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)