Shaping Metal

Bending Metals can be bent in a vice or in folding bars Folding Bars

Test Yourself Why should a card model of the ‘net’ be made?

Test Yourself How can the edges of the tray be made safer?

Test Yourself What advantages are there in using folding bars for bending the edge of a sheet of metal, instead of vice jaws?

Test Yourself How can both the sides and ends of a box or tray be folded up?

Test Yourself How can you avoid the edge of the sides becoming wavy?

Press Forming A “die” is mounted inside a press and then a material (such as metal) is placed inside the die. The press then applies high pressure and the material is formed to match the shape of the die

Blank | Die | Punch | Work Hardened

Test Yourself What is the name given to the sheet of metal at the beginning of the process?

Test Yourself Name the upper and lower parts

Test Yourself What is the name of the machine that cut the metal blank?

Test Yourself What also happens when the metal is stretched (on a molecular level)?

Test Yourself What is a very important mechanical property of metals that will be press formed?

Sand Casting The oldest form of casting involves pouring molten metal into a shaped hole made in damp sand and letting it cool.

Sand Casting

Typical products

Test Yourself

Where is the molten metal poured?

Test Yourself What is the purpose of the riser?

Test Yourself Where is the molten metal poured?

Test Yourself Explain why ‘draft’ is required on the sides of a pattern.

Test Yourself Why is the moulding box made in two halves?

Test Yourself Name five items or parts that can be found at home or on a car or cycle, that would be made by casting.

Die Casting forcing molten metal under high pressure into a mould cavity.

Die Cast Products

Die Casting

Die Casting