Jo Richardson Community School

1. Jo Richardson Community School

2. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1a Grading Criteria: P1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

3. 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: Candidate No: Unit 22: Casting and Moulding Engineering componentsTask: 1a Grading Criteria: P1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

4. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1b Grading Criteria: P1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

5. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1c Grading Criteria: P2 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

6. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1c Grading Criteria: P2 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

7. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1di, ii Grading Criteria: P2 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

8. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1e Grading Criteria: M1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

9. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1fi, ii Grading Criteria: M1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

10. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 1g Grading Criteria: M1 Key Skills: Assignment: 1 – Understanding material melting processes and casting removal Jo Richardson Community School BTEC First Diploma in Engineering

11. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2a Grading Criteria: P3 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

12. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2b Grading Criteria: P3 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

13. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2c Grading Criteria: P3 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

14. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2d Grading Criteria: P4 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

15. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2d Grading Criteria: P4 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

16. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2e Grading Criteria: P4 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

17. Understanding Investment Casting • Using information on the video, justify why investment casting is used in industry. Give and explain its advantages and • disadvantages. Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2f Grading Criteria: D1 Key Skills: Assignment: 2 – Understand how casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

18. Casting Processes • Justify why you have used Aluminium Sand Casting to produce the scribing block base. Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 2g Grading Criteria: D3 Key Skills: Assignment: 2 – Understanding why casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

19. Understanding Gravity Die Casting • Define and provide images for the following: • Common die locations • Floor • Fixed base • Movable base • Carousel • Conveyor/roller track Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3a Grading Criteria: P5 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

20. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3a Grading Criteria: P5 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

21. Understanding Gravity Die Casting • Describe the gravity die casting process when used safely to produce a component Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3b Grading Criteria: P5 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

22. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3c Grading Criteria: P6 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

23. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3c Grading Criteria: P6 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

24. Understanding Pressure Die Casting • Describe the pressure die casting process when used safely to produce a component Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3d Grading Criteria: P6 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

25. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3e Grading Criteria: M2 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

26. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 3f Grading Criteria: D2 Key Skills: Assignment: 3 – Understand how die casting processes are used Jo Richardson Community School BTEC First Diploma in Engineering

27. 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) • Name two types of plastic that can be used in this process 1 2 3 4 Name: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4a Grading Criteria: P7 Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Jo Richardson Community School BTEC First Diploma in Engineering

28. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4b Grading Criteria: P8 Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Jo Richardson Community School BTEC First Diploma in Engineering

29. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4c I, ii Grading Criteria: P8 Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Jo Richardson Community School BTEC First Diploma in Engineering

30. 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: Candidate No: Unit 22: Casting and Moulding Engineering components Task: 4d Grading Criteria: M3 Key Skills: Assignment: 4 – Understand how plastic moulding processes are used Jo Richardson Community School BTEC First Diploma in Engineering