Metal Processes

Question 1

Turning

Answer 1

• Metal turning is done on a centre lathe also called a metal lathe
• The metal piece is first secured in the chuch. A high speed steel cutter held in the tool post moves left to right and towards the center to shape the material

Question 2

Sawing

Answer 2

• The process of cutting away material with tools and equipment
• A good design can minimise the amount of wastage produced.
• There is 2 types of saws these being junior hacksaw and a hacksaw
• Junior hacksaw traditionally used for small jobs varing of materials beimg wood metal and plastic
• Hacksaw used for larger jobs, the blade can be removed and replaced with other tupes of blades.

Question 3

Milling

Answer 3

• Milling is the machining process of using rotary cutters to remove material
• It is also used to cut slots and groove, machine edges amd to smooth large surface areas

Question 4

Drilli g

Answer 4

• Drilling holes in metal is usually carried out using a pillar drill and bit or milling machine with a slot drill.
• In industrial situations jigas and fixtures are used to improve accuracy and speed
• High speed steel twist drill bits are used to drill metals.

Question 5

Cutting & Shearing

Answer 5

Shearing: A cutting and slicing action

Cutting: Many saws used to cut timber - some suit long straight cuts on thicker planks and others suit curves and complex shapes
- Rip saw - for ripping through and rough cutting thicker planks amd boards
- Tenon saw - for cutting straight lines with accuracy
- Coping saw, jigsawas and scroll saws - all for cutting thinner pieces of timber, and can cope with curves too

Question 6

Welding

Answer 6

• 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
• There are several types of welding commonly used depending on the job and material

Question 7

Brazing

Answer 7

• Brazing is a metal joining process whereby a filler metal is heated above melting point and distributed between two or more close fitting parts
• The filler metal is brought slightly above its melting temperature while protected by a suitablr atmosphere, usuallh a flex. It is used for more decorative work as the soft brazing ros is easier to file to shape.

Question 8

Soldering

Answer 8

• Soldering is a process in which two or more metal items are joined together by melting and flowing solder
• Soldering differs from welding in that it does not involve melting the work pieces and it is particularly suitable for intricate work such as soldering components onto a circuit board.

Question 9

Bending

Answer 9

• Simplest form of forming metal. You can bemd simply with a vice and hitting it or in jigs/machines
• Metals can also be bent using commerically profuced metal-floding machines