Meyal Processes

Question 1

Spinning process

Answer 1

A formula called a mandrel is put onto the chuck. The sheet metal blank is held in place between the mandrel and the tailstock.
The roller tool is moved into the blank and is rotated with the mandrel. This starts to stretch the metal over the mandrel.
The roller tall is moved along the mandrel as pressure is maintained against the rotating blank.

Question 2

Spinning scale

Answer 2

Mass or batch

Question 3

Press forming process

Answer 3

Sheet metal is clamped over a dye of the product that would determine the final ship of the pressing.
A hydraulic press pushes the dye into the sheet metal. Cutting blades may be included to punch holes into the sheet and trim the excess from the edges
The hydraulic is lowered and the press sheet component is removed.
The sheet may be placed into further press forming machines for additional pressing where the shape is complex.

Question 4

Press forming scale

Answer 4

Mass or large scale batch

Question 5

Cupping and deep drawing process

Answer 5

Depressing blank is clamped over a deep drawing dye using a pressure pad or camping ring known as a retainer.
A hydraulic press moves the deep drawing pun to be in contact with the blank. It then pushes the blank into the dark cavity to make a cup shape
The cup is then pressed further down through the deep drawing die to make the desired tube shape.

Question 6

Cupping and deep drawing scale

Answer 6

Mass 

Question 7

Drop forging process

Answer 7

A dye is made from cast to steel which resembles a mould and this is secured to the top of the amble.
Aram is also equipped with a guy that resembles a mould.
The metal billet to be forced is heated to above its crystallisation temperature stops the product from work hard as it calls which would make it brittle.
Using tongues the heated billet is placed by an operator in Amble die
And the hydraulic ram is brought down with force. This makes the bullet spread around the shape of the dye.
The ram is lifted and completed product removed for coolingand finishing.

Question 8

Drop forging scale

Answer 8

Mass

Question 9

Wrought iron forging process

Answer 9

The wrought iron is heated in a gas or Coke fired forge it is then shaped by holding it with tongues and hammering it over an anvil and using other tool such as scroll formers or twisting bars.

Question 10

Wrought iron scale

Answer 10

One off or limited batch

Question 11

Bending process

Answer 11

Uses a machine called a press break.
The desired bends are achieved by clamping the stock material between a matching punch and die.
A hydraulic or mechanical break holds the metal sheet or plate and low the punch to bend the material to shape.

Question 12

Bending scale

Answer 12

One off
Largest scale batch in industry

Question 13

Rolling process

Answer 13

Metal is passed through a set of rollers to reduce the thickness of the material. This can be carried out with hot metal that has been heated to above its recrystallisation temperature or can be rolled below the crystallisation temperature.

Question 14

Results of hot rolling

Answer 14

Material with mechanical properties that are uniform throughout the sample. It will not have any defamation or stresses which could result in full of the material. However, the surface is usually coated with carbon deposits which would have to be removed using acid pickling.

Question 15

Results of cold rolling

Answer 15

Results in a material that has a tighter tolerance because carbon deposits are not formed during the rolling process. The surface finish is therefore much better.

Question 16

Sand casting process

Answer 16

A pattern is made and divided into 2/2. One2 will be placed on the bottom of a steel box called a drag. It has a powder release agent applied. The drag is then filled with sand tightly and compact and then levelled off. The track is turned over and the second box called the cope is clamped into position over the top. The top half of the pattern is placed on top of the bottom half of the pattern and wooden steaks repositioned in the cope. These will form the screw or the runner and writer later in the process. Sand is packed into the cope around the runner rise and pattern a small depression is made on the surface around the spray, to make a pouring basin. The cope and drag are separated and stakes and patterns are carefully removed. Connecting channels are cut to join the spirit to the pattern cavity and to form this riser. The cope and drag are then reassembled and the mould is ready for pouring to begin. Small metal spikes may be inserted and removed to make vent holes.

The molten metal is poured into basin and flows down the runner into the cavity. When it is full, the molten metal will flow out the riser. Once it has called the sand will be removed and the runner channels can be cut off.

Question 17

Sand casting scale

Answer 17

One off and batch production

Question 18

Die casting scale

Answer 18

Large batch and mass

Question 19

Gravity die casting process

Answer 19

Metal is melted and poured into a mould. The process relies on gravity to help the metal flow through the mould. There is a runner and a riser. The runner is used to pour the molten metal into the mould whilst the riser will indicate when the mould is full. Once the metal is cool, the mould is opened and the casting can be removed.

