bending and forming

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7 Terms

1

bending

  • physically deforming material

  • easier to bend when heated

  • some metals must be annealled

  • former: helps make accurate bend

  • bending jigs, hydraulic bending machines: when lots of parts need to be bent to the same shape

  • thermoplastics will break if not heated

  • strip heater: heats a specific area that you want to bend

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2

folding

  • bending material over itself, one part covers the other

  • bigger direction change than bends

  • bending bar/mallet or hydraulic press and former

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3

press forming

  • fly press: hand operated, a small number of items

  • hydraulic press: large/multiple parts, hundreds of tons of force

  • moulds: made of high carbon steeel, hard and resists wear. Difficult to machine and expensive.

  • 3D parts from a metal sheet (domes, bowls, car body panels)

  1. sheet of material fit between two moulds or a ram and die

  2. moulds/ram and die fit together with a small gap in the required shape

  3. press applies pressure to permanently deform material

  4. extra material removed

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4

Press moulding

  • press forming for polymers

  1. thermoplastic heated until flexible

  2. placed between parts of a mould (plug and yoke)

  3. mould pressed together

  4. plastic cools/hardens

  5. plastic removed from mould

    1. extra plastic removed

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5

punching & stamping

  • cut shapes in metal sheet

  • pressure applied to push tool through sheet

  • punching/piercing: hole is made, and material pushed out is scrapped

  • stamping/blanking: hole is made, material pushed out is needed

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6

composite lay up

  • for composite materials

  • smooth on one side, rough on the other

  • male mould: smooth inside

  • female mould: smooth outside

  1. mould polished & coated with release agent

  2. gel coat resin brushed on - gives a good finish on smooth side & adds colour

  3. reinforcement material layers (e.g. glass fibres) put in mould

  4. material soaked in resin to form matrix - this can be painted or dabbed on with a brush (stippled)

  5. more layers added/soaked until required thickness

  6. if the product needs to be high performance, everythings put into plastic sheets can a vacuum sucks the air out - ensures resin has been pulled into glass fibre spaces, reducing local weakness

  7. part cured, resin becomes hard. You can either leave it alone for a few hours, heat it gently in an oven, or put it in an autoclave (giving pressure + heat)

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