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Processes Flashcards

1
Q

What is inejction moulding used for

A

Creating 3D complex shapes out of thermo plastics

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2
Q

Give a step by step o finejction moulding

A

Granuels fed into a hopper, which drops them into a screw

Screw is rotated by a motor, pushing the granuels across a heated section

Liquified granels forced into the mould

Mould is cooled and removed by steel ejector pins

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3
Q

Materials used in IM

A

PS
Polythene
Nylon
PP
ABS

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4
Q

Advantages of injection moulding

A

Detailed
High volume
Efficient
No finishing needed

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5
Q

Give sone disadvantages of IM

A

High inital costs
Expensive moulds

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6
Q

Step by step of blow moulding

A

Granuels fed into a hopper
Heated granuels are injection moulded, into a tube like form
Tueb (pre form) is placed in mould
Air is forced into the tube which expands in the mould
The mould si cooled then remoevd

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7
Q

What materials are used for blow moulding

A

HDPE
LDPE
PP
PVS
PET

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8
Q

Pros of BM

A

Rapid method
Suitable for all kind of production scales
Many types of plastic cna be sued
Less expensive then IM

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9
Q

Cons of BM

A

Limited to hollow parts
Moulds can be expensive
Difficult to produce compelx and pointed shapes

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10
Q

Step by step of rotationla moulding

A

Moulds loaded with presice amount of thermo palstic powder
Mould is clamped shut
Mould roatetd and heated
Mould cooled and remove

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11
Q

Materials for rotational moulding

A

Polyethelyne
PP
PVC
Nylon
Polycarbonate

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12
Q

Pros of RM

A

No seems or joins needed
Ideal for rigid, tough shapes
No waste
Surface textures easiluy applied
Cheaper moulds than IM and BM

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13
Q

Cons of BM

A

Only hollow shapes produced
Simpel shapes
Plastic needs alot of work doing to it before it can be used

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14
Q

Thermoforming step by step

A

A plastic sheet is held securley between two halves of a mould
Plastic is heated
Mould halves close togehter adn a vaccum is applied to the lower half
Upper mould is where the details at

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15
Q

Materials used in thermoforming

A

ABS
PS
Acrylic
Polycarbonate

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16
Q

Pros of Thermoformign

A

Low cost
Good to add deatil

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17
Q

COns of thermo formign

A

Deep moulds cn result in stretched products
Limited to simple designs
Trimmin required

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18
Q

Step by step of vaccum forming

A

Sheet of plastic heated
Mould is pushed up against plastic sheet
Vaccum is turned on and sheet moulds aroud mould
Sheet sets

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19
Q

Materials in VF

A

ABS
PS
Acylic
Polycarbonate

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20
Q

Pros of VF

A

Available to schools
Simple easy to use
Low costs
Suiatble for one off lareg scale production

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21
Q

Cons of VF

A

Trimmin reqired
Moulds have no vertical sides, draft angles needed
Can only have udnercuts with special moulds

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22
Q

Step by step of plastic extrusion

A

Granuels fed to a hopper
Motor turns a thread which pushes them alon g a heater
Heated plastic forced through a die
Extruded product cut to desrie length