Question 20

Hot chamber die casting process

Answer 20

Motor metal is stored in a chamber which is part of the high-pressure diecasting machine. A hydraulic plunger forces a shot of molten metal through the gooseneck into the dye. Because this process uses high-pressure all of the mould is filled and it allows fine detailed moulded.

Question 21

Cold chamber die casting process

Answer 21

The motor metal is kept separately in a melting crucible. The melting metal is ladled into the shot chamber and a hydraulic ram forces the molten metal into the mould cavity. When the mould has hardened the mould opens and the eject pins push finished casing out.

Question 22

Investment casting process

Answer 22

An exact replica of the product to be cost is made using wax the wax pattern is dip coated with a refractory clay. It is then fired in a kiln to bake the clay hard the wax is burned away leaving a hollow clay mould. Molten metal is poured into the clay mould once the metal has filled the mould it is allowed to cool. The clay mould is broken away revealing the casting the runner and connecting channels are machined off.

Question 23

Pewter casting process

Answer 23

Mould is made from MDF likely laser cut. It will include a screw or runner which will be used to pour the pewter into the mould is between two pieces of MDF and clamp together. The top of the mould will be level with the top of the side pieces. The computer is melted in a ladle and ladle into the spray. Once the casting is called it is removed from the mould, the screw riser is removed with a junior hacksaw. The casting is then filled and cleaned up using abrasive and dry paper casting can then be polished.

Question 24

Pewter scale

Answer 24

One off

Question 25

Mig welding process

Answer 25

Uses an electric ark to create heat which melts the joint area. White electrode made from the same metal as the material to be joined. Also melts in the ark and fill the gap between the two pieces being joined. The operator swells the world and gun as they move it over the joint formula continuous speed of world. The electrode wire is stored on a real and advanced through the welding gun as the trigger is pressed. It uses an inert to form a flux shielded over the area that is being joined to prevent oxidation.

Question 26

Tig welding process

Answer 26

It is an electric ark welding process and the electrode is made from tungsten but does not melt in the process. Instead, a separate filler is used. A gas shield of organ or helium is used to protect the area from oxidation

Question 27

What is oxy acetylene

Answer 27

Uses a mixture of two high-pressure gases, oxygen and acetylene to form an intense flame that can burn at high temperatures. The two gases are stored in separate bottles and mixed in a blowtorch. The intensity and temperature of the flame can be adjusted by changing the gas and oxygen mixture through valves on the bottles and torch, to allow for either flame cutting welding or braising

Question 28

Oxyacetylene process

Answer 28

The metal is prepared by grinding an angle on the edges of the two pieces to be jointed to form a shape.

This insures the world runs through the entire thickness of the metal. The joint area is heated from a mouthful at the same time is still full of rod is introduced to the joint area. The pool is extended to form a continuous speed along the length of of the joint. The molten metal will flow to the hottest part of the metal therefore by moving the torch along the line continuous scene is for.

Question 29

Brazing process

Answer 29

The material to be jointed is cleaned and degreased. The two pieces are clamped together. A flux is applied. The joint is heated using gas or air torch to a temperature of approximately 850°C. The braising rod is applied to the joint area which is called a spouter and will flow along the joint by using capillary action to the hottest part, so it can be made to follow the joint by manipulating the torch

Question 30

Soldering process

Answer 30

The metal is clean and grease. The joint area is wide up or camped. The metal is heated up to the melting point of the solder. The soda is added to the metal. The solder will flow along the joint using capillary action. The metal is clean to remove any flux residue

Question 31

Flame cutting process

Answer 31

The metal is heated and a melt pool begins to form. At this point an additional jet of oxygen is introduced. This intense buys the flame and pieces the metal sourcing a jet of melted metal and carbon with it. The flame is then moved along the cutting path to continue the cut.

Question 32

Plasma cutting process

Answer 32

The plasma arc is directed out of a torch where a gas such as oxygen or compressed air is forced through a tiny nozzle. An electric ark is generated from a transformer and combined with the gas forms a jet of plasma. The heat generated by the plasma can quickly burn away the material.

Question 33

Laser cutting process

Answer 33

Laserbeam is admitted from a laser tube where is reflected through a series of mirrors. The head contains a lens which focuses the laser into a fine beam for cutting and engraving. Laser beams usually have a very fine tolerance. It melts the material and a high-pressure gas or compressed air blows the melted material through the sheet.