Transcript Understanding material melting processes

Edexcel Level 2
BTEC First Diploma in Engineering
Unit 23
Casting and Moulding Engineering
Components
Academic Year: 2011 - 2012
Jo Richardson Community School
Understanding material melting processes
In order for you to understand producing molten material safely for a given scale of casting or
moulding production you must define and provide images for the following:
Single melt
Batch melt
Continuous melt
Combined methods
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components
Task: 1a
Grading Criteria: P1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding material melting processes
In order for you to understand producing molten material safely for a given scale of casting or
moulding production you must define and provide images for the following: (continued)
Types of furnace:
Cupola
Induction
Rotary
Bale out
Lift out crucible
Tilting crucible
Direct or indirect arc
Air circulating ovens for thermoplastic melting
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1a
Grading Criteria: P1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding material melting processes
In order for you to understand material melting processes, you must know the material
properties of that you wish to make molten. Define, give examples and provide images
for the following:
Ferrous alloys,
Non-ferrous alloys,
Thermoplastics;
Measurement of temperature e.g. pyrometers
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1b
Grading Criteria: P1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding material melting processes
In order for you to understand removing and finishing molten material safely for a given scale
of casting or moulding production you must define and provide images for the
following:
Component removal and finishing
Knocking castings out of moulds
Removing components from the moulding material or dies
De-coring
Removing runner/riser/feeder system
Processes used
Manual
Vibratory tables/grids
Punch-out mechanisms
Chemical leaching
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1c
Grading Criteria: P2
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding material melting processes
In order for you to understand removing and finishing molten material safely for a given scale
of casting or moulding production you must define and provide images for the
following: (continued)
Tooling used
Work-holding devices (vice, clamps, jigs and fixtures)
Disc/angle grinder
Pedestal grinder
Slitting saw
Band saw
Laser cutter
Linisher
Pneumatic chipping hammers
Wire brush
Scraper
Hacksaw
File
Abrasive stone
Abrasive paper
Hammer
Blasting
Air
Water
Sand
Plastic trimming knives and cutters
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1c
Grading Criteria: P2
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding casting removal processes
When sand casting, you are required to remove patterns from the sand, before and after the casting
process, and removing the casting surplus once the cast is cooled.
Describe briefly, the process that you took to remove the pattern including reference to tools you may have used
before creating the runner and riser system for pouring
Describe briefly, the process that you took to remove the aluminium cast including reference to tools you may have
used once the casting process was complete
Describe briefly, the finishing process that you took to remove the surplus (runner and riser) including reference to
tools you may have used after the casting process
ii) YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS
GRADE CRITERIA.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1di, ii
Grading Criteria: P2
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Hazards and PPE during Casting Processes
When sand casting your scribing block base, it has been necessary to identify the risks and hazards that are in the
foundry area of the workshop.
On the grid below, create a plan view for the foundry area showing where there are assessed risks. Include labels to
show how these risks and hazards are controlled.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1e
Grading Criteria: M1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Hazards and PPE during Casting Processes
Label and explain the use of the correct PPE on the man below
Insert a photograph of yourself here to show that you can demonstrate
good use of PPE when using the foundry area in the workshop
ii) YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE CRITERIA.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1fi, ii
Grading Criteria: M1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Hazards and PPE during Casting Processes
Explain the importance of identifying hazards and wearing personal protective equipment when melting
metals and removing and finishing castings
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 1g
Grading Criteria: M1
Assignment: 1 – Understanding material melting processes and casting removal
Key Skills:
Understanding Sand Casting
Define and provide images for the following:
What are the two parts of the moulding box called? Describe each of their purposes.
Part a)
Part b)
What is a pattern used for? You have created a pattern for the manufacture of your aluminium cast of
the scribing block base. Include a photograph in your answer.
Explain the function of the runner and riser in sand casting
What is the type of sand used in sand casting? Why is this used in the workshop in school?
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2a
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P3
Key Skills:
Understanding Sand Casting
For this task you will be required to provide evidence to show that you are able to understand and inform others in how to sand cast a
component that you will be making in the workshop. You have already created a drawing for your mould. You must now describe the
processes from making the pattern to manufacturing an aluminium cast in order to inform your working colleagues the appropriate steps you
have undertaken. Include Health and Safety considerations you have made.
Create a leaflet or poster that can be used in the workshop in the foundry area that offers guidance and important key terms to
others.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2b
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P3
Key Skills:
Understanding Sand Casting
You have been developing your skills in the foundry by producing aluminium casts for your scribing block base.
During this task you will be observed on the following
•
Following the steps of the sand casting procedure explained in task 2b
•
Disseminating accurate information to your working colleagues
•
Working with others in a respectable and co-operative manner
•
Following appropriate Health and Safety considerations
YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS GRADE
CRITERIA.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2c
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P3
Key Skills:
Understanding Investment Casting
Briefly describe investment casting?
