Plastic And Metal Processes

Question 1

Materials for drop forging?

Answer 1

Metals and metal alloys.
Most common:
stainless steel
aluminium
copper

Question 2

volumes of drop forging?

Answer 2

one off hand forging to about 10,000 made by machine

Question 3

materials for compression moulding?

Answer 3

ceramics, thermosetting plastics, elastomers
Most common:
thermoset plastic parts
E.g. urea formaldehyde and melamine formaldehyde

Question 4

what is drop forging used to make?

Answer 4

spanners, automobile parts and machine parts

Question 5

volumes of compression moulding?

Answer 5

batch or high production. tooling costs are moderate

Question 6

what is compression moulding used to make?

Answer 6

Electrical switches and sockets

Question 7

materials for injection blow moulding?

Answer 7

thermoplastics

Question 8

volume for injection blow moulding?

Answer 8

high volume production (high production costs)

Question 9

type of products made using injection blow moulding?

Answer 9

fairly simple hollow shapes with consistent wall thicknesses over whole product

Question 10

materials for extrusion?

Answer 10

plastics or metals 
Plastics:
ABS, Acrylic
Common metals:
Aluminium, copper, magnesium

Question 11

volume for extrusion?

Answer 11

batch and high volume runs

Question 12

type of products for extrusion?

Answer 12

items remain the same along the whole length (e.g. guttering/ pipes)

Question 13

materials for injection moulding?

Answer 13

mainly thermoplastics

Question 14

volume for injection moulding?

Answer 14

high volume production. Minimum is usually 10,000 + as high tooling costs

Question 15

type of products for injection moulding?

Answer 15

packaging, bottle caps

Question 16

materials for extrusion blow moulding?

Answer 16

thermoplastics

Question 17

volume for extrusion blow moulding?

Answer 17

high volume, but can also be used for shorter runs

Question 18

type of products for extrusion blow moulding?

Answer 18

for more complex hollow products, such as milk bottles

Question 19

materials for rotational moulding?

Answer 19

thermoplastics and aluminium

Question 20

volume for rotational moulding?

Answer 20

batch to high volume mass production. moulds are simpler/ cheaper. 100-500 units

Question 21

type of products for rotational moulding?

Answer 21

large hollow products.

soft rounded products

Question 22

materials for sand casting?

Answer 22

metals with low melting points, such as lead, zinc, tin, aluminium, copper alloys

Question 23

volume for sand casting?

Answer 23

used in industry for small batch production runs

Question 24

type of products for sand casting?

Answer 24

tools, machine parts

Question 25

materials for gravity die casting?

Answer 25

metal alloys with low melting points. e.g. aluminium, zinc and copper based alloys

Question 26

volume for gravity die casting?

Answer 26

medium to high volume production

Question 27

materials for vacuum forming?

Answer 27

thermoplastics

Question 28

volume of vacuum forming?

Answer 28

from one offs to large scale production

Question 29

type of products for vacuum forming?

Answer 29

open ended shapes with no undercut. shapes tend to be box/ dish like. also used for packaging

Question 30

materials for calendering?

Answer 30

vinyl, ABS, polymer sheets, HDPE, polypropylene (thermoplastics)

Question 31

volume for calendering?

Answer 31

usually a higher volume so it becomes more efficient

Question 32

type of products for calendering?

Answer 32

thin sheets

Question 33

materials for pressure die casting?

Answer 33

non ferrous materials with a low melting point. e.g. zinc, copper, aluminium alloys

Question 34

volume for pressure die casting?

Answer 34

high volume due to cost of moulds