Metals - Tools, Equipment and Processes

Question 1

Metals are much………and………….than wood

Answer 1

Harder

Tougher

Question 2

Is metal faster or slower at manufacturing than woods

Answer 2

Slower

Question 3

What is a scriber

Answer 3

Performs the same function as a pencil but is used on metals

Hard point will score a fine line on a metal

Question 4

What is an engineers square

Answer 4

Used to mark a line 90˚ to an edge

Question 5

What is marking out fluid

Answer 5

Quick drying blue liquid that is applied metals before production begins

Produces clean crisp lines

Question 6

What is a combination square

Answer 6

Used for a number of measuring and marking out processes

Measures any angle

Question 7

Give 5 production Aids

Answer 7

Old Leg Calliper 
Outside Calliper
Centre Punch
Dividers
Inside Callipers

Question 8

What are old leg callipers

Answer 8

Mark out parallel lines to a ledge

Question 9

What are outside callipers

Answer 9

Used to measure or check outside diameter of a round bar or rod

Typically used when turning steel bar on a metal working tube

Question 10

What are inside callipers

Answer 10

Used to check or measure the inside or diameter of a hole

Question 11

What is a centre punch

Answer 11

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

Question 12

What are Dividers

Answer 12

Used to mark out a circle or an arc on a circle

Question 13

What 3 pieces of equipment when used together increase the accuracy when marking out

Answer 13

Surface Block
Scribing Block
Vee Blocks

Question 14

Always cut lines slightly……… than you need

Answer 14

Bigger

Question 15

What is a scribing block

Answer 15

Firmly holds the scriber at a pre determined hight

Question 16

What is a Hacksaw

Answer 16

Most popular saw for sawing metal and polymers

Hardened and tempted high carbon steel blade

Question 17

What is a Junior Hacksaw

Answer 17

Smaller version of the hacksaw

Blade can quickly be changed

Question 18

What is the piercing saw

Answer 18

Very thin and hardened and tempered steel blade

Blade very fine and delicate so can easily be snapped

Question 19

What is filing

Answer 19

The process of final shaping and smoothing a material once it has been cut to shape

Question 20

Give two basic techniques of filing

Answer 20

Cross Filing

Draw Filing

Question 21

What is Cross filing

Answer 21

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

Question 22

What is Draw Filing

Answer 22

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

Question 23

Files need to be cleaned with a…………

Answer 23

File card

Question 24

How would you bend metals

Answer 24

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

Question 25

Give two ways of joining metals

Answer 25

Brazing | Welding

Question 26

What is brazing

Answer 26

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

Question 27

What is welding

Answer 27

Very strong method of premaritally joining metals together You can use gas or electricity to generate the heat

Question 28

What is the centre lathe used for

Answer 28

It used to make circular components from metals or polymers bars

Question 29

What are milling machines

Answer 29

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

Question 30

How do you cast metals

Answer 30

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.

Question 31

What is pewter casting

Answer 31

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

Question 32

What is Pewter made of

Answer 32

90% Tin Small amount of Copper The copper increases the hardness of the Tin which is quite soft

Question 33

What is Sand Casting

Answer 33

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

Question 34

What is a quality control process

Answer 34

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

Question 35

What is a no-go gauge

Answer 35

Used to specifically to test a part or component to ensure that is within a specific tolerance

Question 36

Give 3 types of gauge

Answer 36

Plug Gauge - used to check holes Gap gauge - Used to check external dimensions Adjustable gauge - Versatile version of the gap gauge

Question 37

What is the depth stop

Answer 37

Simple method od ensuring the holes are drilled to the correct depth Integral part of a pillar drill

Question 38

What is tolerance for metals

Answer 38

Metals are harder than woods so they have much finer tolerances 0.01mm