Plastic And Metal Processes Flashcards
Materials for drop forging?
Metals and metal alloys. Most common: stainless steel aluminium copper
volumes of drop forging?
one off hand forging to about 10,000 made by machine
materials for compression moulding?
ceramics, thermosetting plastics, elastomers
Most common:
thermoset plastic parts
E.g. urea formaldehyde and melamine formaldehyde
what is drop forging used to make?
spanners, automobile parts and machine parts
volumes of compression moulding?
batch or high production. tooling costs are moderate
what is compression moulding used to make?
Electrical switches and sockets
materials for injection blow moulding?
thermoplastics
volume for injection blow moulding?
high volume production (high production costs)
type of products made using injection blow moulding?
fairly simple hollow shapes with consistent wall thicknesses over whole product
materials for extrusion?
plastics or metals Plastics: ABS, Acrylic Common metals: Aluminium, copper, magnesium
volume for extrusion?
batch and high volume runs
type of products for extrusion?
items remain the same along the whole length (e.g. guttering/ pipes)
materials for injection moulding?
mainly thermoplastics
volume for injection moulding?
high volume production. Minimum is usually 10,000 + as high tooling costs
type of products for injection moulding?
packaging, bottle caps
materials for extrusion blow moulding?
thermoplastics
volume for extrusion blow moulding?
high volume, but can also be used for shorter runs
type of products for extrusion blow moulding?
for more complex hollow products, such as milk bottles
materials for rotational moulding?
thermoplastics and aluminium
volume for rotational moulding?
batch to high volume mass production. moulds are simpler/ cheaper. 100-500 units
type of products for rotational moulding?
large hollow products.
soft rounded products
materials for sand casting?
metals with low melting points, such as lead, zinc, tin, aluminium, copper alloys
volume for sand casting?
used in industry for small batch production runs
type of products for sand casting?
tools, machine parts
materials for gravity die casting?
metal alloys with low melting points. e.g. aluminium, zinc and copper based alloys
volume for gravity die casting?
medium to high volume production
materials for vacuum forming?
thermoplastics
volume of vacuum forming?
from one offs to large scale production
type of products for vacuum forming?
open ended shapes with no undercut. shapes tend to be box/ dish like. also used for packaging
materials for calendering?
vinyl, ABS, polymer sheets, HDPE, polypropylene (thermoplastics)
volume for calendering?
usually a higher volume so it becomes more efficient
type of products for calendering?
thin sheets
materials for pressure die casting?
non ferrous materials with a low melting point. e.g. zinc, copper, aluminium alloys
volume for pressure die casting?
high volume due to cost of moulds