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23
Q

Advantages of PE

A

Best way to keep a constient profile
Only requuires simple dies

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24
Q

Cons of PE

A

Not suitabel for one off production
Parts need to be cut to shape and assembled

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25
Step by step of calendaring
Pre mixed thermo plastics fed into rollers ROllers are heated Plastic isforced through the gap roller to determien thickneess FInal roller chills the material
26
Materials used in calendaring
PE PVC ABS MDPE Celluos accetate
27
Advantages of calendaring
Long continuous rolls without joints Lareg quantiites Can be combined with printing etc
28
Disadvantages of calendaring
Only for large scale
29
Step by step of comrpression moulding
Compressed plastic powder placed between two halves of a mould Mould is heated Mould is closed and the powder fits desired shape
30
Materials used in CM
thermo plastics Ceramcis
31
Adv of CM
Ideal for thermosetting plastics Long prodcution runs Low set up and mould costs Little waste Good for solid parts
32
Cons of CM
limited to simple parts
33
Dip moulding step by steop
Mould is dipped into a bath of molten plastic Nould is removed Mould si cooled End product is removed
34
Materials used in dip moulding
PVC Polyurethanes Latex Elastomers Silicolnes
35
Adv of dip moulding
Cost effective Prototypes and formers produced quick No split lines Suitable for large production
36
Cons of dip moulding
Limited to simple shapes
37
Plasma cutting step by step
Doen on a CNC
38
Materials used in plasma cuttign
Stainless steel Alluminuim Any conducitive metal
39
Pros of PC
Economical Smooth cuts Large range of materials cut
40
Cons of PC
High energy use High amount of waste Certain thickness needed
41
Laser cutting
Fine beam of light used by a CNC
42
Materials used in laser cutting
Alot
43
Advantages of laser cuttign
Can engrave and cut High compelx shapes made Sutiable for batch prod Clean edged cuts Lots of materials Low mainetence
44
Cons of LC
Can leave burn marks on woods etc Energy intesive Slwo when working on thicker materials High material waste Only certain thickness can be used
45
3D printing step by step
Plastic filleament fed into a motor which extrudes material into desired shape, layer by laeyr
46
Materials used in 3D printing
Thermoplastics Metals Plasters
47
Pros of 3D printign
Any shape Easy to improvce designs Rapid
48
Cons of 3D printign
Ethical issues Anythign xan be made
49
Press formign step by step
Sheets held into hydralich press and held together Punch of press forces the sheet to take shape of die
50
Materials used in press formign
Steel Copper Brass Aluminium
51
Adv of PF
Make 2D sheets into 3D Carried out in room temp Seamless parts made froma sheet of metak
52
Cons of PF
High tooling costs Very high levels of stress needed
53
Sandcasting step by step
Pattern made Each part of the patter is placed on a base board Half a mould box placed over Sand isi packed around Pattern remove from mould half Otehr half fitted with locating pins Moletn metal fed through a tube type bit Moudl broken once set
54
Materials used in SC
Copper alloys Zinc Aluminium Tin
55
Adv of SC
Low cost Easy to oeprate High detailed parts flexibel levels of production
56
Cons of SC
Laboru intensive Unit cost high when one off Lots of finishing
57
Die casting step by step
Molten metal poured into a chamber Injection pin forces the metal into a cavity at high pressure Pressure is maintained until metal solidfies Injector pins push compoenent out of die
58
Adv of DC
Suitable for materials with low melt points Complex shapes High detail Good surfaces finish Small thin parts made Fast
59
Cons of DC
Expensive Not guarenteed struct sstrength Trimming needed
60
Materials used in DC
Aluminium Zinc
61
Sintering step by step
Materials crushed into powder Powder compacted into a die , which gives final shape Compacted shape is heated and powder form
62
Materials used in sintering
Variety of glass, metals , plastics and ceramics
63
Pros of sintering
Good surface finish No wasted materials Complex shapes Alllows use of wasted material
64
Cons of sinetring
Not suited for thin walls Several stages shrinkage
65
Drop forging step by step
Meta l thing between two halves High force pushes and drops down top half Metal fills the cavity between two halfves
66
Materials used in DF
Ferrous metals Titanium COpper Alluminium
67
Pros of DF
Makes stronger peices Soem metals can be forged cold
68
Cons of DF
Expesnive Dangerous
69
Wood lamionating step by step
Adhesive applied to face of cenner Each venner is stakced ontop of each other Venner clamped in a die Adheisve dries
70
Pros of WL
Accomadates a raneg of thcikensss Creates strong lightweight parts Can eb combined wirth other materials
71
Cons of WL
Many steps Restricted to bends in one directoon
72
Materials used in WL
Wood veneers Birch is the most common
73
Steam bending step by step
Wood placed in steam box Box fed steam from PVC pipe Steam penetrates the grain and wood Wood softens Once softened wood is place around a former to desired shape
74
Pros of Steam Bending
Aesthetic appeal Done with simple eqip Can produce parts with good strenth to weight ratios Any shapes
75
Cons of SB
Only high qualty hard wods should he use Not good for prescion Bending radius depends on wood used
76
Materials used in SB
Hard woods Beech Oak ELm Ash Willow Mapl e
77
Die cutting step by steop
Sharp edges of cutting die brought to thin sheet material Material cut and creased and perfreated in one stpe
78
Materials used in die cutting
Paper All sorts of card PVC PET PP
79
Adv of die cutting
low set up cost effective for batches easil ycombiend with priniting many shapes cut in one action quick for large batchs
80
Cons of die cutting
3D products need to be assembled by hand
81
Brazing step by step
Metal cleaner Flux is brushed along the joint Pressurisied gas and air fed into anozel Nozel is heated with flame so its hot Brazing rod is pushd aganst the joint and the rod will metl along the joint
82
Materials used in brazing
Copper Mild steel
83
Adv of brazing
low costs suitable for all types of production little time needed strong bond clean joints compelx and intricate joints made can be rejoined if it goes wrong
84
cons of brazing
high degrees of cleanlieness joint colour different from metal not as strong as welded joints
85
TIG step by step
arc of electricity jumps from tungsten metal electrode to metal surface heat binds the edges electrode coated in a flux to prevent rusting
86
materials used in TIG
Carbons teel Staineless steel aLUMIUNIUM
87
Pros of TIG
Safer than brazing High quality welds No tooling costs
88
Cons of tig
High set up time Nto user friendly Ezpensive Skill needed to do it
89
what is fdm
fused deposition moulding, where layers are built of polymer to create parts
90
what is sla
stereolithogrpahy, which sues uv lasers to soldify layers of photopolymer
91
what us mjm
multi jet modelling, which gievs a very high quality finish
92
what si sls
selective lser sinetrimg, whcih uses alsers to fuse powdered metals into soldi models

Design (19 decks)

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