Presentation on theme: "Materials processing and forming"— Presentation transcript:
1 Materials processing and forming Year 11 Resistant MaterialsBitesize clip – Production techniquesBitesize clip – Industrial practicesPK/2011
2 Materials processing and forming Deforming – allows the materials shape to changed without changing its stateReforming – involves a change of state within the material used; in other words, the material changes from a solid to a liquid or plasticised state
3 You need to know about Sand casting Drilling Turning in both wood and metalBlow mouldingInjection mouldingVacuum formingExtrusionWood laminating
5 Sand CastingThe pouring, or forcing of molten metal into a cavity and then allowing it to cool and solidify.Used to produce complex shapes such as car engine parts and kitchen/bathroom tapsRelatively cheap and simple to use in the school workshopMaking the pattern can be difficult and time consuming
6 look in programmes: - design technology - Focus on metals - sand Casting - click on the green arrow Quick simulation
7 Advantages & disadvantages Waste can be reusedHollow parts can be made with the use of coresConsumes large amounts of energy to melt the metalA new sand cast has to be packed each time which is time consumingSecondary finishing required to produce a flat surface
8 Sand casting process Make a pattern of the required product Encase the pattern in moulding sandSplit the sand box and remove pattern to leave an empty cavityPour molten metal into the mouldWhen the metal is solidified and cooled, remove the product
9 Sand casting cont.Split patterns allows two sides of a sand mould to be created and complex casting to be produced.The pattern must have sloping sides so it can be easily removed without damaging the walls of the sand.It must have not undercuts or sharp edges and finished off with a fillet radii.The pattern is usually finished off with a coating of gloss paint.
10 Sand casting cont.Most common sands are ‘green sand’ and ‘petrabond’. Green sand uses water to bond it together and can be reused. Petrabond is oil based and can only be used once.Sand has to be sieved and lumps removed.Green sand has to be kept slightly dampBefore pouring molten metal into a mould with green sand, the sand must be dried out thoroughly or the mould will explode.
12 Have a go at an exam question Explain one reason why it is essential that a high-quality finish is achieved on the mould before casting. (2 marks) You have two minutes For top marks Make sure that you explain any defects appearing on the mould will also appear in the cast product, and that the product is likely to rejected, wasting time and effort.
14 DrillingThe process of making holes by using rotating cutting tool that is secured in either a hand operated drill or a drilling machine.Most common type of drill is a twist drill, manufactured from high speed steel and can produce holes in most materials.Two types of twist drills:Parallel shank (held in by chuck)Taper shank (held in by friction)
15 Drilling continued Name Advantages Disadvantages Pillar drill Can be used continuouslyChuck can be removed to accept larger bitsSpeed can be variedFixed in one positioncan be dangerousHand drillPortableYou need to provide the powerWill only hold bits up to 10mmCordless drillUsually has variable speedCan reverse the directionCan be used to put in & take out screwsPower limited to battery type & sizeBatteries have to be chargedLimited to max. 10mm bits
16 Types of drills found Flat bits – used to drill deep holes in wood Forstner bits – used to drill flat-bottomed holes in woodAuger bits – used to drill deep holes using a carpenter’s braceCountersink bits – conical drill bits that allow countersunk head screw to the inserted so it is flush with the surface of the material.
17 Types of drill bits continued Hole saws- saws that are circular shaped cutting rings that range from 20mm to 150mm diameter.Tank cutters – circular cutters that have an adjustable radius for cutting holes in sheet material.
18 Now think of 5 safety precautions Use a chuck key to tighten and remove drill bits but never leave in the machineAlways wear protective equipment such as goggles and an apronTuck loose items of clothing such as ties out the way and fasten long hair backMake sure that the object being drilled is held tightly and securely in the machine viceUse the correct drill speed for the material being drilled and for the size of drill being used.
