Metal processes

Question 1

Press forming

Answer 1

Involves pressing sheets of meta;l to form a shape

Question 2

What is press forming used in?

Answer 2

Car body panels, cones, metal seats

Question 3

What is spinning?

Answer 3

Circular sheet metal components are rotated around a central axis by pushing a metal blank onto a rotating former.

Question 4

Cupping and deep drawing

Answer 4

Used t form tube like shapes such as cans.
The material is pushed down to form a tube shape

Question 5

What is the difference between cupping and deep drawing?

Answer 5

Deep drawing is when the depth is bigger than the diameter

Question 6

Forging

Answer 6

Forging is a manufacturing process involving the shaping of metal using localised compressive forces

Question 7

What is drop forging?

Answer 7

A “hammer is raised and dropped onto the workpiece to deform it so it fits the die

Question 8

What production type is drop forging used in?

Answer 8

Mass or batch

Question 9

Bending

Answer 9

Metal can be bent hot or cold and folded using either a template or a jig

Question 10

Sand casting

Answer 10

Molten metal is poured into a prepared cavity in a sand mould and is allowed to solidify

Question 11

Investment casting

Answer 11

A shell is built up around a wax pattern that can be melted away leaving a cavity that is filled from molten metal

Question 12

Die casting

Answer 12

Metals like silver or pewter can be cast into jewellery and other items using mould carved or cut into MDF, silicone or vanished rubber.

Question 13

MIG welding

Answer 13

Arc welding process where a continuous solid wire electrode is fed through the welding guns into the weld

Question 14

TIG welding

Answer 14

Heat is generated from a tungsten electrode to the metal surface to the weld. The heat is sufficient to melt the joint edges.

Question 15

Spot welding

Answer 15

Two metal sheets are joined by heat and pressure being applied from a current tot he sheet

Question 16

What is oxy-acetylene welding?

Answer 16

Oxygen and acetylene are combusted and the edges of the two pieces of metal and are melted and fused together

Question 17

What can oxy-acetylene welding join?

Answer 17

Mild steel using pressure

Question 18

Soldering

Answer 18

Metal is joint by melting solder with a soldering iron

Question 19

Brazing

Answer 19

A permanent way of joining metal by melting a brazing rod between two parts

Question 20

Riveting

Answer 20

A smooth cylindrical shaft that is pressed into the sheets of metal to join them

Question 21

Self tapping screws

Answer 21

Screws that taps its own hole as it is drilled

Question 22

Machine screws

Answer 22

Screws designed to hold machinery together

Question 23

Nuts and bolts

Answer 23

Parts that work together to hold pieces of material from two sides

Question 24

when is soldering most used?

Answer 24

Electronic and jewellery

Question 25

What is a wasting process?

Answer 25

A process that removes material to form a shape

Question 26

Milling

Answer 26

Rotary cutters remove material to form a shape, similar to routing but with a higher torque. This can be hand held or by CNC.

Question 27

Flame cutting

Answer 27

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

Question 28

Plasma

Answer 28

A super heated ionised gas that is electrically conductive

Question 29

Plasma arc welding

Answer 29

Plasma arc welding uses the plasma gas burn through and blow the metal away

Question 30

Laser cutting

Answer 30

A case file tells the laser cutter where to cut the material with a high-powered laser.

Question 31

Punching or stamping

Answer 31

A shape is punched out of a material using a punch.