Metals - Tools, Equipment and Processes Flashcards
Metals are much………and………….than wood
Harder
Tougher
Is metal faster or slower at manufacturing than woods
Slower
What is a scriber
Performs the same function as a pencil but is used on metals
Hard point will score a fine line on a metal
What is an engineers square
Used to mark a line 90˚ to an edge
What is marking out fluid
Quick drying blue liquid that is applied metals before production begins
Produces clean crisp lines
What is a combination square
Used for a number of measuring and marking out processes
Measures any angle
Give 5 production Aids
Old Leg Calliper Outside Calliper Centre Punch Dividers Inside Callipers
What are old leg callipers
Mark out parallel lines to a ledge
What are outside callipers
Used to measure or check outside diameter of a round bar or rod
Typically used when turning steel bar on a metal working tube
What are inside callipers
Used to check or measure the inside or diameter of a hole
What is a centre punch
When struck with hammer, produces small indication in metal
Helps when drilling a hole in metal as it improves accuracy , to prevent the drill skidding off
What are Dividers
Used to mark out a circle or an arc on a circle
What 3 pieces of equipment when used together increase the accuracy when marking out
Surface Block
Scribing Block
Vee Blocks
Always cut lines slightly……… than you need
Bigger
What is a scribing block
Firmly holds the scriber at a pre determined hight
What is a Hacksaw
Most popular saw for sawing metal and polymers
Hardened and tempted high carbon steel blade
What is a Junior Hacksaw
Smaller version of the hacksaw
Blade can quickly be changed
What is the piercing saw
Very thin and hardened and tempered steel blade
Blade very fine and delicate so can easily be snapped
What is filing
The process of final shaping and smoothing a material once it has been cut to shape
Give two basic techniques of filing
Cross Filing
Draw Filing
What is Cross filing
Removes the most material and involves pushing the file across the material.
You should aim to use the full length of the file and slide it along the edge of the material as you push forwards
What is Draw Filing
Is used to smooth the edge of a surface of the material
Hold the file in both hands and draw it along the edge sideways
Files need to be cleaned with a…………
File card
How would you bend metals
Metal can be placed into a vice and hit with a hammer
When longer bends are required you can use a set of folding bars which act as an extension to the vice jaws
Metals can also be bent commercially using metal bending machines
Give two ways of joining metals
Brazing
Welding
What is brazing
Method of joining steel parts together Heat is applied with a brazing torch in a brazing hearth
The flux is applied to the cleaned joint before heating
What is welding
Very strong method of premaritally joining metals together You can use gas or electricity to generate the heat
What is the centre lathe used for
It used to make circular components from metals or polymers bars
What are milling machines
Used to cut slots and grooves and to smooth large surface areas
Due to the large amounts of work the machine does, casts amount of heat is produced
How do you cast metals
The metal is first heated until in molten form and then is poured into a pre prepared mould
The advantage of casting is that it can be used to produce complex shapes that would be very difficult to make by any over method.
What is pewter casting
Relatively quick and cheap way of metal casting
Pewter melts at allow temperature of 200˚C making it easy to se the school workshop. It can be heated in a furnace with a brazing torch, or in a oven or kiln
Once molten the pewter can be poured into a mould where it can be cooled and set
What is Pewter made of
90% Tin
Small amount of Copper
The copper increases the hardness of the Tin which is quite soft
What is Sand Casting
Process that can be carried out into a small workshop and is used to produce larger metal casting, usually made form Aluminium
A pattern of the casting is first made form a close gained hardwood
the pattern must have sloping sides to allow it to be removed form the mould
What is a quality control process
Often use din the manufacture of metal products in the use of a no-go gauge
This is a method of testing and inspecting the accuracy of part of the manufacturing process
What is a no-go gauge
Used to specifically to test a part or component to ensure that is within a specific tolerance
Give 3 types of gauge
Plug Gauge - used to check holes
Gap gauge - Used to check external dimensions
Adjustable gauge - Versatile version of the gap gauge
What is the depth stop
Simple method od ensuring the holes are drilled to the correct depth
Integral part of a pillar drill
What is tolerance for metals
Metals are harder than woods so they have much finer tolerances
0.01mm
