DT EoY Preparation

Metal Extraction and Processing

• Smelting extracts metal from ore by heating and melting ore with a reducing agent like coke or charcoal.
• Heat and reducing agent remove oxygen from metal oxide, leaving pure metal.

Metal Forms and Applications

• Sheet metal is used for car panels and roofing.
• Round bar is used for axles and shafts.
• Box section is used for frames and furniture.
• Tube is used for bicycle frames and pipework.
• T-section is used for shelving supports.
• RSJs are used for construction and bridges.
• Channel is used for frames and shelving.
• Angle is used for brackets and supports.
• Pipe is used for pipework and fencing.
• Hexagon bar is used for tools and levers.
• Square bar is used for frames and tooling.
• Flat bar is used for brackets and levers.

Components and Fasteners

• Nuts and bolts are used for joining.
• Washers are used for spreading the load.
• Screws are used for joining wood to metal.
• Nails are used for joining wood.

Metal Working Processes

• Sheet fabrication involves working with sheet metal.
• Steel construction involves working with angle, channel, and I-beam.
• Pipe fitting involves working with pipe.
• Machining involves working with round bar and hexagon bar.
• Forging and stamping involve working with round bar and flat bar.

Metal Cutting and Shaping Tools

• Metal shears are used for cutting thin sheet metal.
• Bench shears are used for cutting thicker sheet metal.
• Throatless shears are used for cutting sheet edges.
• Nibbler is used for cutting intricate sheet shapes.
• Hacksaw is used for cutting bars and pipes.
• Files are used for shaping and smoothing surfaces.
• Guillotine is used for shearing sheets and bars.
• Angle grinder is used for cutting and grinding metal.
• Oxyacetylene torch is used for cutting thick sections by melting.
• Plasma cutters are used for cutting conductive metals like steel.

Joining Methods

• Temporary joining (nuts, bolts) allows for disassembly.
• Permanent joining (rivets, gluing) permanently joins metals.
• Temporary joining is used for repairs and adjustments.
• Permanent joining is used for non-separating joints like car panels.

Metal Bonding Methods

• Soldering involves melting filler into a joint, used for electrical connections.
• Brazing involves using a higher temperature filler like brass, creating stronger joints.
• Welding involves melting and fusing base metals, creating very strong joints.
• Folding involves bending sheet along a line using brakes.
• Pressing involves deforming stock into shape by pressing/squeezing.
• Casting involves pouring molten metal into a mold cavity, creating complex shapes.

Cost and Profit Calculation

• Total cost of 10,000 units is 35,000(10,000x(35,000 (10,000 x (35,000(10,000x(2 + $1.50)).
• 25% profit: Selling price = Total cost + 0.25(Total cost) = $43,750.
• Per unit cost = 43,750/10,000=43,750 / 10,000 = 43,750/10,000=4.375.

Lean Manufacturing

• Lean manufacturing maximizes efficiency and minimizes waste.
• Make only what's needed when needed, with continuous improvement.
• Reduces raw materials, energy wasted, and environmental impact.
• Key principles include just-in-time, optimized workflow, and mistake-proofing.
• Reduces scrap metal, excess inventory, and defects.