Exam metal processes

Question 1

types of stamping or pressing

Answer 1

piercing
blanking
notching
croppig
hending
forming

Question 2

what piecing

Answer 2

where suitable punch shears a whoole in piece of metal

Question 3

what is blaking

Answer 3

where punch shears the required shape from metla

Question 4

what is cropping

Answer 4

where pucnh shears a plain or shaped length

Question 5

what is bedning

Answer 5

where shit bent

Question 6

what formig

Answer 6

where metal ks forced into the shape of the surface contous of a die

Question 7

hwo press formign etc etc work

Answer 7

hydralich press just stamps whoels into shit
or forces into a shape
or forces around a jig, which bends it

Question 8

formign step by step

Answer 8

sheet prepped
sheet stamped, formed , with hydralich press

Question 9

how bendign work

Answer 9

aroudna die

Question 10

when a sheet has a whoel or shape in it what is it called

Answer 10

piecing

Question 11

when a sheet has a hole or bit fo metal taken out what is it called

Answer 11

blanking

Question 12

what are majroity fo press related oepartings confiend to

Answer 12

large batch production

Question 13

why majority fo press related shit left to large batch prod

Answer 13

high costs
length tool settign up involbed

Question 14

what can be used to maxamsisie and economies press formign

Answer 14

cnc to work out best nesting of shapes etc

Question 15

types of preses

Answer 15

arbor press
fly press

Question 16

what is arbor pressing

Answer 16

hand operated shit

Question 17

what is fly press

Answer 17

heavy iron frame
square ram
big release
boom

Question 18

pros of balankign and peircing

Answer 18

many sahpes
any metal
high accuracy

Question 19

cons fo blankign and peircing

Answer 19

restrcite to metal sheets
limited to size of stcok meteriasl
can be high waste

Question 20

what press forming (booklet)

Answer 20

sheet metals loaded into press
clamped togheter
inblank holder
pucnh forces metal throguh die to take shape of punch

Question 21

pros of pres formign (bookelt)

Answer 21

3d shapes
icn stiffness
carried otu at room temo
high to med vol
seamless sheets in one go

Question 22

cons of press formign (booklet)

Answer 22

high tooling costs
high levels of force needed

Question 23

what sand castin

Answer 23

low cost method of castign emtal in sand mould
s

Question 24

scale of sand cast

Answer 24

one off or low volume production

Question 25

step by step of sand castin

Answer 25

pattern palced in box box filled with sand sand solidifies sprue channels are made pattern rremoved top mould half doen same process moulds put on top of eahcother, lcoator pins for alignment molten metalin finish

Question 26

what to ensure there is on sand cast diargam

Answer 26

vents sprue channels parting pwoder between the moulds slightly larger pattern than required

Question 27

adv of sand castign

Answer 27

low cost easy to opertate intircate parts flexibel levels of production

Question 28

cons fo sand casting

Answer 28

moudl remade for every part overall accuracy is poor parts need finising

Question 29

is high pressure diecastign economical

Answer 29

yes

Question 30

how die castign work

Answer 30

molten metal poured into champer piston or plunger forces metal at high pressure into caviy pressure kept utnilshti solidifies inejctor pins push out compoenents

Question 31

what die castign diragam look lie

Answer 31

inj mould put instead of scre its plunger that pushs metal into die

Question 32

pros of die castign

Answer 32

re use moulds no finsihign really accurate fast small thin parts

Question 33

cons of die castign

Answer 33

expensive can have weak strcutrue in parts can nneed soem extra finsiing

Question 34

why steels and ferrous metals nto used in die castign

Answer 34

need high temp to metl them , whcih can damage moudls and accuracy leveels

Question 35

what gravity die castign

Answer 35

permanent metl die metal poured in let gravty do its thing

Question 36

why pressure die castign give better quality than gravity

Answer 36

presssure contstantl pushign emanign good contact with the die costantl

Question 37

what to make sure on die cast drawing

Answer 37

soem form fo coolign system

Question 38

what millign

Answer 38

removal of material using mutli tooth cuttign shit work piece is secured to the bachine and then fed udner the cutter

Question 39

what moves on milling machien

Answer 39

the bed

Question 40

what millign allow for

Answer 40

rapid removal fo material slots steps

Question 41

what plasma cuttign

Answer 41

stream of ionisied gase which ebcomes so hot it vaporises metal cut

Question 42

materials used in palsma cutting

Answer 42

any electrically conductive etal commonely stainelss steel or alimiunm

Question 43

pros of plasma cutting

Answer 43

good for small natches clean cuts

Question 44

cons of palsma cutting

Answer 44

nto good for thin metals very enegery intesive high wastage when hand hel

Question 45

how sinterign work

Answer 45

material curshed to pwoeder powder comapcted in die compacted shape then heated partciles bond

Question 46

brazign step by step

Answer 46

metal cleaned flux brushed along joint to prevent oxidisation pressures gas fed through nozzle and lighted joint heated with flame until piping rod pushed aginst until melted

Question 47

addv of brazing

Answer 47

low cost not effect that host mateiral really strong bond no need for 2ndary finishig complex and itnricate joitns achieved shit can eb dismantled and rejoine d all scales of production

Question 48

cons of brazing

Answer 48

cna be time consuming

Question 49

maetriasl sued in brazing

Answer 49

copper steel silver rod

Question 50

how tig welding work

Answer 50

tig generates heat via an arc of electicity jumping from tunsgtene metal electrode to metal you intned to world heat melts edges flux is used

Question 51

adv of tig welding

Answer 51

uses electric current reduces sparks and shit less contamination no toolign costs

Question 52

dis adv fo tig

Answer 52

high set up tiem skilled process expensive complex