Lesson video

Hello there, my name is Mrs. Dhami.

Thank you for joining me for your design and technology lesson today.

Now, the big question for today is, how can we deform metals?

Now, this is one of my absolute favorite topics because you can be so creative when deforming metals.

So, hard hats on, let's get cracking.

Our outcome for today is we will be able to explain and compare small-scale and industrial deforming processes.

We have five keywords today.

Deform, which means a change in the shape of materials when they are put under physical pressure or stress.

Force, which is a push or pull that can affect the movement, direction, or shape of an object.

Automation, which is the use of technology to perform tasks.

Former, which is a solid object that a material is manipulated around to create a specific shape.

And lastly, bending jig, which is a tool used to guide and control the shape of a material as it is bent.

We have two learning cycles to our lesson today.

Small-scale deforming processes and then moving on to industrial deforming processes.

And we'll start off with small-scale deforming processes that you may or may not have done in your school workshop.

A deforming process changes the shape of a material without removing any parts.

It uses a force and sometimes heat to shape metals into a new form.

Deforming metals makes it easier to create curved or angled shapes that will be hard to cut directly.

And the image here of a necklace is one made by one of my students, and they have deformed this piece of metal by embossing and doming.

And we're going to look at those processes in a bit more detail as we move through our slides.

Deforming metals often requires annealing.

Now, annealing is a heat treatment process that softens metals, making it more workable and improving its malleability by heating it to a specific temperature and then allowing it to cool slowly.

In small-scale metalworking, a brazing hearth or forge is typically used for annealing.

And this is mine from my workshop.

Time for a quick check-in.

What is a deforming process in manufacturing?

A, cutting material, B, joining materials, C, changing shape by force without removing material, or D, adding a coating.

Have a think, come back to me when you've got a good idea.

Well done if you got C.

A deforming process is changing the shape by force without removing material.

Small-scale deforming processes for metals often use simple tools, machines, dies, and formers.

Now, a die, that purple word, is a shaped tool used to cut, press, stamp, or draw metal into a specific form during deforming processes, such as forging or metal stamping.

And we'll come back to that word as we make our way through today's lesson.

A former is a solid shape over which material is formed or shaped used in processes such as doming and bending.

Embossing is a small-scale deforming process that creates raised or recessed designs on a material surface.

One example of embossing is called stamping.

Let's take a closer look.

Have a little look at the GIF on the left.

You can see my technician has a stamp and a hammer, and he's hammering that stamp onto the copper.

Now, I have actually annealed that copper to make it more malleable and so that the stamp will imprint on it a lot easier.

Take note, we are doing this on a piece of metal.

You never put a piece of annealed metal on a wooden bench.

You always put it on a piece of metal so that when you stamp, the shape of the stamp gets embossed, but the rest of the metal does not become deformed.

So stamps can add letters, numbers, logos, and patterns onto metal.

The shape to be stamped is known as the die.

There's that word from the last slide.

The force is applied with a hammer.

It's a beautiful technique for creating some lovely personalized patterns on the design of a piece of metal.

Embossing can be achieved by using other techniques, not just stamping.

Let's take a closer look at how these flower petals have been embossed.

One technique, like the top one, is by using metal wire.

So you can get a pair of pliers, you can shape that bit of metal wire into whatever pattern, whatever formation you like, then you simply attach it onto your piece of metal, in my case, copper.

Now, I normally use masking tape, but in this one, I've used sticky tape just so you can see it a bit more clearly.

You then use the hammer to bash that metal wire into your metal, and then when you remove it, whatever shape you have created then gets imprinted and embossed into the metal.

What a great technique.

Chasing is another embossing technique where you basically create a pattern in the surface.

Now, the one where I have pointed an arrow from it, that has been used by a ball-peen hammer, which creates those tiny little domes throughout the surface of the metal.

But you could also use a straight-peen hammer, and if you look at that petal underneath the one that I'm pointing out, that pattern has been created by using a straight-peen hammer too.

It's quite nice to be able to experiment and do a few test pieces before you choose your final embossing technique.

Embossing can be achieved by using a rolling mill with a variety of textures such as lace.

Let's take a little look at the process.

First of all, you need a piece of annealed metal, such as my example being copper.

Now, it's important that it's annealed, otherwise it will not be malleable enough to pass through the rollers.

You then need to grab yourself some texture.

Now, I've got a little bit of netting here, but you could use other things such as lace or dried leaves, whatever you can find.

Now, I always wrap it in a little bit of paper just to make sure that that texture doesn't move.

You then pass that through the rolling mill.

And the force is applied between the two rollers to emboss your piece of metal.

Then when you unwrap it, you will find that your metal has been embossed with whichever pattern you put on top of it.

It'd be great if you could try out a few examples and see what textures you could create.

Doming is a metalworking technique used to shape flat metal into a smooth, rounded form using a doming block, which is the former and a punch.

So first of all, you have to choose what doming block and punch you require for the size of your circle.

You then need to make sure that your metal is annealed so it's malleable enough, and you place it within that doming block.

