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A-level Product Design > Unit 9 - Metal Forming Process > Flashcards

Unit 9 - Metal Forming Process Flashcards

1
Q

What is press forming?

A
  • Press forming shapes from sheet metal into 3D forms
  • E.g. low carbon steel / aluminium
  • Common in mass production
  • Dies are made from hardened steel
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2
Q

What is spinning?

A
  • A way of forming sheet metal giving radial symmetry
  • Kettles, saucepans are made this way
  • used in mass and batch production
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3
Q

What is cupping and deep drawing?

A
  • Used to form tube like shapes from sheet metal
  • E.g. fire extinguisher, aerosol cans
  • Deep drawing is when the depth of pressing exceeds the diameter
  • Corners of the punch are rounded so the metal stretches
  • High set up costs
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4
Q

What is drop forging?

A
  • Used to shape hot metal, used when the product needs to be tough and hard
  • spanner’s, pliers
  • Hot metal is forced into shape under great pressure therefore creating a new shape
  • Mass production, can vary though
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5
Q

What is wrought iron forcing?

A

Wrought iron has a low carbon content making it malleable and easy to shape

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6
Q

What is scrolls?

A
  • Wrought iron is heated in a forge then shaped
  • Scroll formers and twisting bars help make intricate shapes
  • One-off, limited batch production
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7
Q

What is bending?

A
  • A press brake is used for bending sheet or plate metal
  • Stock material is clamped between a punch and die
  • Break holds the metal and lowers the punch to bend the metal into shape
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8
Q

What is rolling?

A
  • Used to reduce the thickness of metals
  • Used to make structural steels like beams, bars and channel for the construction industry
  • Used with hot metal that has been heated above recrystallisation temperature
  • Can result in surface carbon deposits but has no deformation or stresses
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9
Q

What is die casting?

A
  • Uses a lower melting point metal e.g. alluminium, pewter, and zinc
  • It is high cost initial costs and can make complex items
  • High quality finish items
  • E.g. alloy wheels, metal toys
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10
Q

How does die casting work?

A

Molten metal is fed into the die (mould) and where it cools

Ejector pins ensure the casting releases from the die

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11
Q

What is sand casting?

A
  • used to form high melting point metals
  • made from special moulds made from ‘green sand’
  • used for engine blocks, post boxes and train wheels
  • one-off, batch
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12
Q

How does sand casting work?

A

A pattern is used to make the mould. The mould and a able to be opened in halves so the cooled metal can be removed

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13
Q

What is investment casting?

A
  • used to cast items with awkward shapes that would be difficult to mould using any other casting process
  • can be used by many metals
  • produces a high quality finish
  • repeatability is achieved
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14
Q

What is pewter casting?

A
  • the metal has a low melting point and is often used in schools
  • ideal for jewellery
  • can be shaped by common tools
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15
Q

What is MIG welding?

A
  • used to weld thin gauge metal such as aluminium and steels
  • heat is generated from an electrode
  • workpiece is clamped to the negative connection
  • e.g. climbing frames, bike frames
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16
Q

How does MIG welding work?

What does MIG stand for?

A
  • used a filler wire as an electrode
  • the wire electrode melts in the arc and fills the gap between the two metals
  • welding torch is gently swirled to form a bead of weld
  • Metal Insert Gas
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17
Q

What is TIG welding?

What does TIG stand for?

A
  • is used to weld stainless steel, aluminium and copper alloys
  • an electric arc welding process
  • the tungsten does not melt in the process, a filler material is added separately
  • uses a gas shield of argon or helium

-Tungsten Insert Welding

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18
Q

What is spot welding?

A
  • welds sheet metal together without a filler material
  • heat and pressure are applied to the area to be welded
  • surfaces are joined by heat generated from resistance to an electric current
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19
Q

What is oxy-acetylene welding?

A
  • used to weld low carbon steel sheet, tube or plate

- mixes two high pressure gases ( oxygen and acetylene ) forming a very hot and intense flame

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20
Q

What is soft soldering?

A
  • used low melting point metals (solder) to join metals together
  • traditionally a tin/led alloy with a low melting point (320 degrees C)
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21
Q

What is hard soldering?

A
  • uses a higher temperature than soft soldering
  • it is used to join precious metal like gold and silver
  • a flux must be applied to prevent metal oxidisation
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22
Q

What is brazing?

