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DT Paper 1 Revision > 16 - Metal processes > Flashcards

16 - Metal processes Flashcards

1
Q

3 groups for metal processes

A
  • Forming
  • Resditribution
  • Wastage
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2
Q

Metal processes - forming

A

Are processes in which no material is removed, but materials are deformed to produce required shapes

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3
Q

Metal processes - redistribution

A

Are processes where the material is changed from one form to another without loss of material e.g liquid metal poured into a mould to take a solid shape

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4
Q

Metal processes - wastage

A

Are processes that cut away material to leave the desired shape

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5
Q

Types of forming (7)

A
  • Press forming
  • Spinning
  • Cupping and deep drawing
  • Drop forging
  • Wrought iron forging
  • Bending
  • Rolling
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6
Q

Types of redistribution

A
  • Sand casting
  • Gravity die casting
  • Prssure die casting (hot & cold chamber)
  • Investment casting
  • Low temperature pewter casting
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7
Q

Types of wastage (4)

A
  • Milling
  • Flame cutting
  • Plasma cutting
  • Laser cutting
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8
Q

Press forming:

  • stock form
  • products
A
  • Sheet
  • Metal seats, car body panels, boxes and containers
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9
Q

Spinning:

  • stock form
  • products
A
  • Sheet
  • Body of stainless steel kettles, saucepans, metal light shades
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10
Q

Cupping and deep drawing:

  • stock form
  • products
A
  • sheet (round blank)
  • tube-like shapes such as fire extinguishers, aerosol cans, drink cans
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11
Q

Drop forging:

  • stock form
  • products
A
  • Billet
  • Spanner’s, pliers and screwdriver shafts
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12
Q

Wrought iron forging:

  • stock form
  • products
A
  • Bar
  • Decorative metalwork such as gate scrolls, decorative fencing
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13
Q

Key features of wrought iron forging (3)

A
  • Uses wrought iron (carbon content less than 0.08%)
  • Can be hand or hydraulic press process
  • Suitable for one-off or small-batch production
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14
Q

Bending:

  • stock form
  • products
A
  • Sheet or plate
  • Seams on metal edges, bending sheets for product casting or housings
  • mainly used for large scale batches in industry
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15
Q

Rolling:

  • stock form
  • products
A
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16
Q

Key features of rolling (3)

A
  • Hot rolling metal results in uniform mechanical properties, no deformation or stresses
  • 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
17
Q

Sand casting:

  • stock form
  • products (7)
A
  • Molten metal from a billet
  • Railway carriage wheels, wood working clamps, vices, motor housings, bollards, drain covers, post boxes
18
Q

Key features of sand casting (3)

A
  • Labour-intensive process
  • Not a high-quality surface finish
  • Suitable for one-off or small-batch production
19
Q

Gravity die casting:

  • process
  • stock form
  • products
A

•

20
Q

Key features of gravity die casting (2)

A
  • Used for thicker mould sections
  • Used for very large-batch and mass production
21
Q

Pressure die casting (hot chamber):

  • process type
  • stock form
  • products
A
  • Redistribution
  • Molten metal from a billet
  • Toy cars collectible figures, decorative door knobs and handles
22
Q

Key features of pressure die casting hot chamber (2)

A
  • Fast process
  • Uses for very large batch and mass production
23
Q

Pressure die casting (cold chamber):

  • process type
  • stock form
  • products
A
  • Redistribution
  • Molten metal from a billet
  • Toy cars, collectible figures, decorative door knobs and handles
24
Q

Key features of pressure die casting (cold chamber)

A

Used for very large-batch and mass production

25
Q

Investment casting:

  • process
  • stock form
  • products
A
  • Redistribution
  • Molten metal from a billet
  • Cast jewellery or collectable figures, hip replacement joints
26
Q

Key features of Investment casting (3)

A
  • Used for intricate or awkward shapes that would be difficult or impossible to Luke using any other casting process
  • High quality excellent finish
  • Wax patterns are cast from a master mould, repeatable quality process
27
Q

Low temperature pewter casting:

  • process type
  • stock form
  • products
A
  • Redistribution
  • Molten metal from a billet
  • Jewellery, key fobs and decorative components
28
Q

Key features of low temperature pewter casting (3)

A
  • Used for school or college projects
  • Can be used with simple MDF moulds
  • Suitable for one-off production or small batch
29
Q

Key features of press forming (3)

A
  • Shapes sheet metal into 3D forms
  • Often used in conjunction with robots for lifting sheet into place
  • Suitable for mass production or large-scale batch production
30
Q

Key features of spinning (2)

A
  • Products May show parallel lines where the sheet has been forced onto the mandrel
  • Suitable for small-scale batch production
31
Q

Key features of cupping and deep drawing (4)

A
  • Starts with a metal blank
  • Metal is stretched into shape
  • High initial tooling cost
  • Used for large-scale mass or continuous production
32
Q

Key features of drop forging (4)

A
  • Used 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 shaped and cooled
  • Suitable for mass production

DT Paper 1 Revision (9 decks)

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