Industrial Metalwork Processes
Most of the operations you use to complete your work in the school workshops are replicated on a larger scale in industry. You need to be aware of the types of machines and operations that are used in different industries and also be able to consider the benefits and drawbacks of these expensive machines.
What is CNC?
Most industrial processes these days will be driven by computer. This process is called CNC which stands for Computer Numerical Control. Click on the document to see the pros and cons of this type of production.
CNC.pdfCNC Cutting - Sheet metal
Your first project in the workshop involved marking and cutting sheet metal to create the toolbox but how would this have been made in industry? There are a number of CNC cutting processes that can be used to cut sheet steel and aluminium very accurately and quickly. You should be aware of Plasma cutting, Waterjet cutting and Laser cutting. Check out the document below for a bit more information
CNC Cutting.pdfCNC Folding - Sheet metal
You have used folding bars, hide mallets and the box folder to form your sheet metal products. In industry CNC folding machines can be set up to quickly and accurately fold really complex shapes. Have a look at the video to see one of these machines at work.
CNC Machining (Lathe and Mill)
You have created turned cylindrical parts using the centre lathes in the workshop. As you know, these take time and skill to create accurate parts. Industrial machines can be programmed to produce the parts from a CAD model without the need for manual cutting or operation. These machines are capable of greater speed and accuracy than manual machines and can create some incredibly complicated shapes....
CNC Welding
Industrial welding processes are essentially the same as those you have used in the school workshop with M.I.G., T.I.G. and stick welding being used in a range of applications.
Automated (CNC) welding machines can also be used for high volume, repetitive tasks, these are usually T.I.G or M.I.G operations where the filler can be continually fed through.
elding robots are widely used in the Car industry where they can operate 24 hours a day producing identical welds.
CNC Painting and polishing
Even the finishing processes can be computer controlled! A lot of money and setting up will be put into the programming to ensure the robot doesn't miss any part of the car body with the paint so it is only a process that would be used when you are making a lot of the same thing and not for a one-off repair. The robot will do a very efficient job though and won't waste a drop of paint or take any toilet breaks so if you are producing 10,000 cars it will be a more efficient way of doing it.
