Metal Manufacturing Flashcards
What are 3 metal manufacturing processes?
● Wastage,
● Addition
● Deforming/Reforming
(Make your own flashcards David)
What are wastage processes?
● Turning
● Sawing
● Milling
● Drilling
● Cutting & Shearing
What is ‘turning’?
● Metal turning is done on a centre lathe also called a metal lathe.
● The metal piece is first secured in the chuck. A high-speed steel cutter held in the tool post moves left to right and towards the centre to shape the material to produce a symmetrical shape.
- Used to make circular components from metal bars.
What is ‘sawing’?
Cutting away material with a saw (like a junior hacksaw or hacksaw).
What is wastage?
- Wastage is the process of cutting away material with tools and equipment.
- Good design can minimise the amount of wastage produced. For electronic and mechanical systems, there are several wastage processes available.
What is ‘milling’?
- Milling is the machining process of using rotary cutters to remove material. Traditionally a milling machine has cutters that can be moved in three axis and operated manually.
- Used to cut slots and grooves, machine edges and to smooth large surface areas.
What is ‘drilling’?
● Drilling holes in metal is usually carried out using a pillar drill (drill press) and bit or milling machine with a slot drill.
● In industrial situations jigs and fixtures are used to improve accuracy and speed.
● High speed steel (HSS) twist drill bits are used to drill metals
What is ‘cutting & shearing’?
- Shearing: A cutting and slicing action
- Cutting: There are a great many saws used to cut timber - some suit long straight cuts on thicker planks, and others suit curves and complex shapes:
What are addition processes?
● Brazing
● Welding
● Soldering
What is ‘welding’?
- Welding is a fabrication or sculptural process that joins materials, usually metals, by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool).
- Permanent way to join metals by using the same metal that is used to product a joint.
What is ‘brazing’?
- Brazing is a metal-joining process whereby a filler metal is heated just above melting point while protected by a suitable atmosphere, usually a flux, and distributed between two or more close-fitting parts.
- It is used for more decorative work as the soft (Brass) brazing rod is easier to file to shape.
- Method of joining steel parts together.
What is ‘soldering’?
- Soldering is a process in which two or more metal items are joined together by melting and flowing solder (an alloy of Tin) into the joint, the solder having a lower melting point (180°) than the adjoining metal.
- It is particularly suitable for intricate work such as soldering components onto a circuit board.
- Is a joining process used to join different types of metals together by melting solder
What are the Deforming/reforming processes
● Bending
● Casting
What is ‘bending’?
- Simplest form of forming metal. You can bend with simply a vice and hitting it or in jigs/machines.
- Metals can also be bent using commercially produced metal-folding machines.
What is ‘pewter casting’?
- Pewter is a quick and simple method of casting
- Pewter casting is a common method of “low tech” casting in schools as it doesn’t require use of sophisticated machinery and the pewter has a relitively low melting point
- Melted pewter can be cast into jewellery and other items using moulds carved or cut into MDF, Cuttlefish, Silicone or Vulcanised Rubber.