A
  • uses either an oxy-acetylene flame or gas and compressed air brazing hearth
  • needs a lower temp than welding as brazing melts lower
  • not as strong as others
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23
Q

What is riveting?

A
  • is semi-permanent joining method used to join sheet or plate metal
  • are metal fasteners that have a head at one end and a shaft or tail the other end
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24
Q

What is cold-formed rivets?

A
  • require access to both sides of the sheet material

- they are installed with a ‘set’ and ‘snap’ which domes the ends while pressure is applied

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25
Q

What is pop riveting?

A
  • quick and easy to use
  • not very strong
  • require a pop riveting gun
  • ideal where the underside of the joint is inaccessible
  • a form of pop rivets is used in aircraft production
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26
Q

How does pop riveting work?

A
  • create a semi-permanent fixing between two thin sections of metal
  • the gun applies pressure to the rivet by pulling the shank until it breaks
  • this action splays the inserted end to create the bond
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27
Q

What are self tapping screws?

A
  • cut their own thread as they are screwed into sheet metal/some plastics
  • used in panel products which require maintenance
  • some can create their own hole, a pilot hole is advised for a precise and accurate result
28
Q

What are machine screws?

A
  • a type of bolt with a fine thread
  • used in motor and gear housings and in many electronic product castings
  • different types include: cheese head, round head, counter sunk
  • identified by their length, diameter and head profile
29
Q

What is the purpose of nuts and bolts?

A
  • they are passed all the way through, then a nut is tightened at the other end
  • some types of nut, like castle and nylon are designed to be loose
30
Q

What is a wasting process?

A
  • involve the removal of material by cutting

- they produce waste or unusable material

31
Q

What are milling machines?

A
  • cut vertically or horizontally but some advanced mills can now cut on many axes
32
Q

What is complex milling?

A
  • used to create highly accurate machine parts
  • the workpiece and the rotary cutting tools move through x, y and z axes
  • completely geometry can be creating using a 4th and 5th axis
  • can be done manually and with a CNC
33
Q

What is 3D milling?

A
  • some mills use multi-tooled cutters to waste the workpiece
  • mills can be used to create holes, chamfers, slots
  • slots can be machined using special cutters with accurate profiles
  • milling is suitable for one-off intricate components but can be set up to run repeatedly as part of batch production
34
Q

What is turning?

A
  • a centre large or engineer’s large is used to turn metal
  • the workpiece is held with a three or four jaw Chuck, the cutting tool moves in two axes
  • a Chuck can also be fitted to the tail stick for centring and drilling
  • longer workpieces are often centred using the tail stock
35
Q

What is a centre lathe?

A
  • centre lathes use single point cutting tools usually made from HSS or silicone carbide
36
Q

What is a manual turning lathe?

A
  • manual turning

- can produce bespoke and one-off pieces

37
Q

What are CNC turning?

A
  • use multi-tool heads which change tools automatically for a given task
  • CAD programmes allow complex and accurate shapes to be repeated quickly and efficiently
38
Q

Name as many lathe turning techniques (out of 6)

A
  • facing
  • parallel turning
  • taper turning
  • parting
  • drilling
  • knurling
39
Q

What is flame cutting?

A
  • uses oxyacetylene gas and a flame cutting torch to focus a flame up to 3500 degrees C
  • oxygen intensifies the flame and forces the molten metal out
  • used to cut low carbon and alloy steel plate
40
Q

What is plasma cutting?

A
  • plasma is an ionised gas which is electrically conductive at very high temperatures
  • plasma cutting generates a faster, cleaner cut than flame cutting
  • suitable for one off and batch production
  • applications: sculptural signs and bespoke gates
41
Q

How does plasma cutting work?

A
  • can be manual or done by CNC
  • electric arc is sent though plasma cutting gas and out a constructed opening
  • can cut steel, aluminium, stainless steel etc up to 150mm thick
42
Q

What are metal laser cutters?

A
  • a high powered laser beam is directed through optics at the workpiece on the laser bed
  • the beam focus, speed and power can be adjusted
  • lasted melts the metal and compressed air/gas blows the molten metal clear
  • fine beam allows for high levels of accuracy
43
Q

What is laser cutting

A
  • can be used on sheet metal
  • cannot cut metal plate that is too thick
  • fast, high accuracy levels and high quality finishes
  • high energy consumption
  • suitable for one-off to large batch production
44
Q

What is punching and stamping?