You then apply the force with a hammer, and basically, you punch that circle into the doming block.

And that will create a domed metal product, such as this necklace, which I actually created myself out of an old cuff link and domed it into its shape.

Quick check-in.

Which image does not represent embossing?

A, B, or C?

Have a think, come back to me when you've got an answer.

Well done if you've got C.

Doming is not an embossing technique, whereas embossing using stamping or embossing using the rolling mill are both examples of embossing.

If a metal has deformed unintentionally, a planisher can then be used to apply force to restore it to its original shape.

And here's me showing you using the planisher in my workshop.

If I zoom in, you can see that the piece of copper has been reshaped in the first image, and then in the second image, you can see that it has restored it to its original flat shape.

Now, quite often, say if you pass it for a rolling mill, you're going to create a curve in the metal.

Therefore, using a planisher gets it back to its flat state.

A mandrel is a former for making metal circular such as rings and bracelets.

So on the left at the top, we have a bracelet mandrel, which has a wide diameter for creating those beautiful bangles underneath.

On the right, we have a ring mandrel, which obviously has a much smaller diameter for creating smaller things such as rings.

Let's take a little look at how this works.

So you need a rawhide mallet to apply the force so that the metal can be shaped around the former.

If you want it smaller, you bring it towards the end away from the vice.

If you want the diameter larger, you obviously move it closer to the vice.

Now, the reason we use a rawhide mallet is because rawhide mallets will not create embossing or indentation on the metal.

So it protects the metal and only shapes it.

That's why you mustn't use a hammer when you use a mandrel.

A hand drill can be used to create a beautiful twist in wire.

So basically use the hand drill, which is the force, and you need to hook it onto the wire.

Now, I've just made that hook out of a bit of metal rod.

You can then use that to hook onto your piece of metal wire and twist it into a shape.

Look at the outcome.

Isn't that beautiful?

You can then use that twisted wire to make it into different designs, such as jewelry, and this is one of my student's.

She has made a beautiful anchor out of twisted wire, and we also use it around a mandrel, just like on our last slide, to create beautiful rings and bracelets.

Metal bending can be achieved either cold, with heat or after annealing, and it all depends on the metal's thickness.

Bending jigs are often used to produce consistent and precise curves repeatedly.

Now, here's an example from my school.

This is five millimeter diameter metal rod that I haven't needed to heat, I haven't needed to anneal.

This is being bent cold.

So the metal rod is bent around a wooden bending jig to create three identical hairpin legs, which is used in a side table project that I do with my students.

The jig makes sure each of the legs are exactly the same.

Which of the following is a bending jig?

A, B, or C?

Have a think, come back to me when you've got an idea.

Well done if you got A.

A is the bending jig, B is the rolling mill, and C are the doming blocks and punches.

With small-scale deforming processes, there are benefits and limitations.

The benefits are that it is low cost and quite often easy to set up.

It's good for one-off prototype pieces, and it can achieve detailed and bespoke shapes.

The limitations are, it's often time-consuming compared to industrial methods.

It requires skill and patience, and sometimes, you're limited in the size of the product that you can produce.

Quick check-in.

Which of the following is a limitation of small-scale deforming processes?

A, time-consuming, B, can achieve bespoke shapes, C, low-cost, or D, good for prototypes.

Have a think, perhaps speak to the person next to you.

Come back to me when you've got an idea.

Well done if you got A.

A limitation of small-scale deforming processes is that they're often time-consuming.

Onto task A.

Part one, I'd like you to explain what is meant by a deforming process in metal manufacturing.

Part two, I'd like you to draw a diagram to describe the deforming process of embossing using a rolling mill.

Part three, what is the purpose of a bending jig when bending metal?

And lastly, give two benefits and two limitations of small-scale metal deforming processes.

Good luck, come back to me when you've got some great answers.

Part one, I asked you to explain what is meant by deforming processes in metal manufacturing.

You might have said, a deforming process changes the shape of the metal without cutting away any material.

It uses force and sometimes, but not always, heat to bend or shape the metal into a new form.

Metal often needs to be annealed first, though, if heat is not required in the actual process.

Part two, draw a diagram to describe the deforming process of embossing using a rolling mill.

Step one, the metal needs to be annealed.

Step two, the texture needs to be added just like the netting have popped in here.

Step three, it needs to be passed through a rolling mill to apply the force.

And step four, the metal will come out embossed.

Part three, what is the purpose of a bending jig when bending metal?

You might have said, bending jigs are often used to produce consistent and precise curves repeatedly.

Metal bending can be done either cold or with heat or prior annealing, depending on the metal's thicknesses.

Part four, give two benefits and two limitations of small-scale metal deforming processes.

You might have said, benefits are low cost and easy to set up, good for creating custom or prototype pieces.

And limitations, they are sometimes time consuming and require skill, often limited to smaller or thinner pieces of metal too.

Onto learning cycle two, industrial deforming processes.

