Large-scale production processes
Metal can be formed and shaped through different methods in a Associated with business and profit. setting:
- A method of spinning a material so that a cylindrical shape or bowl can be produced.
- The process of using a machine with a rotary cutter to cut and shape material.
- A process of making a mould in sand so that a molten metal can be poured to take a form.
- sheet metal folding
- Applying force to a material to deform it.
- Applying force to a material to deform and cut it.
Turning
Metal can be turned in a A machine used to turn material so that it can be shaped to a cylindrical shape or bowl., which can be hand operated or controlled via a computer on a computer numerical controlled (CNC) lathe.
A lathe spins the work at high speed as a cutting tool is introduced to the metal to produce round and cylindrical shapes. Round pieces of metal are held in a lathe using a three-jaw chuck, and metal that is not round is held by a four-jaw chuck.
Milling
Metal can be shaped using a A machine with a rotary cutter, used in cutting and shaping. - a very versatile tool for smoothing a surface or edge and for cutting grooves and profiles. Milling machines can work either horizontally (horizontal milling machine) or vertically (vertical milling machine) - both machines perform the same tasks; the main difference is the direction the cutting tool is held.
If a part is too complex to shape by hand or on a milling machine, it can be Molten material poured into a mould. by melting metal and then pouring it into a mould. It is possible to cast A soft alloy of tin and copper. quite easily. The melting point is low, around 200°C, and moulds can be made from laser-cut or hand-shaped A type of engineered wood made of compressed wood and fibre particles held together with glue..
Sand casting
A process of making a mould in sand so that a molten metal can be poured to take a form. can be used to cast larger and more complex shapes as it uses a two-part mould:
- a A solid shape that is often used to make a mould. is made, usually by hand, and is placed in the Sand used for sand casting - it is not green in colour but is used in a wet state so stays in position in the casting box., which is packed tightly around the former before it is removed
- this is repeated on the other part of the mould
- two holes are made in the sand, one for the molten metal to be poured into (the runner) and one for the metal to come up and out the other side (the riser)
- once they are both ready, parting powder is applied to the sand and the two moulds are placed together, one on top of the other
- the molten metal, often A chemical element often used for making drinks cans. in schools, is poured into the runner until it comes up to the riser when the cavity in the sand is full of metal
Sheet metal folding
Sheet metal folding enables sheets of metal to be bent into place. It typically involves placing a sheet of metal between a press and a A forming tool that material is pushed on to so as to create a fixed shape. (or A solid shape that is often used to make a mould.) and the pressure of the press forces the sheet down and into the die.
Pressing
Similar to sheet metal folding, a press moves down onto sheet metal and forces it into a former. In this process, though, more detailed shapes are formed, such as metal trays or brackets. This typically means more force is needed to create A rounded form on an edge. edges on the shape formed rather than sharp corners.
Stamping
The stamping process is similar to bending and pressing in that a large force is applied to create the effect. Whilst it can form and bend metal into shape, it is typically used to cut or Creating holes in a sheet material. out a shape from the metal by using sharp A method cutting paper or card by pushing a blade through the material. tools. Car parts (example below) are often produced this way.
