carriage wheels, clamps, vice, drain covers and park benches.

Question 7

Die casting process.