Shaping Metal

Bending

• Metals can be bent in a vice or in folding bars

Folding Bars

Test Yourself

• Why should a card model of the ‘net’ be made?

Test Yourself

• How can the edges of the tray be made safer?

Test Yourself

• What advantages are there in using folding bars for bending the edge of a sheet of metal, instead of vice jaws?

Test Yourself

• How can both the sides and ends of a box or tray be folded up?

Test Yourself

• How can you avoid the edge of the sides becoming wavy?

Press Forming• A “die” is mounted inside a press and then a

material (such as metal) is placed inside the die. The press then applies high pressure and the material is formed to match the shape of the die

Blank | Die | Punch | Work Hardened

https://www.youtube.com/watch?v=0oyL9JfG1GQ&feature=player_embedded

Test Yourself

• What is the name given to the sheet of metal at the beginning of the process?

Test Yourself

• Name the upper and lower parts

Test Yourself

• What is the name of the machine that cut the metal blank?

Test Yourself

• What also happens when the metal is stretched (on a molecular level)?

Test Yourself

• What is a very important mechanical property of metals that will be press formed?

Sand Casting• The oldest form of casting involves pouring molten

metal into a shaped hole made in damp sand and letting it cool.

Sand Casting

https://www.youtube.com/watch?v=szOwGvYO_Tc&feature=player_embedded

Typical products

Test Yourself

Test Yourself

• Where is the molten metal poured?

Test Yourself

• What is the purpose of the riser?

Test Yourself

• Where is the molten metal poured?

Test Yourself

• Explain why ‘draft’ is required on the sides of a pattern.

Test Yourself

• Why is the moulding box made in two halves?

Test Yourself

• Name five items or parts that can be found at home or on a car or cycle, that would be made by casting.

Die Casting

• forcing molten metal under high pressure into a mould cavity.

Die Cast Products

Die Casting

https://www.youtube.com/watch?v=bzSSfBgkWfc&feature=player_embedded

Die Casting

https://www.youtube.com/watch?v=WptzR_-o9aY&feature=player_embedded