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Dt Unit 1.4 > Metal Forming Processes > Flashcards

Metal Forming Processes Flashcards

1
Q

What metals tend to be used in press forming ?

A

Aluminium and medium carbon steel (because they are ductile and malleable)

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2
Q

What scale of production is press forming used in?

A

Mass or large scale batch production ( because dies are Supes expensive to make)

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3
Q

What is the die in press forming?

A

Made from hardened steel, dies are in the shape that the product will take.

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4
Q

What is press forming used for?

A

Used to shape sheet metal into 3D form, for example car body panels, metal seats, containers.

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5
Q

What is used to push the die into the sheet metal?

A

Hydraulic press

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6
Q

What products may use spinning to form them?

A

Body of a stainless steel kettle, saucepan, products with radial symmetry

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7
Q

What is the part in spinning which the sheet metal will be formed over?

A

Mandrel

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8
Q

When would spinning be used instead of press forming ?

A

When the quantity required in a batch doesn’t justify the cost of press forming.

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9
Q

What tool is used to aid spinning?

A

Roller tool

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10
Q

What is the name of the mould used to shape the press blank in cupping?

A

Deep drawing die

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11
Q

What products would be made from cupping?

A

Fire extinguishers, aerosol cans

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12
Q

Why is cupping/ deep drawing only used in mass/continuous production?

A

Because the cost of the hydraulic press and materials and specialists to make the dies are so high that thousands of products must be sold to justify them

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13
Q

What is the name of the clamp which holds the press blank in place?

A

Retainer

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14
Q

What products can be made using the DROP FORGING method?

A

Spanner, plier and screwdriver shafts

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15
Q

When would drop forging be used?

A

When a finished product needs to be tough and hard!

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16
Q

What would a die be made from in drop forming?

A

Cast tool steel

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17
Q

In drop FORGING, what needs to happen to the billet (piece of metal to be formed)before it is placed under the ram?

A

It has to be heated to recrystallisation temperature

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18
Q

Define recrystallisation temperature? And why is it necessary to hear a metal above it in DROP FORGING?

A

Temp below the melting point at which it is possible to change the size and shape of the grains that make up the metal. Necessary so that product doesn’t work harden as that would make it brittle

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19
Q

What pieces are used to achieve the desired shape of product in drop forging?

A

An upper and lower die

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20
Q

What are the two parts in bending which sandwhich the component sheet metal in order to bend it?

A

The punch and the die

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21
Q

What is used to push the punch and the fur together?

A

Hydraulic break

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22
Q

What is the use of a back gauge in modern press brakes?

A

To accurately position the piece of metal.

23
Q

In bending, a back gauge can be controlled by a computer to achieve what?

A

To repeatedly bend a metal to achieve complex shapes

24
Q

Rolling is a metal forming process to achieve what?

A

Reduce thickness of metals

25
Q

What temperature has to be exceeded in hot rolling?

A

Recrystallisation temperature

26
Q

What are the benefits of hot rolling?

A

Materials whose mechanical properties are even through

27
Q

What is a con of hot rolling?

A

Surface normally cited in carbon deposits which need to be removed by acid pickling

28
Q

What is cold rolling used in?

A

Home appliances: filing cabinets, chairs, steel drums

29
Q

What are the specialist factories in which sand casting takes place called?

A

Foundaries

30
Q

What is sand casting used to make?

A

One off products: railway carriage wheels, wood working clamps and vices, heavy duty park benches

31
Q

What is a con of sand casting?

A

Doesn’t give a high quality surface finish bc of the sand grains

32
Q

What scale of production is sand casting used and why?

A

One off because it is slow and labour intensive and moulds are single use

33
Q

What is the name of the first steel box the top half of the patter in placed into called?

A

Drag

34
Q

What is the name of the second box the bottom half of the patter placed into called?

A

Cope

35
Q

What types of metals is die casting used for?

A

Lower melting point metals

36
Q

What are the two types of die casting?

A

Pressure and gravity

37
Q

What are the two types of pressure for casting?

A

Hot chamber die casting and cold chamber die casting

38
Q

What is a benefit of pressure due casting?

A

All of the mould is filled because of high pressure hence products with fine details can be moulded

39
Q

In cold chamber die casting, how is the metal inserted into the shot chamber?

A

Using a ladell

40
Q

What is investment casting used to make?

A

Cast jewellery, collectible figures, medical applications such as hip replacements

41
Q

In investment casting, what is the wax model dipped in to make the hollow mould?

A

Refracting clay

42
Q

What parts of the product are machined off?

A

Rubber and any connecting parts

43
Q

What is pewter?

A

An alloy with a low melting point, often used in school projects

44
Q

What is pewter casting used to make?

A

Jewellery, key fobs, decorative components

45
Q

What scale of production is SPINNING typically used in?

A

Mass production because it can be set up using computer controlled machines

46
Q

What is the main concept of SPINNING?

A

Using a roller tool and pressure to form a metal sheet over a mandrel (casting of product)

47
Q

What is the general concept of PRESS FORMING?

A

Using a hydraulic press to press sheet metal into the shape of a die

48
Q

When does cupping become deep drawing?

A

When the depth of the pressing exceeds the dismeter

49
Q

What is the general idea of DEEP DRAWING/ CUPPING?

A

Using a hydraulic press to form tube like products

50
Q

What’s scale of production is DROP FORGING suitable for and why?

A

Continuous or mass production due to high setup costs of dies and hydraulic press

51
Q

What is the part called in BENDING which is used to create the top part of the bend?

A

Punch

52
Q

What is the use of the back gauge in BENDING?

A

To accurately position the metal. It can be controlled by a computer so that it can bend metal repeatedly for bending more complex shapes

53
Q

What is the general process of SAND CASTING?

A

Use wooden model and put in bucket of sand. Turn over put sand on other side. Remove mould and vents and riser. Pour in molten metal. Use hack saw to remove excess

54
Q

What is the general idea for INVESTMENT CASTING?

A

Exact wax model made including and runners or risers. Model covered in clay and kilned. Metal pored in mould . Clay broken away. Extra parts machined off

Dt Unit 1.4 (8 decks)

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