STARTER-RECAP-DISCUSSION
Considering your own design project
What anthropometric data have you used?
Is there any data you should have used but haven’t yet?
If you were designing you product for a different age group (child/adult/elderly) how would the data you need change?
ANTHROPOMETRICS
PSYCHOLOGY
PHYSIOLOGY
CONSIDER-
MACHINING-MILLING, TURNING AND STAMPING
Yr13- Theory recap
Including use of specialist tools
OBJECTIVES
Understand the difference between each process
Identify the products created by the different processes.
Explain the use of CNC in metal working processes, identifying suitable machines
Explain how each of the processes work, with detail and reference to specialist machines
(Stretch)Create a top grade answer to an exam questions
DISCUSS OUR UNDERSTANDING
What does wasting mean? (give an example process)
What does redistribution mean? (give an example process)
What category are these processes?
Turning?
Milling?
Bending?
WASTING VS REDISTRIBUTION
A form of machining, a material removal process, creating parts by cutting away unwanted material.
(Wasting Processes)
Process whereby materials are reshaped without loss of material.
(Redistribution)
TURNING
TURNING
Turning is one of the most basic machining processes. Involving a single rotating part (secured in rotating chuck) while a cutting tool is moved in to the work.
• Lathes are used when turning.
• Operates to create cylindrical parts.
• A work piece rotates as a cutting tool is fed into the work.
• The tool axes of movement is linear.
• Turning can be done on external surfaces as well as internally, when talking about internal turning it is called boring.
TURNINGTurning Operations-
• Facing
• Parting
• Groving
• Boring
• Knurling
• Drilling
• Reaming
• Threading
• Taper turning
VIDEO SHOWING STAGES OF USING LATHE TO MAKE PEN
• https://www.youtube.com/watch?v=kLLeVCJgNkk
VIDEOS TO HELP UNDERSTANDING OF TURNING
IF NEEDED
https://www.youtube.com/watch?v=fDSLWYHuj4g -
Lathe Workshop for Beginners Part 1, Turning
MILLING
MILLING
Milling operates on the principle of rotatory motion. A milling cutter is rotates while the workpiece is advanced into the cutting part progressively removing material.
Workpiece is clamped to the axle. The cutting is determined by moving the table along the axis (X and Y). The depth of the cutting tool into the work is determined by the Z axis, moving the height of the bed.
• When milling the cutting tool rotates and the work is fixed.
• Material is removed with each passing of the cutter, performed gradually.
It is important to know the difference.
In summary; the key difference is in the style of cutter and its direction of rotation.
The cutting tool in a horizontal is like a disk that rotates horizontally. This is beneficial for cutting slots and groves. (like a circular saw) Called a arbor.
The cutting tool on a vertical milling machine is positioned (like a pillar drill) orientated vertically, called a spindle.
With both the cutting tool is fixed and the bed is moved along the axis using handles.
VERTICAL AND HORIZONTAL
VERTICAL AND HORIZONTAL
MILLING
• Milling operations-
• Face milling
• End milling
• Cutting
• Boring
• Drilling
• Gear cutting
CRASH COURSE IN MILLING1- BASIC ANATOMY
• https://www.youtube.com/watch?v=U99asuDT97I&list=PLyv4Q1JxT_Rh0Fv5loUN9ZTm74VkxYjhJ&index=1
VIDEO TO HELP UNDERSTANDING OF MILLING
IF NEEDED
https://www.youtube.com/watch?v=TecC9_nwpUw
BEGINNERS GUIDE TO MANUAL & CNC MACHINING!MANUAL AND CNC
STAMPING
STAMPINGMetal stamping is a manufacturing process used to convert flat metal sheets into specific shapes. It is a complex process that can include a number of metal forming techniques — blanking, punching, bending and piercing, etc.
-Often multi step process
- Starts with flat sheet of metal
Example of
product.
Compound dies are press tools whereby only
cutting operations are done. (Blanking and
punching)
Whereas combination dies are press tools where
blanking is combined with forming operations.
Another way to achieve a product that is both cut
and shaped is with a multiple station operation, the
part will move through different stations where
each one carries out single specific step.
VIDEO TO HELP UNDERSTANDING OF STAMPING
• https://www.youtube.com/watch?v=5CuJjSk4U38
EXPLANATION OF PROCESS AND DIFFERENCES
IF NEEDED
THINKING ABOUT CNC• What benefits could CNC, CAD and CAM have for manufacturing products
using turning and milling?
(CNC Lathe, CNC Milling machine, CNC Router)
and disadvantages?
Discuss
TASK-Looking at the product(s) of you link it to its suitable manufacture methods and answer-
What metal has been used?
How did this metal start off before the process to make it in to the product it is now?
What machine would have been used?
How to set up and start working with machine?
What are the steps (processes/operations)?
TASK ANSWERS- CENTRE PUNCH (TURNING)
(Insert images)
TASK ANSWERS- LAMP BASE (MILLING)
(Insert images)
TASK ANSWERS- BRACKETS (STAMPING)
(Insert images)
EXAM QUESTIONS
EXAM QUESTION
MARKS SCHEME
EXAM QUESTION- PRESSING
MARKS SCHEME
EXTENSION-
Using the notes made on the products and how they would be machined, create a suitable detailed answer as if it was a 10 mark exam question.
(Using diagrams where necessary)