Metal processes

Question 1

Spinning

Answer 1

Circular sheet metal components which are symmetrical about a central axis can be produced by forcing a metal blank onto a rotating former

Question 2

Cupping and Deep drawing

Answer 2

Cupping and Deep drawing processes are used to from tube like shapes such as fire extinguishers and areosol cans

Deep drawing is when the depth of the pressed exceeds the diameter

Question 3

Forging

Answer 3

Manufacturing process involving the shaping of metal using localized compressive forces.

Question 4

Drop forging

Answer 4

Drop forging is a forging process where a hammer is raised and then drpped onto the workpiece to deform it according to the shape of the die

Question 5

Bending

Answer 5

Meta; can be bemt cold or hot and sheet metal can be folded in similar way to heated sheet thermoplastics, although it requires specialist high pressure machinery

Question 6

Rolling

Answer 6

The stock metal is passed through sets of rollers to reduce the thickness of the material

Question 7

Sand casting

Answer 7

The oldest form of casting and is still widely used today. This involves pouring molten metal into a prepared cavity in a sand mould and allowing it to solidify

Question 8

Investment casting

Answer 8

Investment casting is also known as the lost wax process. A shell mould is build up around a wax pattern that can be melted away leavign a cavity whcih is then filled with molten metal

Question 9

Die casting

Answer 9

Die casting is the process of forcing molten metal under high pressure into the cavities of steel moulds, the moulds are called dies.

Question 10

Low temperature casting

Answer 10

Metals such as Pewter and silver can be cast into jewlery and other items using moulds carved out or cut into MDF, Cuttlefish, sillicone or Vucanised Rubber

Question 11

Metal inert gas welding

Answer 11

MIG welding is an arc welding process in which continous solid wire electrode is fed through a welding gun and into the weld pool, joining the two base materials together

Question 12

Tungsten inert gas welding

Answer 12

• TIG generates heat via an arc of electricity jumping from a (tungsten metal) electrode to the metal surfaces you intend to weld
• The heat is sufficient to melt the joint edges
• The electrode is coated in flux which when melted, prevents the joint becoming oxidised

Question 13

Spot welding

Answer 13

Spot welding (also known as resistance spot welding) is a resistance welding process

This welding process is used primarily for welding two or more metal sheets together by applying pressure and heat from an electric current to the weld area

Question 14

Oxy-acetylene welding

Answer 14

Oxyacetylene welding, commonly reffered to as gas welding. It is commonly used to permanently join mild steel. This type of welding is suitable for the prefabrication of steel sheet, tubes and plates.

Question 15

Soldering (soft and hard)

Answer 15

Soldering is a joinging process used to join different types of metals together by melting solder

Question 16

Brazing

Answer 16

• A way of forming permanent joints in metal by melting a brazing rod at 880C between two parts
• Brazing is a metal joining process in which two or more metal items are joined together by metling and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal. Brazing differs from welding in that it does not involove melting the work pieces

Question 17

Riveting

Answer 17

A rivet is a mechanical fastener composed of a head on one end and a cylindrical stem on another which has the appearance of a metal pin

Question 18

Temporary joining methods and fasteners

Answer 18

• Self tapping screws, is a scre that can tap its own hole as it is driven into the material
• Machine screws, used to hold parts together in all types of machines such as electronics and engines
• Nuts and bolts, a nut is a type of fastener witha threaded hole, nut are almost always used in conjection with a mating bolt to fasten

Question 19

Milling - Wasting processes

Answer 19

Milling is the machining process of usong rotary cutters to remove material. Traditionally has cutters that can be moved in three axis and operated manually. It works in a similar way to routerign, milling machines have greater tirque and use more durable cutting tools

Question 20

Turning - Wasting process

Answer 20

• Metal turning is done on a centre lathe also called a metal lathe. This is a machine that is used to turn material so that it can be shaped to a cylindrical shape or bowl
• Metal piece secured in the chuck, a high speed steel cutter held in the tool post moves left to riight and towards the centere to shape the material to produce a symmetrical shape

Question 21

Flame cutting - wasting process

Answer 21

Flame cutting is a wastong process that uses oxygen acetylene gas and a specifical flame - cutting torch to deliver a very intense and focused flame above 3500 degrees

Used to cut low carbon and alloy steel plate

Question 22

Plasma cutting

Answer 22

Plasma is a super heated ionised gas that is electrically conductive.
Plasma arc cutting machines are used to cut components accurately, quickly and economically from sheet metal

Question 23

Lasercutting

Answer 23

A laser cutter can use a computer aided design to cut or engrave complex shapes out of materials

Question 24

Punching/ stamping

Answer 24

For components requiring a series of holes to be cut in them, it is often quicker to punch rather than drill