Metal Processes Flashcards
What is press forming
Mass / batch scale production - hydraulic press pushes a die into a sheet metal
What is spinning
Mass production - metal is spun at high speeds while a die / mandrel is pushed into it, creating a round object like a kettle
What is cupping / deep drawing
Mass / continuous production - a blank metal is attached to a die, then its pushed into the die cavity, creating a cup shape, if pressed further down it creates a tube shape
What Is drop forging
Mass production - heated billet / metal is placed onto a die, in which a hydraulic ram and gravity smash down spreading the material into the shape of a die
What is bending
Large scale / one off production - stock material clamped in between a punch and die, then is slowly bent into shape
What is rolling
Set of rollers that gradually reduce the thickness of the material
What is sand casting
One off / batch production - mould is made and placed in a wooden box packed full of sand, removed, then metal is cast into the empty space in the sand- sometimes two moulds are used, and ventilation shafts are needed
What is die casting
Large batch / mass production - melt metal, then pour it into the mould allowing gravity to do the rest
What is investment casting
Exact replica of item to be made is made using wax, covered in clay then the wax is burnt out. Metal is then poured into the clay mould, and then clay is broken off
What is milling
A drill for metal, can cut slots, holes and shape the edges / surfaces of metal
What is turning
Done on a CNC lathe, metal is inserted and spun, gradually reducing the size of the metal
Types of cutting used on metals
Laser, flame and plasma cutting
What is punching / stamping
Sections of steel are stamped out using hardened punches
