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Design > Processes > Flashcards

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
Q

Step by step of calendaring

A

Pre mixed thermo plastics fed into rollers
ROllers are heated
Plastic isforced through the gap roller to determien thickneess
FInal roller chills the material

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26
Q

Materials used in calendaring

A

PE
PVC
ABS
MDPE
Celluos accetate

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27
Q

Advantages of calendaring

A

Long continuous rolls without joints
Lareg quantiites
Can be combined with printing etc

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28
Q

Disadvantages of calendaring

A

Only for large scale

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29
Q

Step by step of comrpression moulding

A

Compressed plastic powder placed between two halves of a mould
Mould is heated
Mould is closed and the powder fits desired shape

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30
Q

Materials used in CM

A

thermo plastics
Ceramcis

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31
Q

Adv of CM

A

Ideal for thermosetting plastics
Long prodcution runs
Low set up and mould costs
Little waste
Good
for solid parts

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32
Q

Cons of CM

A

limited to simple parts

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33
Q

Dip moulding step by steop

A

Mould is dipped into a bath of molten plastic
Nould is removed
Mould si cooled
End product is removed

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34
Q

Materials used in dip moulding

A

PVC
Polyurethanes
Latex
Elastomers
Silicolnes

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35
Q

Adv of dip moulding

A

Cost effective
Prototypes and formers produced quick
No split lines
Suitable for large production

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36
Q

Cons of dip moulding

A

Limited to simple shapes

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37
Q

Plasma cutting step by step

A

Doen on a CNC

38
Q

Materials used in plasma cuttign

A

Stainless steel
Alluminuim
Any conducitive metal

39
Q

Pros of PC

A

Economical
Smooth cuts
Large range of materials cut

40
Q

Cons of PC

A

High energy use
High amount of waste
Certain thickness needed

41
Q

Laser cutting

A

Fine beam of light used by a CNC

42
Q

Materials used in laser cutting

A

Alot

43
Q

Advantages of laser cuttign

A

Can engrave and cut
High compelx shapes made
Sutiable for batch prod
Clean edged cuts
Lots of materials
Low mainetence

44
Q

Cons of LC

A

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
Q

3D printing step by step

A

Plastic filleament fed into a motor which extrudes material into desired shape, layer by laeyr

46
Q

Materials used in 3D printing

A

Thermoplastics
Metals
Plasters

47
Q

Pros of 3D printign

A

Any shape
Easy to improvce designs
Rapid

48
Q

Cons of 3D printign

A

Ethical issues
Anythign xan be made

49
Q

Press formign step by step

A

Sheets held into hydralich press and held together
Punch of press forces the sheet to take shape of die

50
Q

Materials used in press formign

A

Steel
Copper
Brass
Aluminium

51
Q

Adv of PF

A

Make 2D sheets into 3D
Carried out in room temp
Seamless parts made froma sheet of metak

52
Q

Cons of PF

A

High tooling costs
Very high levels of stress needed

53
Q

Sandcasting step by step

A

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
Q

Materials used in SC

A

Copper alloys
Zinc
Aluminium
Tin

55
Q

Adv of SC

A

Low cost
Easy to oeprate
High detailed parts
flexibel levels of production

56
Q

Cons of SC

A

Laboru intensive
Unit cost high when one off
Lots of finishing

57
Q

Die casting step by step

A

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
Q

Adv of DC

A

Suitable for materials with low melt points
Complex shapes
High detail
Good surfaces finish
Small thin parts made
Fast

59
Q

Cons of DC

A

Expensive
Not guarenteed struct sstrength
Trimming needed

60
Q

Materials used in DC

A

Aluminium
Zinc

61
Q

Sintering step by step

A

Materials crushed into powder
Powder compacted into a die , which gives final shape
Compacted shape is heated and powder form

62
Q

Materials used in sintering

A

Variety of glass, metals , plastics and ceramics

63
Q

Pros of sintering

A

Good surface finish
No wasted materials
Complex shapes
Alllows use of wasted material

64
Q

Cons of sinetring

A

Not suited for thin walls
Several stages
shrinkage

65
Q

Drop forging step by step

A

Meta l thing between two halves
High force pushes and drops down top half
Metal fills the cavity between two halfves

66
Q

Materials used in DF

A

Ferrous metals
Titanium
COpper
Alluminium

67
Q

Pros of DF

A

Makes stronger peices
Soem metals can be forged cold

68
Q

Cons of DF

A

Expesnive
Dangerous

69
Q

Wood lamionating step by step

A

Adhesive applied to face of cenner
Each venner is stakced ontop of each other
Venner clamped in a die
Adheisve dries

70
Q

Pros of WL

A

Accomadates a raneg of thcikensss
Creates strong lightweight parts
Can eb combined wirth other materials

71
Q

Cons of WL

A

Many steps
Restricted to bends in one directoon

72
Q

Materials used in WL

A

Wood veneers
Birch is the most common

73
Q

Steam bending step by step

A

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
Q

Pros of Steam Bending

A

Aesthetic appeal
Done with simple eqip
Can produce parts with good strenth to weight ratios
Any shapes

75
Q

Cons of SB

A

Only high qualty hard wods should he use
Not good for prescion
Bending radius depends on wood used

76
Q

Materials used in SB

A

Hard woods
Beech
Oak
ELm
Ash
Willow
Mapl e

77
Q

Die cutting step by steop

A

Sharp edges of cutting die brought to thin sheet material
Material cut and creased and perfreated in one stpe

78
Q

Materials used in die cutting

A

Paper
All sorts of card
PVC
PET
PP

79
Q

Adv of die cutting

A

low set up cost
effective for batches
easil ycombiend with priniting
many shapes cut in one action
quick for large batchs

80
Q

Cons of die cutting

A

3D products need to be assembled by hand

81
Q

Brazing step by step

A

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
Q

Materials used in brazing

A

Copper
Mild steel

83
Q

Adv of brazing

A

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
Q

cons of brazing

A

high degrees of cleanlieness
joint colour different from metal
not as strong as welded joints

85
Q

TIG step by step

A

arc of electricity jumps from tungsten metal electrode to metal surface
heat binds the edges
electrode coated in a flux to prevent rusting

86
Q

materials used in TIG

A

Carbons teel
Staineless steel
aLUMIUNIUM

87
Q

Pros of TIG

A

Safer than brazing
High quality welds
No tooling costs

88
Q

Cons of tig

A

High set up time
Nto user friendly
Ezpensive
Skill needed to do it

89
Q

what is fdm

A

fused deposition moulding, where layers are built of polymer to create parts

90
Q

what is sla

A

stereolithogrpahy, which sues uv lasers to soldify layers of photopolymer

91
Q

what us mjm

A

multi jet modelling, which gievs a very high quality finish

92
Q

what si sls

A

selective lser sinetrimg, whcih uses alsers to fuse powdered metals into soldi models

Design (19 decks)

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