16-Metal Processes

Question 1

What are the three types of metal processes?

Answer 1

• Forming
• Redistribution
• Wasting

Question 2

Metal Processes - Press Forming

Answer 2

• Metal sheet placed over die
• Press will be lowered to form the sheet to the die

Question 3

Metal Processes - Spinning

Answer 3

• Used to form sheet metal into round objects such as a kettle
• Sheet metal is spun while rollers push the sheet metal to form around the shape of the mandrel

Question 4

Metal Processes - Cupping and Deep Drawing

Answer 4

• Forms Tube shaped shapes for example a fire extinguisher
• Uses metal blank stock form
• This is held over a cavity and pressed down by a deep drawing punch to form the shape

Question 5

Metal Processes - Drop Forging

Answer 5

• A lower die placed on top of an anvil and an upper die on the end of the Ram
• A heated metal billet will be placed onto the lower die, it will be heated to just above its recrystallisation temperature
• Ram will lower onto the billet to form the metal to the desired shape
• Makes products like spanners

Question 6

Metal Processes - Wrought Iron Forging

Answer 6

• Metal is heated and then hammered, bent, and rolled into its correct shape
• Only works for Iron with a carbon content of less than 0.08%
• Will usually use a bar stock form

Question 7

Metal Processes - Bending

Answer 7

• Sheet metal placed over a V shaped die
• Punch will then lower to push the sheet metal into the V forming an edge

Question 8

Metal Processes - Rolling

Answer 8

• Thicker metal will go through rollers which will compact and thin out the metal
• This can be done hot or cold

Question 9

Metal Processes - Sand Casting

Answer 9

• Mould created in sand
• Molten metal will be poured into the mould and left to cool
• Used on metals with high melting points
• Labour intensive and doesn’t produce a high quality finish on the metal

Question 10

Metal Processes - Die Casting

Answer 10

• Molten metal from a billet is poured into a die
• This will usually rely on gravity for the metal to take the shape
• Used with metals with lower melting point like aluminium
• Often used to make door knobs

Question 10

Metal Processes - Investment casting

Answer 10

• exact replica of model is made in wax
• This is then submerged in refectory clay, and placed in a kiln
• This melts the wax, leaving a perfect mould within the clay
• Molten metal is then poured into the mould and left to cool
• This is mainly used for intricate designs like jewellery

Question 11

Metal Processes - Low Temperature Casting (Pewter)

Answer 11

• Two piece mould made out of MDF usually will be clamped together
• Molten pewter then poured into the mould and left to dry
• Used mainly in schools for one off production
• Used to make small decorative items