WorksheetsUnit R014 - Engineering Manufacture - Topic Area 1 - D
Total questions: 23
Worksheet time: 22mins
Forming Processes
A blacksmith uses what engineering technique?
Casting
Forging
Stereolithography
Water jet cutting
Forming Processes
Put these steps into the correct order for forging.
Forming Processes
Forging creates products with a higher quality internal grain structure?
True
False
Forming Processes
Forging can be done in 3 typical ways. Match the picture to the technique.
Open Die
Closed Die
Upsetting
Forming Processes
Select the disadvantages of forging.
Intense safety procedures need to be followed.
Secondary operations are almost always required.
The surface of forged metal is prone to rapid oxidisation.
Forging gives a linear grain profile.
Forming Processes
What does the animation show?
Vacuum Forming
Laser Sintering
Press Forming
Forging
Forming Processes
Press forming is using a (a) force to (b) deform a material to match the size and shape of the (c)
Forming Processes
This is the most common type of machine used when press forming. What is it called?
Punch
Pyramid Roll
Press Brake
Knibbler
Forming Processes
Press brakes can be difficult to fully safe guard. What does the light beam guard actually do on this example?
Make the danger area glow so you can see properly.
Provide a red warning light.
Cut the machines power if you step in the path of the light beams whilst it is running.
Flash when the machine is in use and sound a warning claxon.
Forming Processes
Press forming uses dies. What product form would you expect to be made from this die arrangement?
Forming Processes
When press forming engineers have to take into account spring back. What is spring back?
When the materials natural elasticity tries to return the form to it's original shape after working.
The material bouncing away from the die.
The press flexing under pressure when folding thick material.
The die warping out of shape over time.
Forming Processes
Match the press forming tooling/features to the name.
Back Stop
Top Die
Foot Pedal
Bottom Die
Axis Control / E-Stop
Forming Processes - A press brake can form simple bends or the dies can be designed to create a fully formed product like the tray in this example. What are the advantages of press forming?
Dimensional accuracy is guaranteed by the mould.
There are no risks to the operator when press forming
Parts can be manufactured with high surface quality.
Thin walled products can be produced with good rigidity.
Forming Processes - Match the polymer based product to the process most likely used to create it.
Line Bender
Injection Moulding
Vacuum Formed
Rotationally Moulded
Extrusion
Forming Processes - Strip heating of polymers is using a (a) heated strip of (b) to (c) heat a plastic (d) The sheet at this localised point becomes (e) and flexible allowing it to be manipulated into other shapes and profiles.
Forming Processes - This shows a basic strip heater. Put the steps into order for creating a simple 90 degree bend in a sheet of plastic.
Ensure the area is ventilated.
Turn on machine and allow the heating element to come to temperature.
Mark the location of the bend line on the plastic.
Clamp the plastic over the heated wire and leave until malleable.
Raise the bend platform with the red arms to the desired angle.
Forming Processes - The PPE and safety measures below are required when strip heating polymers. Match the picture to the name.
Extractor / Ventilation
Safety Glasses
No loose clothing etc.
Heat Resistant Gloves
Electrical Wiring Inspection
Forming Processes - Vacuum forming uses what category material?
Alloys
Ceramics
Thermoplastics
Thermosetting Plastics
Forming Processes -
Select the specific materials most appropriate for vacuum forming.
Acrylic
Urea Formaldehyde
HIPS
Melamine Formaldehyde
Forming Processes -
Which of the steps below is not a part of the typical vacuum forming process?
Feed plastic granules through a screw.
Place plastic sheet under heaters.
Remove air between sheet and pattern/mould.
Trim away excess material.
Forming Processes -
Put the pictures in order to show the sequence of steps when vacuum forming.
Forming Processes -
Select the vacuum formed product.
Forming Processes -
Match the close up Vacuum forming machine part to the name.
Heater
Platform Raiser
Sheet Clamps
Control Panel
Motor, pump and cylinder
