tools and processes and moulding Flashcards
What does wasting mean
Wasting is the term given to any of the cutting processes that produce waste material wasting change of both the size and the shape of the resistant material, e.g. sawing, filling, panelling, lathe work, drilling, and machining
What does fabrication mean
Fabrication is the joining of pieces of material, using the most appropriate method. This includes joints, screws, rivets, and giving to from a desired shape.
What are the 5 Steps for bending plastic
1 mark bend line with non permanent pen and a dashed line
2 line the bend line up with the wire of the line bender strip heater
3 wait until the plastic is soft
4 bend to desired angle
5 hold until cool
What are the 3 steps for Bending metal
1 mark bend line with a scribes and a dashed line
2 line up the bend line with the folding bars or top of a vice
3 use scrap wood and a hammer to bend the metal to desired angle
What is a pencil used for in wood
Drawing and marking lines
what is a steel rule used for in wood
measuring in mm and marking straight lines
what is a tri-square used for in wood
marking and testing right angle
what is a sliding bevel used for in wood
marking and testing any desired angle
what is a marking knife used for in wood
to break the grain to keep marking accurate
what is a marking gauge used for in wood
marking drill holes
what is a steel rule used for in metal
make your scriber marks stand out
what is a scriber used for in metal
marking out lines by scratching the surface
what is a engineer’s square used for in metal
marking and testing right angles
what is a centre punch used for in metal
marking drill hole
what is a engineer’s marker blue used for in metal
make your scriber marks stand out
what is a spring leg dividers used for in metal
marking circle and regular intervals
what is a steel rule used for in plastic
measuring in mm and marking straight lines
what is a tri-square used for in plastic
marking and testing right angle
what is a non permanent pen used for in plastic
marking and drawing lines
shape of a cutting line in plastic (solid line)
____________
shape of a bending line in plastic (dashed line)
shape of a hole in plastic (cross)
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what is a Vernier Caliper
the Vernier Caliper is a precision instrument that can be used to measure internal and external distances extremely accurately
what is a Micrometer
the Micrometer is a precision measuring instrument, used by engineers. each revolution of the rachet moves the spinel face 0.5mm towards the anvil face.
name the 4 types of saws
tenon saw
coping saw
hacksaw
scroll saw
features of a tenon saw
bid blade
long brass spine
application of a tenon saw
cuts wood
cuts straight lines
features of a coping saw
small blade
metal spine
application of a coping saw
cuts curve lines in wood and plastic
features of a hacksaw
medium blade
metal spine
application of a hacksaw
cuts curves in metal and plastic
features of a scroll saw
coping saw that goes up and down
application of a scroll saw
accurate curves in wood and plastic
name the 3 wood wasting tools
hand plane
wood chisel
mallet
features of a hand plane
made out of metal for fine thin wood
application of a hand plane
shaves down the edge of the wood
features of a wood chisel
sharping cutting edge and a sharp edge to slice across the grain
application of a wood chisel
press down from the chest with pressure to remove waste
features of a mallet
made out of rubber or wood
application of a mallet
used to hammer in a nail and to strike a chisel
name the 5 dill bits
twist drill bit
flat drill bit
forstner bit
hole cutter
countersunk drill bit
features of a twist drill bit
made from carbon or high speed steel
application of a twist drill bit
drill small holes in wood, plastic and metal
features of a flat drill bit
very quick cutting of holes with a power drill
application of a flat drill bit
drill large flat bottomed holes on wood and plastics
features of a forstner bit
designed to drill a flat-bottomed hole in wood
application of a forstner bit
drilling larger diameters into wood
features of a hole cutter
cup-shaped metal cylinder with a toothed cutting edge on the open end
application of a hole cutter
cutting round holes in wood and plastic
features of a countersunk drill bit
the metal pointed tip
application of a countersunk drill bit
creating circular holes in material from drywall and wood to metal and masonry
name the 3 types of drills
hand drill
cordless drill
pillar drill
features of a hand drill
The hand drill consists of a cranking handle that turns pinion gears on the main shaft. A chuck at the end of the shaft holds a drill bit.
application of a hand drill
Place the bit’s tip where you want to cut a hole, making sure the bit is at the same angle as the desired hole. Turn the cranking handle to rotate the bit and drill the hole.
features of a cordless drill
Cordless drills work on rechargeable batteries, allowing the user to insert a battery pack and instantly have an operating drill without a power cable.
application of a cordless drill
This tool may be used to drill holes in metal, plastics, wood, and stone, as well as drive screws with an electric screwdriver.
features of a pillar drill
The machines are relatively simple and are centred around a substantial steel column; onto one end is attached the motor, drive belt system and chuck.
application of a pillar drill
These bits are then used to accurately machine, drill or tap holes in a variety of materials such as metal and wood.