Industrial metal deforming processes are usually automated and used in large-scale manufacturing to increase speed, machines can work continuously and quickly with minimal downtime, accuracy, CNC, computer numerical control, machine systems produce highly consistent forms and dies, and lastly, consistency, every product matches the design exactly, ideal for higher-volume production.

What is one key benefit of using industrial deforming processes over small scale ones?

A, they require more human input, B, they provide faster and more consistent results, C, they use less electricity, or D, they are more random in shape.

Have a little think, come back to me when you've got an idea.

Well then if you got B.

A key benefit of using industrial deforming processes over small scale ones is that they provide faster and more consistent results.

Industrial rolling involves passing sheet of metal for a set of rollers to gradually curve it into a desired radius or cylindrical shape, such as arch structural components, or metal barrels.

Now, the rolling machine might be manual, but on quite a large scale for industrial, or it might be automated.

Let's take a little closer look at those rollers.

The radius of the rollers and their positioning will determine the curve or angle of the bent.

Industrial drawing is a metal deforming process that involves pulling metal, the dark blue part, through a die, notice the die, to reduce its diameter and increase its length.

And this is commonly used to make wires, rods, or tubes.

Deep drawing is a metal deforming process where a sheet of metal, in this instance, it's that flat piece of black metal in the left-hand side, the sheet of metal is drawn into a die.

Notice where the die is on the diagram.

And it's drawn into a die by a punch, which is the blue part.

So it's drawn into a die by a punch applying the force to create deep hollow shapes like cans, sinks, or car panels.

Notice the sheet metal on the left turned into the deformed metal on the right.

Drop forging is a process where heated metal is shaped by being hammered, which is the force, into a die using repeated high impact blows, which produces strong and durable components like tools and automotive parts.

Press forging is similar, but uses a hydraulic or mechanical press rather than being hammered to form more precise and complex shapes.

Cold press forging without heat is used in the manufacture of automotive parts.

Now, a lovely company called AEC Engineering have kindly provided us with some pictures to show how cold press forging works.

So first of all, they get the former ready.

Now, this is the complex bottom half of the former, and they actually call this a transfer press.

They then place a sheet of aluminum above that first half of the former.

A mechanical press provides a huge load of force, which basically presses the aluminum between both formers.

And what is released is an automotive part, which is a shaped piece of our aluminum, which has been trimmed, and that takes the direct shape of the former.

Impressive.

Time for a quick check-in.

Which deforming process is likely to be used to make this sink?

Is it A, press forging, B, drop forging.

C, rolling, or D, deep drawing?

Have a think, perhaps tell me or the person next to you.

Come back to me when you've got an idea.

Well done if you got deep drawing.

Deep drawing is the likely deforming process to be used to make this sink.

In industrial settings, formers, dies, and bending jigs are often made from hardened metals such as steel, because they are strong in compressive and tensile strength.

This means they are ideal for repeated use.

They are highly accurate, so formers, dies, and bending jigs are usually CNC machined to make sure they're highly accurate.

And they are also durable because they can withstand heat, pressure, and moisture, which is so important in these industrial deforming processes.

Quick question to you.

Why are bending jigs, dies and formers used in industry made from metal?

A, they provide strength and precision for repeat shaping.

B, they are easier to shape.

C, they are flexible, or D, they are recyclable.

Have a think, come back to me when you've got an idea.

Well done if you got A.

Bending jigs, dies, and formers used in industry are usually made for metal because they provide strength and precision for repeat shaping.

Onto task B.

Part one, I'd like you to explain why industrial deforming processes are more suitable than small-scale methods for higher volume production.

Part two, I'd like you to use diagrams to explain how drop forging is used to deform metals.

And lastly, part three, I'd like you to compare the role of a former in doming in small scale, and press forging in industrial.

Good luck, come back to me when you've got some great answers.

Part one, I asked you to explain why industrial deforming processes are more suitable than small-scale methods for higher-volume production.

You might have said, the use of machines and automation help to produce complex shapes quickly and consistently.

This ensures every product is identical, which is essential for higher-volume production.

Part two, I asked you to use diagrams to explain how drop forging is used to deform metals.

Step one, the metal is heated.

Step two, high impact shapes the metal.

And lastly, the part is produced.

And lastly, I asked you to compare the role of a former in doming, which is a small-scale process, and press forging, which is an industrial process.

You might have said, in both small-scale doming and industrial press forging, a former shapes the metal and ensures consistent, accurate results.

Doming formers may be made from metal or timber, while press forging formers are made from hardened metal to withstand high pressure, heat, and repeated use.

Well done with all the efforts on your answers.

This brings us to the end of our lesson today.

Let's summarize what we have found out.

Deforming involves using force to change the shape of a material.

Metal often requires annealing to improve their malleability before deforming.

Small-scale production methods can be used to deform metals such as doming and embossing.

Deforming materials on a larger scale requires different techniques and is often automated.

Well done with all of your hard work today, I hope you have found it really interesting exploring these wonderful processes, and I hope to see you in another lesson soon.

Take good care.

Bye-bye-bye.