20 TurningTurning can be undertaken using either a metalworking lathe or a woodturning lathe.Two basic processes that the lathe can perform are:Facing off – the smoothing of the end of a piece of materialTurning down – reducing the diameter of a piece of materialTwo types of chuck:Three jaw self centring for hold round or hexagonal barsFour jaw independent chuck for holding material of any cross section
22 Wood latheThe cutting tools are held in the hand and rested on the toolrestThe work being machined is usually secured to a faceplate or turned between centresThree basic tools:GougesChiselsscrapers
23 Wood latheBefore turning, timber has to be prepared – corners planed down or on small pieces cut offAvoid pieces of timber with knotsOn long pieces, the centre should be carefully established so that when it is secured and rotated it is not unbalanced.Once materials is secured on the machine, the tool should be checked for sharpness
24 Wood latheTool post positioned so that the top of the turning tool is at centre height of workMake sure the correct spindle speed is selected for the task in hand.
25 CNC lathe A computer automatically controls all the tools movement Identical items can be manufactured which is difficult to do by hand
26 Advantages of wood turning Waste can be reused for other purposes such as animal beddingOne off shapes and products can be producedSmall off cuts from the workshop can be turned into other products
27 Disadvantages of wood turning Long objects can flex if not correctly supportedOnce product removed, difficult to reset it to centreTools need to be sharpened regularlyWorkpiece and tools get hotDifficult to make exact copies by handTools can catch on edges which can be dangerous
28 H&S points The user should wear a protective face mask The tool rest should be as closed as possible to the work without it touching to stop the tool snagging or being pulled out of the operator’s handThe tool rest and tool must be fixed at the correct heightThe bigger the diameter of the workpiece, the slower the speedHold the tool firmlyUse the correct shaped tool for the piece being turned
29 Metalworking Centre Lathe The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including; steels and plastics. Many of the components that go together to make an engine work have been manufactured using lathes. These may be lathes operated directly by people (manual lathes) or computer controlled lathes (CNC machines) that have been programmed to carry out a particular task. A basic manual centre lathe is shown on the next slide. This type of lathe is controlled by a person turning the various handles on the top slide and cross slide in order to make a product / part.
31 ‘Facing off’ A very basic operation is called ‘facing off’. A piece of steel has been placed in the chuck and the lathe cutting tool is used to level the end. This is done by turning the cross-slide handle so that the cross-slide moves and the cutting tool cuts the surface of the steel.
32 Drilling with the centre lathe The tailstock of a lathe can be used for drilling, with the aid of a drill chuck attachment. The drill chuck has a morsetaper shaft which can be push into the shaft of the tailstock, locking it in position.
33 Centre drillingThe usual starting point for drilling with a centre lathe is to use a countersink bit. This is used to drill slightly into the material and creates a starting point forother drills that are going to be used. Attempting to drill with a traditional drill bit without countersinking first will lead to the drill bit slipping straight away. It is not possible to drill a hole successfully or safely with out using a centre drill first.
34 Producing a screw-thread A cutting tool ground to the correct thread form angle is set up in the tool post and is used to cut along the bar to produce the correct thread profile of the barTwo important factors:The cutting tool profile must match the thread profile requiredThe rate of rotation of the work must be in relation to the longitudinal cut in order to create correct thread pitch.
35 Knurling Used to put a pattern onto the surface of the material Often a shape of a diamond patternKnurling tool consists of two hardened steel rollers that have the pattern to be cut engraved on themThe pattern comes in two forms, straight or diamond shapesAs the work rotates, the rollers on the knurling tool are pushed into the workAs the steel rollers are harder than the bar being knurled a pattern is imprinted on the bar.Usually undertaken at slow speed
37 Parting off Usually the final stage of work A special tool is put into the tool post and used to cut right through the piece of work, thus severing itMust be kept sharp with correct angles ground into itMust be set exactly at centre height and fed into the work at a uniform rate
38 Metalworking centre lathe tools ApplicationRight-hand knife toolUsed to face the left-hand edge or cut a shoulder to the leftLeft-hand knife toolUsed to face the right-hand edge or cut a shoulder to the rightRound nose toolCut in any direction and produce radiiParting off toolMoves at right angles into the work to sever materialForm toolSpecial profiles to cut specific shapesKnurling toolProduce pattern or textured surfaceBoring toolTool to enlarge existing hole when large drill unavailable or to produce a flat-bottomed hole.
