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MATERIALS, METALS AND POLYMERS

V. Ryan 2012

 

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QUESTIONS
 

Using notes and diagrams, how could the metal container be manufactured. Use the opposite page for diagrams / sketches.

 
 
 
 
NOTES
 
 
 
 
 
 
 
 
 
 
 
 
 
DIAGRAMS












Name a polymer that you consider suitable for the ‘top/lid’.
 
Write three reasons why the polymer you named, is suitable for the manufacture of the top/lid.
 
REASON 1:
 
 
 
 
REASON 2:
 
 
 
 
 
REASON 3:
 
 
 
 
SAMPLE ANSWERS
 
Using notes and diagrams, how could the metal container be manufactured. Use the opposite page for diagrams / sketches.
 
DIA 1. The first process is called ‘blanking’. A press with a hardened punch, is used to ‘stamp out’ circles of stainless steel, from a stainless steel strip. The strip is ‘pierced’. The circles of stainless steel that will eventually form the container part of the thermo-cup, are called ‘blanks’ at this stage of the manufacturing process.

DIA 2. The stainless steel blanks then go through as process called ‘cupping’.

The blanks are clamped between a blank holder and a die.

The punch is then pushed downwards, stretching the blank as it is forced through the die.

It takes the form of a basic cup shape.

DIA 3. The cupped stainless steel is transferred to another punch and die, for deep drawing.

As the punched moves downwards, the cupped stainless steel is forced through another die, stretching the stainless steel even more. This creates a deeper final container.
 
 
 
 
Name a polymer that you consider suitable for the ‘top/lid’.
 
Polypropylene (polypropene). Also LDPE, HDPE, ABS. HIPS.
 
Write three reasons why the polymer you named, is suitable for the manufacture of the top/lid.
 
REASON 1:
Polypropylene is a thermoplastic and can be formed / shaped through injection moulding, making this materials ideal for the manufacture of the top/lid.
 
REASON 2:
Polypropylene can be finished in a variety of ways. It can be accurately machined, producing a range of shapes, making it suitable for the manufacture of the top/lid. The surface of PP can be textured, so that inks and paints can be applied to it, during the printing process.
 
REASON 3:
PP is ideal because it does not alter the flavour of the drink. It helps to keep the drink warm as it is an insulator and does not contaminate the liquid, as it is a food grade polymer. Furthermore, it is non toxic.
 
 
 
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