1. Machining Techniques Turning Milling Drilling Forming Techniques Die Casting Sand Casting Investment Casting Drop Forging Press Forging For each Technique you need to know: 1.WHAT it is 2.HOW it works 3.WHY you would do it 4.EXAMPLES of products made in this way

2. Machining Techniques: Turning Lathes are used to make round parts like cylinders, bolts, knobs etc The machine is a Centre Lathe It is used for TURNING (reducing diameter) and FACING (making shorted and neater) DRILLING on a Lathe BORING a hole to make it bigger Cutting a THREAD KNURLING PARTING OFF (where a finished object is chopped off)

3. Machining Techniques: Turning Some examples of objects that have been turned on a lathe… BEARINGS CLAMPING KNOB BRAKE DISCS PULLEYS MACHINE PARTS (CHUCK) PIPE FLANGES PLUMBING FITTINGS

4. http://www.technologystudent.com/equip1/mlathe1.htm http://www.technologystudent.com/pdf2/lathey1.pdf http://www.youtube.com/watch?v=qZtS7xW45Xo Centre Lathe Machining Techniques: Turning

5. Machining Techniques: Milling Milling Machines are used to make accurate parts with holes, slots and flat sections The machine is a MILLING MACHINE It is used for SHAPING metal objects using a rotating bit that con both drill down and cut sideways DRILLING holes CUTTING SLOTS CUTTING SHOULDERS (like steps)

6. Machining Techniques: Milling Some examples of objects that have been cut on a milling machine… Golf Clubs Brackets & Mountings Engines and engine parts Alloy Wheels

7. http://www.youtube.com/watch?v=CVnSq2fD fGU&list=PL1688EC2A1583EED2 http://www.youtube.com/watch?v=CVnSq2fD fGU&list=PL1688EC2A1583EED2 Milling Machine Machining Techniques: Milling

8. Forming Techniques: Casting Casting is a way of melting metal and pouring it into a mould to make a complex shape. https://www.youtube.com/watch?v=WptzR_-o9aY Die Casting is where a metal Die (mould) is used and the molten (liquid) metal in injected in under pressure The machine is large and expensive but once set up the cost is low for each product Die Casting

9. Forming Techniques: Casting Examples of products that are CAST using… Die Casting Metal toy cars Iron pans High end Cameras Engine parts Handles

10. Forming Techniques: Casting Casting is a way of melting metal and pouring it into a mould to make a complex shape. Sand Casting Sand Casting is where there is no Die but a mould made of sand that can only be used a few times The equipment and mould is cheaper to buy and make but it takes a LONG time so is no good for making lots of products http://youtu.be/7BI4v0Gqc7k http://youtu.be/rgL2Jn5mk1A

11. Forming Techniques: Casting Examples of products that are CAST using… Sand Casting Ornamental railing ends Engine parts (pipes) One-off Sculptures / ornaments PLUS anything else that could be die cast but could also be sand cast if you only wanted a small number.

12. Forming Techniques: Casting Casting is a way of melting metal and pouring it into a mould to make a complex shape. Investment Casting Investment casting used to be called “Lost-wax Casting” because: 1.You make a shape out of wax 2.You dip it in ceramic to make a hard shell 3.You MELT to wax so it dribbles out 4.You can the use the ceramic shell as a mould to cast steel or aluminium 5.You the SMASH (or remove) the ceramic shell to get the metal out

13. Forming Techniques: Casting Examples of products that are CAST using… Investment Casting Basically anything that needs to be CAST but is a very complicated shape that could never be removed from a normal Die (mould)

14. Forming Techniques: Forging Forging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it. Drop Forging In Drop Forging there is a metal Die (similar to Die Casting). A Billet (lump) of steel is placed in between the 2 halves. The top half is lifted and dropped repeatedly onto the bottom half until the steel is the right shape Forging is much stronger than casting because the crystal structure in the steel or aluminium is compressed http://www.youtube.com/watch?v=UJ2-jm9CjiM

15. Forming Techniques: Forging Forging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it. Press Forging Press Forging is VERY SIMILAR to Drop Forging. HOWEVER… instead of dropping the upped Die it is PRESSED slowly down from above Press Forging tends to be used for BIGGER Forged products

16. Forming Techniques: Forging Examples of products that are FORGED using… Drop Forging / Press Forging Tools fixings Brackets Weapons Basically anything steel that needs to be STRONG and withstand IMPACT Alloy Wheels