39 Injection MouldingMaterials such as polystyrene, nylon, polypropylene and polythene can be used in a process called injection moulding. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes
40 Injection moulding: the process The injection moulder is made up of:A hopper unitA screw and injector unitA heating elementA mould
41 Advantages Can operate 24 hours a day Can be used to make different coloured productsInserts can moulded directly inSeveral smaller items can be manufactured into a single mould
42 Advantages Suitable for high volume continuous production High level of accuracyIdentical components formed each timeLittle or no secondary surface finishing requiredUnit costs low in comparisons with the initial set up costs
43 Disadvantages Initial machine and mould costs high Some flashing may have to be removedSprue pins need to be cut off
44 Blow mouldingBlow moulding follows the same stages of manufacture as injection moulding. Polymer granules / powder is placed into the hopper. It drops down on to a rotating thread and travels along its distance. During this process the granules / powder is heated and becomes fluid. However, when it reaches the mould compressed air is also blown into the mould. This pushes the polymer around the edges of the mould, forming a hollow shape
46 Advantages Very cheap unit costs Highly automated process Not very labour intensiveIdeal for high volume, continuous production since it can run for 24 hours a dayVery little secondary finishing required due to nature of plastic material and mould surface finish
47 Disadvantages Initial costs of machine and tooling very high Not suitable for small production methodsSometimes a seam is left around the product where the mould closesProducts sometimes need to have flashing removed
48 Dome mouldingInvolves blowing compressed air through a small inlet valve onto the softened polymer.
49 Vacuum formingVacuum forming is a technique that is used to shape a variety of plastics. In school it is used to form/shape thin plastic, usually plastics such as; polythene and acrylic. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed.
51 Vacuum formingVertical surfaces have to slightly tapered (5o) – this is called draught angle.Round off sharp corners so they don’t puncture the plastic.Incorporate vent holes to avoid pockets of air to get trapped which would stop the plastic from not forming correctly.Round off internal edges to help plastic form over the moulded surfaces.
52 Designing vacuum forming moulds External edge radiusedDraught angle5oInternal radiussoftenedVent holes to allow air to escape
53 Advantages Lightweight, hollow products can be made Relatively cheap moulds can be made from MDF in the school workshop for one-off productsSurface textures can be moulded into products
54 DisadvantagesThermoplastic material sometimes thins too much and may burst or popWebs sometimes form between itemsProducts need to be trimmed and cut out
55 ExtrusionMaterials such as polystyrene, nylon, polypropylene and polythene can be used in a process called extrusion. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes and sectionsThese are cut and welded to form whole units such as uPVC window frames
57 Plastic extrusionUsed to coat products such as copper wire, this is called extrusion coating.
58 Metal extrusion Aluminium and copper are cold extruded This leaves no surface oxidation which would occur if heated so better surface finishIn hot extrusion - starts with a billet (a large lump of metal) that is heated up in an ovenPlaced into the extrusion machineA ram is used to push the material from behind through the die
59 Steel dieThe picture below shows a close up of the steel die. The hole in its centre is a hexagon. This means that the fluid metal forms a hexagonal section when it is forced through the hole. Dies can be manufactured to almost any section / shape, including tubes
60 advantages Continuous lengths Complex profiles Seamless tubes Small production runs achievableExcellent surface finish on plasticsHigh tolerances achieved
61 disadvantages Initial set up costs of machinery and up- keep are high Die costs can be very highHot extrusion of metals such as steel leaves oxidised surface finish
62 Wood laminating Involves building up thin layers of around a former Uses thin veneers or skin plyThe grain has to run in the same direction and following the curve
63 Glued together using PVA or cascamite Then trapped in a former or a jig and held under pressure by clampsLeft until the adhesive is setCan also use a vacuumbag – the air is sucked outusing a pump. Theatmospheric pressure forces the layers together and around the former while the adhesive sets
65 advantages Complex shapes Large sections can be built up Several small products can be laminated at the same time
66 disadvantages Requires a former to be made Special adhesives required if product to be used outsideMust be left for 24 hours to let the glue set
67 Exam questionsSalad servers are laminated from thin pieces of plywood. Choose one adhesive from the list below which is best suited to gluing the pieces of plywood together. 1 mark.Tensol cementPVAContact adhesiveEpoxy resin
68 Exam questionsDraw a cross section of the mould which would have been used to form this package.
69 Exam questionsExplain two advantages of producing the handle for a screw driver using the injection moulding process. (4 marks)