Paper Two: New methods of manufacture

Question 1

MODERN METHODS OF MANUFACTURE

electrohydraulic forming

Answer 1

• method of forming complex sheet metal parts
• uses single-sided former
• forms using a shockwave from electric spark in tank of water
• trad. equivalent: press forming, deep drawing

Question 2

MODERN METHODS OF MANUFACTURE
electrohydraulic forming
(advantages) (6)

Answer 2

• only needs single sided former
• can produce deep, complex, finely detailed shapes
• range of materials & thicknesses
• single stage process
• very fast
• material evenly distributed

Question 3

MODERN METHODS OF MANUFACTURE
advanced 3D printing of metals
(summary)

Answer 3

• aka direct metal laser sintering (DMLS)
• laser used to fuse (sinter) metal particles together layer by layer
• good for making one-off parts/prototypes
• trad. equivalent is casting

Question 4

MODERN METHODS OF MANUFACTURE
advanced 3D printing of metals
(advantages) (3)

Answer 4

• creates strong & lightweight parts
• can achieve complex shapes not possible with casting (eg undercutting, internal voids)
• no need to purchase & store highly expensive dies

Question 5

MODERN METHODS OF MANUFACTURE
fibre injection moulding
(summary)

Answer 5

• reinforced fibre roving (slightly twisted stands of continuous reel) incorporated with polymer being moulded
• very similar to trad. injection moulding
• trad. equivalent would be lay up process
• many parts can be made with this process instead of casting (eg aluminium parts for cars, bikes, etc)

Question 6

MODERN METHODS OF MANUFACTURE
fibre injection moulding
(advantages) (4)

Answer 6

• parts are strong, stiff & lightweight
• much cheaper & quicker to mould than metal alternatives
• some polyamides (nylons) can be electroplated to achieve aesthetically pleasing finish)
• more sustainable- use carbon fibre cut offs & waste

Question 7

MODERN METHODS OF MANUFACTURE
laser beam welding
(summary)

Answer 7

• laser beam used to heat up very small areas of the metal to weld 2 surfaces together
• trad. equivalent is MIG/TIG welding

Question 8

MODERN METHODS OF MANUFACTURE
laser beam welding
(advantages) (6)

Answer 8

• laser beam is very precise so can heat up very small areas of the metal meaning less distortion
• can weld dissimilar materials
• weld smooth enough not to require additional finishing
• more accurate
• no need for filler rods
• small, thin components can be welded

Question 9

MODERN METHODS OF MANUFACTURE
physical vapour deposition
(summary)

Answer 9

• produces thin film of material/coats products with finishing surface
• alternative to electroplating
• used for: semi-conductor components, food packaging, machine tool cutting tips, decorative products, phone waterproofing
• base material is heated until it vapourises
• then passes through a vacuum to condense of target material

Question 10

MODERN METHODS OF MANUFACTURE
physical vapour deposition
(advantages) (3)

Answer 10

• can get into very small gaps & coat small components (unlike electroplating/normal films)
• very durable
• environmentally friendly- happens in a vacuum, no toxic gases produced