Embed Size (px)
Citation preview
Machining Techniques
TurningMillingDrilling
Forming TechniquesDie Casting
Sand CastingInvestment Casting
Drop ForgingPress Forging
For each Technique you need to know:
1. WHAT it is
2. HOW it works
3. WHY you would do it
4. EXAMPLES of products made in this way
Machining Techniques: Turning• Lathes are used to make round parts like cylinders,
bolts, knobs etc
The machine is a Centre Lathe
It is used for TURNING (reducing diameter) and FACING (making shorted and neater)
DRILLING on a Lathe
BORING a hole to make it bigger
Cutting a THREAD
KNURLING
PARTING OFF (where a finished object is chopped off)
Machining Techniques: Turning• Some examples of objects that have been turned
on a lathe…BEARINGS
CLAMPING KNOB
BRAKE DISCS
PULLEYS
MACHINE PARTS
(CHUCK)
PIPE FLANGES
PLUMBING FITTINGS
http://www.technologystudent.com/equip1/mlathe1.htm http://www.technologystudent.com/pdf2/lathey1.pdf http://www.youtube.com/watch?v=qZtS7xW45Xo
Centre Lathe
Machining Techniques: Turning
Machining Techniques: Milling• Milling Machines are used to make accurate parts
with holes, slots and flat sectionsThe machine is a MILLING MACHINE
It is used for SHAPING metal objects using a rotating bit that con both drill down and cut sideways
DRILLING holes
CUTTING SLOTS
CUTTING SHOULDERS(like steps)
Machining Techniques: Milling• Some examples of objects that have been cut on a
milling machine…Golf Clubs
Brackets & Mountings
Engines and engine parts
Alloy Wheels
• http://www.youtube.com/watch?v=CVnSq2fDfGU&list=PL1688EC2A1583EED2
Milling Machine
Machining Techniques: Milling
Forming Techniques: Casting• Casting is a way of melting metal and pouring it
into a mould to make a complex shape.
https://www.youtube.com/watch?v=WptzR_-o9aY
Die Casting is where a metal Die (mould) is used and the molten (liquid) metal in injected in under pressure
The machine is large and expensive but once set up the cost is low for each product
Die Casting
Forming Techniques: Casting• Examples of products that are CAST using…
Die CastingMetal toy
carsIron pans
High end Cameras
Engine parts Handles
Forming Techniques: CastingCasting is a way of melting metal and pouring it into a mould to make a complex shape.
Sand Casting
Sand Casting is where there is no Die but a mould made of sand that can only be used a few times
The equipment and mould is cheaper to buy and make but it takes a LONG time so is no good for making lots of products
http://youtu.be/7BI4v0Gqc7k
http://youtu.be/rgL2Jn5mk1A
Forming Techniques: Casting• Examples of products that are CAST using…Sand Casting
Ornamental railing ends
Engine parts (pipes)
One-off Sculptures / ornaments
PLUS anything else that could be die cast but could also be sand cast if you only wanted
a small number.
Forming Techniques: CastingCasting is a way of melting metal and pouring it into a mould to make a complex shape.
Investment Casting
Investment casting used to be called “Lost-wax Casting” because:1. You make a shape out of
wax2. You dip it in ceramic to
make a hard shell3. You MELT to wax so it
dribbles out4. You can the use the
ceramic shell as a mould to cast steel or aluminium
5. You the SMASH (or remove) the ceramic shell to get the metal out
Forming Techniques: Casting• Examples of products that are CAST using…
Investment Casting
• Basically anything that needs to be CAST but is a very complicated shape that could never be removed from a normal Die (mould)
Forming Techniques: ForgingForging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it.
Drop Forging
In Drop Forging there is a metal Die (similar to Die Casting). A Billet (lump) of steel is placed in between the 2 halves.
The top half is lifted and dropped repeatedly onto the bottom half until the steel is the right shape
Forging is much stronger than casting because the crystal structure in the steel or aluminium is compressed
http://www.youtube.com/watch?v=UJ2-jm9CjiM
Forming Techniques: ForgingForging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it.
Press ForgingPress Forging is VERY SIMILAR to Drop Forging.
HOWEVER… instead of dropping the upped Die it is PRESSED slowly down from above
Press Forging tends to be used for BIGGER Forged products
Forming Techniques: Forging• Examples of products that are FORGED using…
Drop Forging / Press Forging
Toolsfixings
Brackets
Weapons
Basically anything steel that needs to be STRONG and withstand IMPACT
Alloy Wheels