name the 3 types of hammers
claw hammer
pin hammer
ball pein hammer
features of a claw hammer
The face, shaped into a circular anvil about an inch in diameter, is primarily for driving nails. The claws can be straight or curved, flat or pointed.
application of a claw hammer
used to hammer and remove large nails particularly when roofing houses
features of a pin hammer
r. The diagonal-peen hammer’s head, as the name implies, is at a 45° angle from the handle.
application of a pin hammer
used to hammer in small nails
features of a ball pein hammer
It has two heads, one flat and the other, called the peen, rounded.
application of a ball pein hammer
used to hammer in larger nails and to flatten the heads of metal rivets
name the 3 types of files
flat files
half round files
round files
features of a flat file
It has a flat surface with parallel edges, ideal for general-purpose filing. Its versatile shape makes it suitable for both concave and flat surfaces.
application of a flat file
used to remove waste material (wood, metal and plastic) to a finished size. using a file is the first stage of finishing/smoothing material.
features of a half round files
The combination of a flat side and rounded side means that the half round file is ideal for use on concave, convex and flat surfaces making it a very versatile tool.
application of a half round files
is it used for filing out internal curves
features of a round file
the whole thing is round very good to smooth out holes to your desired shape
application of a round file
is it used for filing out holes
explain the process of cross filing
Cross filing involves securing the metalwork piece firmly, choosing an appropriate file, and holding it perpendicular to the work surface while applying pressure. The file is then moved diagonally across the metal in one direction, ensuring consistent strokes until the file loses its bite. To maintain evenness, the filing direction is alternated diagonally in the opposite direction. Regular checks for a smooth, levelled surface are made by running a hand or a straight edge across it. Once the desired levelness is achieved, finishing touches using finer abrasives or files help smoothen the surface further, resulting in a flat and uniform finish on the metal.
explain the process of draw filing
Draw filing is a metalworking technique used to refine surfaces to a high level of smoothness and flatness. In this process, a file, often a single-cut mill file, is used with the workpiece firmly secured. The file is positioned at an angle, typically around 15-30 degrees to the work surface, and pulled lengthwise with long, steady strokes. This action removes small imperfections left from previous filing processes, creating a finer and more polished surface. The file is lifted at the end of each stroke and returned to the starting position to maintain a consistent filing pattern. Draw filing continues until the desired level of smoothness and flatness is achieved, resulting in a refined and even surface on the metal.
name the 5 machines
bandfacer/linisher (sanding machine)
pedestal polisher
milling machine
wood lathe
metal/plastic lathe
features of a bandfacer/linisher (sanding machine)
the abrasive belts are available from 40 grit to 400 grit to suit the material removal rate or the finish required
application of a bandfacer/linisher (sanding machine)
a linisher turns a belt or a disc of abrasive material to smooth a workpiece, creating a level, even surface
features of a pedestal polisher
perform operations of brushing, buffing, polishing and for the lathes finishing of any metal material
application of a pedestal polisher
used to sharper high-speed steel cutting tools used on the laths and milling machines, or used to remove surface imperfections and to work extremely hard material.
features of a milling machine
milling machine operates by a rotating cutter to remove material from the work pieces
application of a milling machine
used the T-slots on the table to directly clamp the work and also use a machine vice with a swivel base
application of a wood lathe
the work is held between the head stock and the tail stock and rotates a high speed while cutting tools, including a variety of chisels and gouges, gradually cut and shape it.
features of a wood lathe
the wood lathe uses a range of chisels and gouges to cut the spinning wood into complex profile.
features of a metal/plastic lathe
The main use is to remove unwanted parts of the material, leaving behind a nicely shaped workpiece.
application of a metal/plastic lathe
Metal turning lathes are used to precision machine circular (round) features on metal, plastic, and composite work pieces.
what is vacuum forming
vacuum forming is used for food and confectionary packaging, trays, shop fittings and baths.
What are the 8 steps for vacuum forming
1 put the mould in the machine
2 put the plastic over the mould
3 make the vacuum air tight
4 heat the plastic
5 raise the mould
6 suck the air out
7 wait until its cool
8 remove the mould
What are the 7 properties of vacuum forming
mould has to have higher melting point
harder stronger material
smooth shape
has to have straight lie or inward sloop
mast common mould is MDF
easy to work with
very smooth surface
very cheap
steps for blow mould
1 parison inserted into mould its then heated
2 base of parison squeezed by mould
3 air blown into parison, parison expands to fill mould
4 finished product
what is press moulding
press or compression moulding. a mould is made in two halves sheets plastic is placed between the two halves which are then heated and pressure applied, enabling the plastic to assume the new shape.
what is laminating
wood is usually bent by laminating. this is done by cutting thin strips of wood. putting glue on the strips and clamping them into a mould. steam makes it easier to bend.
