1.16 Metal Processes Flashcards
Describe the term forming
No material is removed, but materials are deformed to produce required shapes
Describe the term redistribution
The material is changed from one form to another, e.g. liquid metal poured into a mould to take a solid shape
Describe the term wastage
Material is cut away to leave the desired shape
State two features of press froming
Process form: Forming
- Shapes sheet metal into 3D forms
- Often used in conjunction with robots for lifting the sheet into place
- Suitable for mass production or large-scale batch production
State two features of wrought iron forging
Process type: Forming
- Uses wrought iron (carbon content less than 0.8%)
- Can be hand or hydraulic press process
- Suitable for one-off or small-batch production
State two features of cupping and deep drawing
Process form: Forming
- Starts with a metal blank
- Metal is stretched into shape
- Used for large-scale mass or continuous production
State two features of drop forging
Process type: Forming
- Use for products that need to be tough and hard
- Maintains the internal grain structure which retains the strength
- Hot metal billet shaped on an anvil or die and then pressed into shape and cooled
- Suitable for mass production
State two features of spinning
Process form: Forming
- Product may show parallel lines where the sheet has been forced onto the mandrel
- Suitable for mass production or small-batch production
Describe the term addition/fabrication
Process where components and products are made by adding pieces together
State two features of sand casting
Process type: Redistribution
- Labour-intensive process
- Not a high-quality surface finish
- Suitable for one-off or small-batch production
State two features of blending
Process type: Forming
- Does not include any punching or trimming of the metal
- Simple bending can be carried out in school or college workshops
- Used for large-scaled batches in industry
State two features of rolling
Process type: Forming
- Hot rolling metal results in uniform mechanical properties, no deformation or stress
- Surface is usually coated with carbon deposits, which must be removed using acid pickling
- Cold rolling results in a material that has a tighter tolerance and better surface finish
State two features of gravity die casting
Process type: Redistribution
- Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
- Relies on gravity to help the metal flow into the mould
- Used for thicker mould sections
- Used for very large-batch and mass production
State two features of pressure die casting (hot chamber)
Process type: Redistribution
- Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
- Molten metal stored in a shot of molten metal is forced into the die
- Fast process
- Used for very large-batch and mass production
State two features of pressure die casting (cold chamber)
Process type: Redistribution
- Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
- Molten metal ladled into shot chamber and hydraulically pushed into the chamber
- Used for very large-batch and mass production
