Content theory 3

 as a box.

Using a plywood ‘substrate’ board into which steel cutting dies and creasing rules are inserted. The sock material placed under the board, and a press pushes board into the sock material.

Bending - stamped out nets is placed onto folding table, some die cutting presses might be equipped with owing parts that help bend or fold parts of nets.

Laser cutting - perfect for prototype construction or small scale production because they can be used to cut engrave perforate and carve. Details, speed and accuracy.

Vacuum forming - make 3d products such as lightweight trays or insets. Used for large number of items. Mould is placed on the bed of the machine which is the platen. Polymer is clamped over the mould and a heater is pulled over the polymer sheets.

• Polymer sheet softened, the platen is raised into the polymer and heat is removed.

• Vacuum pump sucks polymer onto the mould

• The mould is removed form the moulding. Excess polymer is then trimmed off

Line bending - used to produce bends in sheet thermometer plastics such as acrylic. The line bending process uses an electrically heated element over a line used to bend.

Injection moulding- manufacture complex items from plastic, screw posts, battery housing and circuit board holders.

1. Thermoplastics granules poured into  hoppers

2. Granules through the chamber and past electric heaters

3. Heaters melt the polymer

1. Sufficient charge of polymer has melted and formed at the end of the screw. Hydraulic ram forces the screw threat forward.

2. Mould is water cooled, polymer hardened

Blow moulding: produce PET LDPE HDPE and PP

1. Polymer fed into hopper

2. Screw pulls polymer through heated section

3. Melted polymer is extruded as a tube, which is called parison

4. Mould sides close around the parison and air is injected into mould

Rotational moulding - is used to produce heavy duty, hollow objects large wall thickness.

1. Polymer powder or granules are loaded into a mould which is clamped and sealed.

2. Mould transferred to an oven where it is heated - mould is rotated slowly

3. Once the polymer has achieved the correct thickness, the mould is cooled

Metal processes

Press forming is used shape sheet metal into 3d forms, for example metal seats, car body panels, boxes and containers

Spinning is alternative process to forming for shaping objects such as the body of stainless steel kettles, saucepans or other process with radial symmetry.

Drop forging

Is used to shape hot metal into finished products, manufacturers use this process when the finished product manufacturers use this process when the finished product needs to be tough and hard.

Die casting - is generally used to mould lower melting point metals such as aluminium, alloys of aluminium and zinc based alloys. Die casting process uses tool steel moulds that are reusable. This along with the complexity and cost of making the dies.

Melting metal and pouring it into the mould

MIG welding - fabrication process used to weld thing gauge metal or aluminium.

TIG - welds non ferrous metals such as aluminium and copper or magnesium alloys.

Oxy-acetylene is used to weld low carbon steel. 2 gases oxygen and acetylene.

Soldering is similar to Brazil, joining precious metals, filler material

Wasting processes

Milling uses a machine similar to drilled clamped on a table.

Turning turns cyndlically shapes cnc

Lathes are used for wood, metal, polymers and styrofoam.

This can either be a wood lathe (wood) or a centre lathe but both involve the rotation of the material to be worked; hence the name Turning.

Wood processes -

Butt joint - similes joint of 2 pieces of timber

Do well joint - round pegs used to join wood pieces

Mitre joint similar to butt joint in that rely on similar int gluing being glued on 90 degree corner.

Dovetail joint - used in making drawers.. They are perfect for this application because they have directional strength.

Steam bending - combined heat and steam enable strips of timber to be made pliable so that they can be shaped over a former.

Jigs and fixtures is something holds work in a given position while a process takes place.

__________________________________________________________________________________________

For the material can be any metal such as aluminium in a stock form which you will use a wasting process such as turning which can achieve the shape of a round tube but you can use metal milling to achieve the bottom half of the shape.

Steam bending - bombarding wood with steam until it becomes flexible. It is then bent into shape and held in place while the water content is slowly removed form the wood leaving the wood bent.

Kerfing - this process is not actually deforming the wood (it could be considered wasting) but involves cutting grooves into the wood in order to make deforming by bending much easier. Guitar and violin shells were traditionally made this way and many still are.

Spinning - is a process a disc of metal is rotated at high speed and formed into a symmetrical part. Does not remove material but forming of sheet material over an existing shape.

Punching is a metal forming process that uses a punch press to force a tool, called a punch through the work piece to create a hole via shearing. The punch often passes through the work into a die.

Blanking and piercing are shearing processes in which a punch and die are used. The tooling and processes are the same between the two, only the terminology is different: in blanking the punched ou piece is used and called a blank; In piecigng the punched piece is scrap. He process for parts manufactured simultaneously with both techniques is often termed. Pierce and blank.

Forging is a manufacturing process involving the shaping of metal using localised compressive forces. Forging is often classified according to the temperature which it is performed: cold, warm or hot forging. Can range in weight from less than a kilogram to 580 metric tons. Forged part usually require further processing to achieve a finished part.

Drop forging is a forging process where a hammer is raised and then dropped onto the work piece to deform it according to the shape of the die. There are two types of drop forging.

Drawing is a metalworking process which uses tensile forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. Plastic deformation over a curved axis.

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. The process is considered ‘deep drawing’ when the depth of the drawn part exceed its diameter. This is achieved by redrawing the part through a series of dies.

Press forging is a sheet metal process that uses a pair of tools called a die mounted inside a press and then the metal is placed inside the die.

Sand casting is also known as sand moulded casting, is a metal casting process characterised by using sand as the mould material. A suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water.

Lost wax casting is the process by which a metal object (pewter, silver, gold, brass or bronze) is cast from an original wax sculpture. Dependent on the sculptors skills, intricate works can be achieved by this method.

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The extrusion process can be done with the material hot or cold.

Rotational moulding involves a heated hollow mould which is filled with a charge or set weight of material. It is then slowly rotated causing the softened material to disperse and stick to the walls of the mould,

Compression moulding is the main process used to produce products using thermosetting polymers such as urea formaldehyde. The moulding material, generally preheated, is first placed in an open, heated mould cavity.

Aluminium is easy to form and shape, it is aesthetically pleasing, thermal conductivity, lightweight materials whilst being strong making good weight-strength ratio, corrosion resistant.