Metal Processes

Question 1

Name and describe the three types of metal processes

Answer 1

• Forming: processes where no material is removed but materials are deformed to produce the required shape
• Redistribution: processes where materials are changed from one form to another without loss of material (eg liquid metal poured into a mould to take a solid shape)
• Wastage: processes to cut away material to leave the desired shape

Question 2

Name 7 Forming processes

Answer 2

Press forming
Spinning
Cupping and deep drawing
Drop forging
Wrought iron forging
Bending
Rolling

Question 3

Process: Press Forming. Talk about:
- Stock Form
- Process Type
- Products
- Key Features

Answer 3

• Stock Form: Sheet
• Process Type: Forming
• Products: Metal seats, car body panels, boxes and containers
• Key Features:
  1. Shapes sheet metal into 3D forms
  2. Often used with robots to lift sheet in place
  3. Suitable for mass production and large scale batch production

Question 4

Process: Spinning. Talk about:
- Stock Form
- Process Type
- Products
- Key Features

Answer 4

• Stock Form: Sheet
• Process Type: Forming
• Products: Body of stainless steel kettles, saucepans, metal light shades
• Key Features:
  1. Product may show parallel lines where the product has been forced onto the mandrel
  2. Suitable for mass production and small scale batch production

Question 5

Process: Cupping and Deep Drawing. Talk about:
- Stock Form
- Process Type
- Products
- Key Features

Answer 5

• Stock Form: Sheet (round blank)
• Process Type: Forming
• Products: Tube like shapes such as fire extinguishers, aerosol cans, drink cans
• Key Features:
  1. Starts with a metal blank
  2. Metal is stretched into shape
  3. High initial tool cost
  4. Used for large-scale mass or continous production

Question 6

Process: Drop Forging. Talk about:
- Stock Form
- Process Type
- Products
- Key Features

Answer 6

• Stock Form: Billet
• Process Type: Forming
• Products: Spanners, pliers, and screwdriver shafts
• Key Features:
  1. Used for products that need to be tough and hard
  2. Maintains the internal grain structure which retails strength
  3. Hot metal billet shaped on an anvil or die and then pressed into shape and cooled
  4. Suitable for mass production

Question 7

Process: Wrought Iron Forging. Talk about:
- Stock Form
- Process Type
- Products
- Key Features