Metal processes Flashcards
Press forming
Involves pressing sheets of meta;l to form a shape
What is press forming used in?
Car body panels, cones, metal seats
What is spinning?
Circular sheet metal components are rotated around a central axis by pushing a metal blank onto a rotating former.
Cupping and deep drawing
Used t form tube like shapes such as cans.
The material is pushed down to form a tube shape
What is the difference between cupping and deep drawing?
Deep drawing is when the depth is bigger than the diameter
Forging
Forging is a manufacturing process involving the shaping of metal using localised compressive forces
What is drop forging?
A “hammer is raised and dropped onto the workpiece to deform it so it fits the die
What production type is drop forging used in?
Mass or batch
Bending
Metal can be bent hot or cold and folded using either a template or a jig
Sand casting
Molten metal is poured into a prepared cavity in a sand mould and is allowed to solidify
Investment casting
A shell is built up around a wax pattern that can be melted away leaving a cavity that is filled from molten metal
Die casting
Metals like silver or pewter can be cast into jewellery and other items using mould carved or cut into MDF, silicone or vanished rubber.
MIG welding
Arc welding process where a continuous solid wire electrode is fed through the welding guns into the weld
TIG welding
Heat is generated from a tungsten electrode to the metal surface to the weld. The heat is sufficient to melt the joint edges.
Spot welding
Two metal sheets are joined by heat and pressure being applied from a current tot he sheet
What is oxy-acetylene welding?
Oxygen and acetylene are combusted and the edges of the two pieces of metal and are melted and fused together
What can oxy-acetylene welding join?
Mild steel using pressure
Soldering
Metal is joint by melting solder with a soldering iron
Brazing
A permanent way of joining metal by melting a brazing rod between two parts
Riveting
A smooth cylindrical shaft that is pressed into the sheets of metal to join them
Self tapping screws
Screws that taps its own hole as it is drilled
Machine screws
Screws designed to hold machinery together
Nuts and bolts
Parts that work together to hold pieces of material from two sides
when is soldering most used?
Electronic and jewellery
What is a wasting process?
A process that removes material to form a shape
Milling
Rotary cutters remove material to form a shape, similar to routing but with a higher torque. This can be hand held or by CNC.
Flame cutting
A process that uses oxy-acetylene gas with a flame. This is used to cut low carbon and alloy steel plates. The flame is very intense and focused
Plasma
A super heated ionised gas that is electrically conductive
Plasma arc welding
Plasma arc welding uses the plasma gas burn through and blow the metal away
Laser cutting
A case file tells the laser cutter where to cut the material with a high-powered laser.
Punching or stamping
A shape is punched out of a material using a punch.