A
  • stamping pierces the metal sheet to cut out a shape or slot -> the cut outs are recycled
  • blanking creates cut out parts for further processing and recycled the original punch sheet
45
Q

What are the two main reasons finishes are applied to metals?

A
  • enhance appearance (aesthetics)
  • ferrous metals rust over time - some metals do not form a strong oxide layer to protect them from corrosion so something is added to help protect them
46
Q

What does cellulose paint provide metal with?

A
  • colour and a barrier against corrosion
  • needs multiple layers
  • high quality finish
  • contains VOC’a
  • workpiece must be degreased before hand
  • used on cars
47
Q

What does acrylic paint provide metal with?

A
  • water-based, durable and hard wearing
  • usually require heat, professional equipment
  • up to 24 hours to cure, doesn’t take many coats (e.g. 2/3)
  • application include bicycles
48
Q

What is electroplating?

A
  • uses a desired metal to coat a (usually) cheaper base metal
  • provides a protective layer with increased aesthetic appeal
  • negative electrode is the object to be plated
  • positive electrode is the coating metal
  • electrolyte solution is a solution of the coating metal
49
Q

How do sealants work?

A
  • block the passage of air and fluids through metal points
  • used on metals that are usually polymer based and act as a gasket, often in machinery
  • help prevent decay/ corrosion
50
Q

What are preservatives for metal?

A
  • can provide temporary or long term protection
  • often used in moulds or dies to prevent atmospheric corrosion or condensation build up
  • mainly oil-based, used on machine beds
51
Q

How does anodising work?

A
  • aluminium work piece is immersed into an acid electrolyte bath
  • electric current is passed through it
  • cathode in the tank, aluminium cast as an anode
  • magnesium and titanium can be anodised
52
Q

What does anodising do to a workpiece?

A
  • mainly on aluminium

- provides a hard wearing corrosion resistant surface

53
Q

What is galvanising?

A
  • costs iron or steel with zinc

- zinc is the protective layer

54
Q

How does galvanising work?

A

Zinc carbonate forms when zinc is exposed to air and water

This layer is extremely resistant to corrosion and very strong

55
Q

What is the zinc hot dipping method?

A

A workpiece is coated using a four stage process to ensure a good bond is made
- good for large pieces and thick coverage

56
Q

What is included in the zinc hot dipping method?

A
  • workpiece dipped into molten zinc bath at 830-850 degrees C
  • then cooled, cleaned up and inspected to insure even thickness and good coverage
  • good for large pieces and thick coverage
57
Q

What are the first two parts of the anodising process?

A

Pre-treatment

  • cleaning
  • brightening / etching
58
Q

What is done in the anodising process after pre-treatment?

A

Electrolysis

  • the acid (electrolyte) is in a bath
  • aluminium in in the acid alongside the cathode
  • aluminium acts as anode
  • electric current is passed through aluminium
59
Q

What is the last two parts of the anodising process?

A

Post-treatment:

  • colouring
  • sealing

Finished

60
Q

What can planting and metal coatings do?

A
  • Increase wear and lubricity

- Offers a thermal barrier/improved conductivity

61
Q

How does planting work?

A
  • done using physical vapour deposition (PVD)

- uses heat and pressure to o fuse metal together

62
Q

What is polymer coating?

A

-provides a thick, wear, water resistant and an air tight finish

63
Q

How does polymer coating work?

A
  • the metal is heated to 230 degrees C
  • it’s dipped into a tank of fluidised polymer powder as warm air blows around it
  • the heat from the metal bonds the metal and the polymer together
  • then cooled and if solidifies
64
Q

What is powder coating?

A
  • provides an even coat
  • move hardwearing than paint
  • sprayed through an air gun
65
Q

How does powder coating work?

A
  • the charge creates a strong attraction between powder and the workpiece
  • the piece is baked in an oven where the coating melts and bonds to metal
66
Q

What is cathodic protection?

A
  • Sacrificial anodes are used to control the corrosion of a metal surface
  • The process makes the metal protected with an electrochemical cell
  • The anode is bonded to the surface which corrodes instead of the metal
  • Used in pipelines, fuel, oil rig foundations, and boat hulls

A-level Product Design (2 decks)

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