Metals: Cutting, Forming & Machining Processes
Design & Technology: AQA GCSE, topic 4.8.3
Cutting, Forming, and Machining Processes
Cutting, forming, and machining are some of the commonly used processes for metal.
Cutting
- Cutting processes are used to separate or remove material from metal workpieces.
Cutting processes
- Common cutting processes include:
- Sawing - using a saw or abrasive cutting tool to cut metal.
- Shearing - cutting metal sheets or plates using specialised shearing machines.
- Laser cutting - employing a laser beam to melt, burn, or vaporise metal to achieve precise cuts.
- Plasma cutting - utilising a high-temperature plasma jet to cut through electrically conductive metals.
Forming
- Forming processes reshape metal materials.
- Forming processes do not remove material.
Forming processes
- Common forming processes include:
- Bending - applying force to metal to create angles, curves, or shapes.
- Rolling - passing metal sheets or bars through rollers to shape them into desired profiles.
- Extrusion - forcing metal through a die to create continuous profiles with a specific cross-section.
- Drawing - pulling metal through a die to reduce its diameter and form wires or tubes.
Machining
- Machining processes involve removing material from a metal workpiece.
- Machining processes use cutting tools.
Machining processes
- Common machining processes include:
- Turning - rotating a workpiece on a lathe while cutting tools remove material to create cylindrical shapes.
- Milling - using rotary cutters to remove material from a workpiece to create complex shapes or features.
- Drilling - creating holes in metal using a rotating drill bit.
- Grinding - abrasively removing material to achieve smooth surfaces.
Test yourself on Metals: Cutting, Forming & Machining Processes
What process does NOT remove material from metal workpieces?
What forming process involves pulling metal through a die?
What are the most common cutting processes?