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Edexcel AS Product Design - Industrial And Commercial Practice > Material Processing And Forming Techniques > Flashcards

Material Processing And Forming Techniques Flashcards

1
Q

What is casting?

A

The pouring or forcing of molten metal into a cavity and then allowing metal to cool

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2
Q

What are the basic steps of sand casting?

A
  1. Produce a mould out of wood
  2. Pack drag (bottom) with sand
  3. Pack cope (top) with sand
  4. Mould removed and cope and drag screwed in place
  5. Molten metal poured into cavity via runner
  6. Excess metal will rise up riser
  7. Metal is left to cool and is split apart
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3
Q

Give 3 advantages of sand casting

A

Inexpensive
Complex shapes can be produced
Large components can be produced

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4
Q

Give 4 disadvantages of sand casting

A

Moulds can only be used once
Surface finish not always good
Labour intensive
Slow production rate

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5
Q

Give 3 applications of sand cast products

A

Engine blocks
Garden furniture
Caterpillar tracks

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6
Q

What are the basic steps of die casting?

A
  1. Mould sprayed with lubricant
  2. Molten metal shot into die at high pressure
  3. Pressure maintained till metal is solidified
  4. Die opened and removed with ejector pins
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7
Q

Give 3 advantages of die casting

A

High production rate
Good surface finish
Elements e.g. screw thread can be included in the mould

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8
Q

Give 3 disadvantages of die casting

A

High set up costs
Long lead time
Large volume required to be economical

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9
Q

Give 2 applications of die cast products

A

Taps

Model cars

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10
Q

What are the basic steps of injection moulding?

A
  1. Plastic granules in hopper are forced into heat chamber using a Archimedean screw
  2. Plastic is forced into two-part mould under pressure
  3. Component is rapidly cooled and ejected
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11
Q

Give 3 advantages of injection moulding

A

Low unit costs; ideal for mass production
Precision moulding
High quality finish

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12
Q

Give a disadvantage of injection moulding

A

High initial set up costs due to expensive mould

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13
Q

Which polymers are used in injection moulding?

A

ABS
HDPE
Nylon
PP

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17
Q

Give 2 applications of injection moulded products

A

Castings for electronic products

Containers

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18
Q

What is extrusion?

A

Used to create long products with a particular cross section

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19
Q

What are the basic steps of blow moulding?

A
  1. Plastic granules are fed into hopper
  2. Archimedean screw feeds granules through heated chamber
  3. Softened plastic is extruded into parison
  4. Parison clamped into mould and air pumped into it
  5. Parison inflates to shape of mould
  6. Once cooled mould is opened and bottle ejected
20
Q

Give 3 advantages of blow moulding

A

Intricate shapes can be formed
Low unit costs; ideal for mass production
Can produce hollow shapes with thin walls

21
Q

Give a disadvantage of blow moulding

A

High initial set-up costs due to expensive mould

22
Q

Which polymers are used in blow moulding?

A

HPDE
LDPE
PP
PVC

23
Q

Give an application of a blow moulded product

A

Plastic bottle

Containers

24
Q

What are the basic steps of vacuum forming?

A
  1. Produce high quality former, with 1° taper and no undercuts
  2. Former place into machine and plastic clamped over
  3. Heat applied, plastic softens
  4. Former raised into plastic, air removed
  5. Pressure forces plastic around former, taking shape
  6. Once cooled, remove from machine
25
Q

Give 2 advantages of vacuum forming

A

Inexpensive; ideal for batch production

Easy to make moulds that can be modified

26
Q

Give 2 disadvantages of vacuum forming

A

Mould needs to be accurate to prevent webbing

Large amounts of waste

27
Q

Which polymers are used in vacuum forming?

A

Acrylic
PVC
HIPS

28
Q

Give 2 applications of vacuum formed products

A

Yoghurt pots

Insides of fridges

29
Q

What are the basic steps of rotational moulding?

A
  1. Powdered polymer is loaded into mould
  2. Heat is applied and mould is rotated in tumbling action
  3. Polymer is melted and sticks to mould wall
  4. Cooled by water or air, component removed
30
Q

Give 4 advantages of rotational moulding

A

Easy to produce large products
End product has no seams
Wall of product is uniform thickness
Rarely need finishing

31
Q

Give 3 disadvantages of rotational moulding

A

Lower volume production
Long cycle times
Labour intensive

32
Q

Give 3 applications of rotational moulded products

A

Plastic footballs
Buckets
Traffic cones

Edexcel AS Product Design - Industrial And Commercial Practice (6 decks)

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