1. ENGINEERING MANUFACTURING METHODS

3. Subjects to be Covered:
Turning Milling Drilling Welding Drop forging Press forging Upset forging

4. Hardening
Die casting
Sand casting
Investment casting
Permanent mould casting

5. TURNING
Achieved by using a lathe to shape material into cylindrical profiles.
Advantages: high accuracy, high work volume, automation with feed and CNC, creative / interesting, versatile
Disadvantages: limited to producing cylindrical profiles, machine prices, tooling failure can lead to scrapped work, machines are hazardous, require time to master using, high power consumption, machine setting takes time
Safety: keep away from rotational parts especially loose clothing & dangling objects, care with sharp tooling and sharp edges of work

6. MILLING
Achieved by using a Milling Machine to shape material into rectangular / square profiles
Advantages: high accuracy, high work volume, automation with feed and CNC, creative / interesting, versatile
Disadvantages: limited to producing cylindrical profiles, machine prices, tooling failure can lead to scrapped work, machines are hazardous, require time to master using, high power consumption, machine setting takes time
Safety: for the student to tell

7. DRILLING
Achieved by using a selection of drill machines to produce round holes of different sizes and depths by rotating drill tool
Advantages: ability to produce a wide range of hole diameters to a set specified depths
Disadvantages: limited to producing holes of a circular profile
Safety: for the student to tell

8. WELDING
Achieved by applying electrical supply to metal wire / rods to produce molten metal for use in bonding neighbouring pieces of metal together
Advantages: quick and easy in the hand of an expert to provide a strong and permanent joint
Disadvantages: if incorrect electrical supply is selected this can produce poor quality joint which will be unsuitable for purpose
Safety: for the student to tell

9. DROP FORGING
Achieved by heating metal and hammering it in to a special die (cast die) to produce a final product
Advantages: one advantage is it produces products which need to be strong and durable
Disadvantages: poses a dangerous environment to the workers
Safety: for the student to tell

10. PRESS FORGING
Achieved by forcing the heated metal into a specially crafted shape of die via either pressing or hammering into place until the desired shape has been formed
Advantages: change the shape and interior of the workpiece at the same time
Disadvantages: can only be used for short production runs due to the high tooling cost
Safety: for the student to tell

11. UPSET FORGING
Achieved by increasing the diameter of the hot metal to be shaped by decreasing its length
Advantages: gives the material being casted greater strength due to the material grain flow is oriented to the component's shape
Disadvantages: again the high cost of the tooling involved
Safety: for the student to tell
Most forging methods:

12. MATERIAL STRESSES

13. HARDENING
Achieved by heating a metallic to a glowing bright orange colour, followed by quenching in water or oil to improve the hardness properties in the material
Advantages: absolutely effective in achieving the task required
Disadvantages: limited to steels with a high carbon content
Safety: for the student to tell

14. DIE CASTING
Achieved by forcing molten metal under high pressure into a mold cavity. The mould cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mould during the process.
Advantages: excellent in achieving high accuract
Disadvantages: limitation in producing castings to a size and weight
Safety: for the student to tell

15. SAND CASTING
Achieved by pouring molten metal into a bespoke mould made from sand to form a metallic structure once cooled down
Advantages: can form large parts and complex shapes
Disadvantages: poor surface finish and tolerance
Safety: for the student to tell

16. INVESTMENT CASTING
Achieved by pouring molten metal into a bespoke made ceramic mould, which is then broken to remove the metallic parts once cooled
Advantages: has the ability to make intricate parts to a high accuracy
Disadvantages: its initial costs and production size limitation
Safety: for the student to tell

17. PERMANENT MOULD CASTING
Achieved by pouring molten metal into a reusable mould which is then removed from the moulded object once cooled
Advantages: mould is reusable and produces to a high accuracy
Disadvantages: high tooling costs and limited to low point cooling metals
Safety: for the student to tell

18. References:
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