Manufacturing Processes - The De Montfort School

Manufacturing Processes - The De Montfort School

Resistant Materials Manufacturing Processes These icons indicate that teachers notes or useful web addresses are available in the Notes Page. This icon indicates that the slide contains activities created in Flash. These activities are not editable. For more detailed instructions, see the Getting Started presentation. 1 of 15 Boardworks Ltd 2005 Learning objectives

Learning objectives To understand how reforming and deforming processes change the shapes of materials. To know how to deform wood, metals and plastics. To know how to reform metals and plastics. 2 of 15 Boardworks Ltd 2005 Deforming materials

3 of 15 Boardworks Ltd 2005 Deforming wood Wood can be bent gently and carefully! If you make small cuts part way through the wood it is easier to produce a curve. The process of making small cuts part way through the wood in this way is called kerfing.

4 of 15 Boardworks Ltd 2005 Laminating 5 of 15 Boardworks Ltd 2005 Deforming plastics

Thermoplastics can easily be bent when they are heated. Thermoplastics can be bent using the heated wire strip in a line bender or strip heater. 6 of 15 Boardworks Ltd 2005

Deforming plastics Vacuum forming is a process which deforms thermoplastics into new shapes. Press play to see a video of the vacuum forming process. 7 of 15 Boardworks Ltd 2005 Vacuum forming Vacuum forming is often used to produce packaging items such as the

insides of boxes of chocolates. A sheet of plastic is forced down over a mould to create the desired shape. The sides of the mould need to be tapered. Corners must be smooth curves so that the plastic does not get punctured. Holes are drilled to allow air to be extracted. 8 of 15 Boardworks Ltd 2005

Blow moulding 9 of 15 Boardworks Ltd 2005 Deforming metal Metals can be beaten or folded to change their shapes. The process of re-shaping metal in this way is called deforming.

Mild steel sheet being bent into an angled shape. 10 of 15 Copper being beaten with a mallet into a curved shape. Boardworks Ltd 2005

Reforming plastics 11 of 15 Boardworks Ltd 2005 Reforming metals casting Metals are reformed using casting processes. There are two main types of casting: Sand casting can be done in schools uses an aluminium alloy that has a low melting point

is labour intensive. Die casting is used in industry uses metal moulds which are expensive but re-usable is very accurate and quick is expensive to initially set up. 12 of 15 Boardworks Ltd 2005 Sand casting

13 of 15 Boardworks Ltd 2005 Die casting Die casting is used in industry for producing large quantities of very accurate castings for machinery such as engines. The molten metal is forced into the mould by a piston. It is then cooled before the mould is opened. 14 of 15

Boardworks Ltd 2005 Key points Key points Deforming involves changing the shape of a material by bending, squashing, heating or bending. Reforming involves melting a material before making it into a new shape. Wood can be curved using a kerfing technique or by

laminating strips of wood to produce plywood. Thermoplastics can be bent using a line bender or strip heater. They can also be deformed using vacuum forming and blow moulding processes. Plastics can be reformed using injection moulding. Metals can be bent or folded, and reformed using sand or die casting processes. 15 of 15 Boardworks Ltd 2005

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