METAL WORKS

INTRODUCTION TO INDUSTRIAL ARTS PART 2

INTRODUCTION TO METAL
WORKING/FABRICATION
LESSON 1
 METAL WORKING

• The process of working with metals to

manufacture specific pieces. It is the shaping
and reshaping of metals to produce usable
items, pieces, assembles, and large scale
structures.
3 CATEGORIES OF METAL WORKING
OPERATIONS
 1. FORMING METAL

• The process of shaping metal objects by deforming without the

addition or removal of any material. A basic metal forming
process will bend or deform a metal workpiece to a desired
geometric shape. Heat and mechanical loads are used in the
deformation process, metal forming is an exceptionally suitable
manufacturing process for producing large quantities of parts
and components.
 A. METAL BENDING
A manufacturing process that employs
ductile materials, most commonly sheet
metal, to create equipment such as
specialized machine presses. It is a
process in which metal can be deformed
by applying force to the subject, causing
it to bend at an angle and shape itself
into the desired shape, which often
results in a ‘V’ or ‘U’ shape. For small
to medium-sized batches, metal bending
is considered to be quite cost-effective.
On a press brake, there are three basic
types of bending; air bending,
bottoming, and coining.
 B. FORGING
One of the oldest metalworking
techniques. Metal is shaped using
local compressive forces. Nowadays,
industrial forging is performed with
specialized pressing equipment
(hammers) weighing thousands of
pounds. One of the most significant
advantages of forging is that it can
produce a stronger part than casting
or machining. During the forging
process, the metal is shaped, and its
internal grain texture gradually
deforms to follow the general shape
of the part.
 2. CUTTING METAL (MACHINING)

• Machining is a catch-all term for a variety of processes that involve

removing some parts of a raw material in order to shape and size it to a
desired shape and size using computer-controlled tools. These methods
are known as subtractive manufacturing, as opposed to additive
manufacturing (3D printing), which creates a product from the ground
up. Machining is commonly associated with the production of metal
parts, but it is also used with a variety of materials such as plastic, wood,
composites, and others.
3 PRIMARY MACHINING PROCESSES
 A. MILLING

The operation in which a

cutting tool or rotary cutter
rotates and remove
material, bringing cutting
edges into contact with a
workpiece. Computer
Numerical Control (CNC)
milling machines are the
latest machine tools used
in milling.
 B. ROUTING
Similar to milling in that some
Computer Numerical Control
(CNC) routing machines can
perform nearly the same tasks as
milling machines. Routing's
primary functions are to cut,
engrave, and carve objects from a
workpiece - essentially a
replacement for the traditional
hand-held router, but with the
assistance of computer-controlled
processes to eliminate human error.
 C. TURNING/SPINNING

The operation that

rotates the workpiece as
the primary method of
moving metal against the
cutting tool. Computer
Numerical Control
(CNC) lathes are used in
turning as the leading
principal machine tool.
 3. JOINING METAL

• The joining of several parts of a

metal product. It is a method of
melting or heating metal just below
the melting point using heat.
 A. WELDING

• A fabrication process that joins materials through fusion,

which is a combination of pressure and heat. In general, a
filler material is added to the welded joint to make it
stronger than the original material in some cases.
Simultaneously, the welding process must protect the filler
metals/melted metals from contamination and/or oxidation.
 B. SOLDERING
A joining process that uses
molten solder to join different
types of metals together. Solder
is a metal alloy typically
composed of tin and lead that
is melted with a hot iron. The
iron is heated to temperatures
exceeding 600 degrees
Fahrenheit (315 degrees
Celsius), then cooled to form a
strong electrical bond.
 C. BRAZING
A metal (but also ceramic)
joining process in which molten
filler metal (the braze alloy)
flows into the joint. The melting
point of the filler metal is above
450°C, but always lower than the
melting temperature of the parts
to be joined, distinguishing the
process from welding, which
uses high temperatures to melt
the base metals together.
4. METAL CASTING

A metalworking process that

dates back to ancient times
and is still widely used today
to create sculptures, tools,
and jewelry. It is the process
of pouring molten metal into
a mold with a hollow cavity
of a desired geometrical
shape and allowing it to cool
to form a solidified part.