Define the following terms used in investment casting processes
Wax patterns
Single waxes
Wax assemblies
Mounting of wax patterns
Handles
Bars,
Hangers
Slurry
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2d
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P4
Key Skills:
Understanding Investment Casting
Define the following terms used in investment casting processes (continued)
Producing shells/moulds…
Manually
Automatically
Combined manual
Semi-automatic
Single
Multiple
curing shells/moulds
natural air
forced air
gas activated
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2d
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P4
Key Skills:
Understanding Investment Casting
For this task you will be required to provide evidence to show that you are able to understand investment casting. You must watch the video
that has been played to you and take notes on the stages of manufacture. Use this page to record your notes.
http://www.youtube.com/watch?v=BX8w-GUPz1w
Using your notes, create a simplified version in the form of a flow chart showing each of the main steps. You must also include the
Health and Safety considerations you must make during the process as well as the quality control procedures taken in industry.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2e
Assignment: 2 – Understand how casting processes are used
Grading Criteria: P4
Key Skills:
Understanding Investment Casting
Using information on the video, justify why investment casting is used in industry. Give and explain its advantages and
disadvantages.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2f
Assignment: 2 – Understand how casting processes are used
Grading Criteria: D1
Key Skills:
Casting Processes
Justify why you have used Aluminium Sand Casting to produce the scribing block base.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 2g
Assignment: 2 – Understanding why casting processes are used
Grading Criteria: D3
Key Skills:
Understanding Gravity Die Casting
Define and provide images for the following:
Common die locations
Floor
Fixed base
Movable base
Carousel
Conveyor/roller track
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 3a
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P5
Key Skills:
Understanding Gravity Die Casting
Define and provide images for the following: (continued)
Types of die
Split die with no secondary movement,
Split die with one secondary movement,
Split die with two or more secondary movements,
Split die with no cores,
Split die with one core,
Split die with two or more cores,
Water cooling
Use of cores
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3a
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P5
Key Skills:
Understanding Gravity Die Casting
Describe the gravity die casting process when used safely to produce a component
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3b
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P5
Key Skills:
Understanding Pressure Die Casting
Define and provide images for the following:
Types of pressure Die Casting processes
High pressure hot chamber
High pressure cold chamber
Squeeze process
water cooling;
use of cores
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3c
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P6
Key Skills:
Understanding Pressure Die Casting
Define and provide images for the following: (continued)
Types of die
Split die with no secondary movement,
Split die with one secondary movement,
Split die with two or more secondary movements,
Split die with no cores,
Split die with one core,
Split die with two or more cores,
Core assembly with external cores,
Core assembly with internal cores,
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3c
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P6
Key Skills:
Understanding Pressure Die Casting
Describe the pressure die casting process when used safely to produce a component
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3d
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: P6
Key Skills:
Understanding Die Casting
Often it is necessary as a manufacture to weigh up the advantages and disadvantages of different
manufacturing processes. Explain when die casting would be used in preference to sand casting. Note
the advantages and disadvantages of each and conclude.
http://www.castingstechnology.com/public/services/technologies/TECGravityDieCasting.asp
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3e
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: M2
Key Skills:
Understanding Die Casting
Justify why it is sometimes necessary to make the use of a pressure die casting process for
components. List the advantages of Pressure Die Casting.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
3f
Assignment: 3 – Understand how die casting processes are used
Grading Criteria: D2
Key Skills:
Understanding Injection Moulding
Label the parts of the diagram and briefly describe the four main stages of the process. Use
images to support your understanding.
(http://technologystudent.com/equip1/inject1.htm)
1
2
3
4
Name two types of plastic that can be used in this process
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task: 4a
Assignment: 4 – Understand how plastic moulding processes are used
Grading Criteria: P7
Key Skills:
Understanding Vacuum Forming
You need to produce a casing for your electronic circuit so that it is secure. Create an informative guide that can
be used to assist a Year 8 Design and Technology student through the process of Vacuum Forming.
http://technologystudent.com/equip1/vacform1.htm
Make notes below to show the 6 main stages of the process.
Name two types of plastic that can be used in this process
•
•
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
4b
Assignment: 4 – Understand how plastic moulding processes are used
Grading Criteria: P8
Key Skills:
Understanding Vacuum Forming
You need to produce a casing for your electronic circuit so that it is secure. You will be
observed operating the Vacuum Former safely. Show using a photograph that you can
demonstrate this well and the Health and Safety considerations you have made.
YOU MUST MAKE SURE YOU GET YOUR OBSERVATION SHEET SIGNED TO ACHIEVE THIS
GRADE CRITERIA.
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
4c I, ii
Assignment: 4 – Understand how plastic moulding processes are used
Grading Criteria: P8
Key Skills:
Understanding Wet Lay-up Composite Moulding
Briefly describe the Wet Lay-Up technique
Explain when a wet lay-up technique would be used in preference to injection moulding or
vacuum forming
Name:
Jo Richardson Community School
BTEC First Diploma in Engineering
Candidate No:
Unit 22: Casting and Moulding Engineering components Task:
4d
Assignment: 4 – Understand how plastic moulding processes are used
Grading Criteria: M3
Key Skills: