Metal Processes 3.1.4 Flashcards
What is Sand Casting (Metal Redistribution Process)?
suitable for one off productions
USES post boxes wood working clamps
Stock form - Molten metal from billet.
What is hot chamber Pressure die casting (Redistribution process)?
- Molten metal is stored in a chamber and then is forced into a die.
lower melting point metals - ejector pins - Fast process
- Used for large batch and mass production
USES - toy cars
What is a metal-forming process?
A process in which no material is removed but materials are deformed to produce the required shapes.
What is a metal redistribution process?
A process where the material is changed from one form to another without losing material
What is a waste metal Process?
Process that cuts away material to leave the desired shape.
What is Press forming (Metal Forming Process)?
These are usually products made in aluminium / medium carbon steel, as they are more malleable. Process can be automated and can include trimming
e.g car body containers
die , drawing force , punch
What is Spinning (Metal Forming Process)?
USES - kettles lamp shades
use a mandrel, clamp, spindle, and headlock.
pit sheet of metal between the mandrel and clamp. uses a head and tail lock.
What is Cupping (Metal forming process)?
start with a metal blank, metal is stretched into shape, high initial tooling cost, continuous production.
USES - cans, aerosol cans tube-like shapes.
What is drop forging (Metal Forming Process)?
Used for products that need to be tough and hard
- Hot metal billet shaped on an anvil or die then pressed into shape and cooled.
- suitable for mass production
USES - screwdriver shafts
What is wrought iron forging (Metal forming process)?
Uses wrought iron carbon
- Can be hand or hydraulic-pressed
- suitable for one-off or small bat h production
USES - decorative metal work, decorative fencing.
What is the process for Bending (Metal forming process)?
Punch a metal into a die using pressure
used for large-scale batches in industry.
What is the process for rolling (metal forming process)?
**Hot rolling **- uniform mechanical properties
USES - railway tracks
**Cold Rolling **- material that has a tighter tolerance and better surface finishing.
Cold rolling - cabinets, chairs, steel drums
What is cold Chamber Pressure Die casting (Redistribution Metal process)?
same as hot chamber pressure die casting
uses a shot chamber and ladle, ejector pins
USES - toy cards door handles
What is Gravity Die casting (Redistribution Metal process)?
Lower melting point metals
Relies on gravity to help metal flow into the mould
- Used for thicker mould section
- Used for large batch and mass production
USES - Allow wheels engine components
What is investment Die casting (Redistribution process)?
Used for complex shapes that are hard to mould
- high quality excellent finish
- wax patterns are cast from a master mould
USES - cast jewelry, hip replacement joints.
What is low-pressure die Casting(Redistribution process)?
Used for school projects
can be used with simple MDF moulds
Suitable for one production or small batch.
USES - jewelry, key fobs
What is MIG welding (Addition process )?
metal inert gas
Uses an electrode wire.
- suitable for thin-gauge metals, medium carbon steel or aluminum
- uses inert gas such as co2 or argon
USES - tubular products such as climbing frames, bike frames, and vehicle exhausts.
What is TIG welding (Addition process )?
Tungsten inert gas
Uses a filler rod
- accurate and strong welds , slow method requires high skill
What is Oxy acetylene Welding (Metal addition process)?
- Uses a steel filler rod
- Useful for quick pair jobs or in remote locations where there Is no electric power supply
What is spot welding (metal addition process)?
sheet held between two copper electrodes that form a weld when the charged electrodes make contact with the metal.
USES - used to weld steel sheet metals at a point along a length
What is Soldering (Metal Addition Process)?
Uses a filler material of a lower melting point than the metal being a joint
USES - lightweight applications, jewelry
What are temporary fasteners and joining methods (metals)?
Temporary fasteners are used where a permanent joining method is not required, or in situations where a product may need to be disassembled or accessed for repair.
What are examples of temporary fasterners used for metals?
Self-Tapping screws - join thin sheet of metal , a pilot hole is drilled through the metal and the scree cuts its own thread holding the screw together.
Machine screws - Used in machines, hold machine parts together , the thread is the whole length of the shaft.
Nut and bolt - bolts go through metal and a nut is tightened to the end to keep it together
What is Milling (Metal Wasting Process)?
- work is clamped down to the table of the machine. The table can move in X Y Z directions to be cut and shaped.
What is Turning (Metal Wasting Process)?
- Carried out on a lathe
- a bar is clamped so it can be held in a rotating chuck and machined to reduce the diameter, and to square or face off the end, thread, and drill.
- Turning can be done manually or using CNC lathes
- The material can be moved in and out.
What is Flame Cutting ( Wating Process)?
- USes Oxy-aceylene gas and a special flame cutting torch to deliver a very intense and focused flame above 3500 degrees
- used to cut low carbon and allow steel plate
- Difficult to maintain a parallel line with high levels od tolerance
What is Plasma Cutting (Wasting Process)?
- plasma is a superheated ionised gas that is electrically conductive.
A plasma cutter will use this conductive gas to transfer the energy from the power supply to a conductive material such as a steel plate. - heat burns through the material
- clean and fast cut
What is Punching/ Stamping (Wasting process)
- Using CNC machines to stamp out sections of material
- uses an upper punch and lower tool die
- The process is suitable for small and medium size production runs.
