F: manufacturing methods

F: manufacturing methods

1. common processes for working with materials

   • drilling
     • drilling can be carried out by machine or manually and is gennerally the best method of producing through or blind holes in a workpiece.
       • when drilling, material, hole size, hole quality, rotation speed and depth should be taken into account.
   • Sawing
     • A wide range of Saws are available, all varying in size and with different sized teeth that are set accoriding to the material to be cut.
       • back saws
       • frame saws
       • Hand saws
       • Jig saws
       • Band saws
       • Power hack saws
   • Abrading
     • Material can be removed from woods, metals and plastics by the use of abrasives. an abrasive is any substance that wears down a surface by rubbing against it.
   • shaping
     • Shaping of materials can be carried out with tools such as files, rasps and suforms. Files are available in a variety of shapes, length and grade of cut.

2. Processes used to manufacture metal

3. Processes used to manufacture products from plastic

   • compression moulding
     • compression mouldinh is a process that is mainly used to process thermosettinh plastics. exmples of common products made by this process include light switces plug sockets and tops for jars and bottles
   • Injection moulding
     • Injection moulding is the most commonly used method for mass production of thermo plastics due to high production rates, accuracy and quality of finishing
   • Vacuum forming
     • vauum forming is a process that is commonoly used to make simple trays or containers. In industry, products produced can vary from polystyrene food trays used in supermarkets to acrylic sinks and baths. Products are manufactured from thermoplastic sheets by a sequence of heating forming, cooling and trimming.
   • rotational moulding
     • Rotational moulding diffeers from other plastic processing methods in that the heating, melting, shaping and cooling stages all occur after the plastic is placed in the mould. no external pressure is applied during forming. hollow shaped products such as traffic cones, litter bind and plumbing components e..g undegrounf frainage pipe connectors can be produced using rotational moulding.
   • Extrusion
     • Extrusion is a continuous process used to produce both solid and hollow products that have a constant cross section. polythene pipes and nylon , curtain rails are produced by extrusion. and uPVC window and door drames are extruded in a semi automated process to meet the volume demand in construction industry
   • Blow moulding

4. processes, materials and components used to manufacture products from different materials

5. processes used in assembling and joining similar and dissimilar materials

6. The design of simple jigs, presses and moulds

7. joining methods using fittings, adhesives heat and common joints

   • Fastners
     • screws- self taping screws are those that cut their own thread and require only a plain hold called a pilot hole (or somtimes no hole at all) before use. they are characterised by a fairly coarse open spiral thread reaching a sharp point.
     • Screws-machine screws rely on the hole into whichthey will be inserted having a thread already formed internally. machine screws can be identified by their evenly pitched thread and constant (non tapering ) It is essential that the thread of the screw and hole correspond exactly historically
   • special purpose fastenings and fittings

8. Methods of joining using heat

9. Joints

   • halving joint
   • dove tail
   • tongue and groove with loose tongue
   • A biscuit joint
   • Bridle joint

10. Processes used to manufacture products from wood

    • Bending
      • Due to its grain structure, trying to bend wood can create a range of different problems and cause weaknesses in its structure. a traditional method of shaping wood is curfing. small cuts are made on the bend of the wood giving space for compression once wood is bent. steam applied under controlled conditions to a piece of wood will make it soft, semi plastic and compressible. in this state, the wood can be clamped to a jig or former.
    • Laminating
      • Thin sheets of wood known as veneers can be joined together and cramped onto formers to form shapes that may not be associated with natural timber. by doing this, it can improve a material's strength greatly
    • routing/profiling
      • Routing/ profiling can be carried out using portable electric routers and also by CNC routers/CAM. The routing process allows a variety of shapes and sections to be created on the surface and edges of strips of wood.
    • Turning
      • Wood can be turned using a wood Lathe in 2 ways: a faceplate holding it on the Lath headstock. this method used to create items such as bowls, plates and dishes.