Demonstrate knowledge of motor industry engineering tasks Flashcards
ABS Plastic can be found in
Grills,body and instrument pannels
It is light, malleable and ductile. It resists corrosion and is a good conductor of heat.
Aluminum
Polyethylene can be found in
Interior trim
Uses in the moter industry include: rocker covers and wheel rims
Aluminum
TPUR can be found in
Upholstery
It is malleable, ductile and is a good conductor of heat and electricity.
Copper
Acrylic be found in
Light lenses and covers
Uses in the motor industry include: electrical wiring, radiators and pipes.
Copper
Polyamide or nylon can be found in
Exterior trim, radiator tanks or gears
It is soft, heavy, malleable and highly plasic.
Lead
Polystyrene can be found in
Sound deadening and seat filler
Uses in the motor industry include: batteries, wheel balance weights.
Lead
Why is hardening carried out?
To increase resistance to penetration
It has a low melting point and is a good conductor of electricity. It is also less likely to cause heat damage.
Solder
Why is case hardening carried out?
Hardens the surface of the metal
Used in the motor industry to join metals together and for making electrical connections.
Solder
Why is tempering carried out?
To remove brittleness
Uses in the motor industry include: filler rods for welding and electrical terminals.
Brass
Why is annealing carried out?
To soften metal
It resists corrosion and rusting and is a good conductor of heat and and electricity.
Bronze
Why is normalizing carried out?
To relive internal stresses an return metal to its original standard
Uses in tje motor industry include: brushes and thrust washers.
Bronze
Before drilling a hole one must consider
- The size of the drill bit
- The need for a pilot hole
- The cutting speed to suit the material
- The need for lubricant to suit the material
- The drill angles
It resists corrosion and provides an attractive finish.
Chromium
Four factors to be considered when selecting a twist drill.
1 Diameter of the drill
2 Length of the twist drill
3 Type of cutting tip
4 Material to be drilled
Uses in the motor industry include: bumpers, grills and wheels.
Chromium
Explain why the trailing edge of the twist drill lip must be lower than
the leading edge.
To provide clearance for the cutting edge
It is easily shaped and welded, it is soft and ductile.
Mild steel
List three reasons why cutting fluid is used when drilling.
Acts as a coolant
Acts as a lubricant
Will improve the cutting finish
It is very versatile, diffrent combinations of zinc and copper produce brass with different characteristics
Brass
Explain why it is important to refer to the manufacturer’s charts when
drilling a hole for tapping
Manufacturers provide tap and drill size charts to enable technicians to
select the appropriate drill size to form the tapping hole and the appropriate
tap to form the thread
Uses in the motor industry include: body panels and parts that are not load bearing.
Mild steel
Describe the procedure involved when sharpening a twist drill.
Install a fine grade wheel on the grinder.
Switch on the grinding wheel.
Holding the drill bit firmly, place the drill bit against the tool rest at the correct
angle.
Applying light pressure offer the drill bit cutting edge to the grinding wheel.
Twist the drill bit to form the cutting edge clearance.
Repeat this procedure for the second cutting edge.
Cool the bit and check both cutting edge angles on a drill angle gauge.
It is relatively light but strong. It is also cheap to manufacture.
High tensile steel
List three outcomes that should be avoided when drilling a hole.
A rough hole An oversize bore A split drill web Damaged corners Drill breakage
Uses in the motor industry include: chassis rails, front and rear impacts bars and body panels
High tensile steel
State a safety precaution that must be observed when using drilling
equipment to protect tools and equipment.
Inspect tools prior to use – leads, plugs, drill body, drill bit
Use a RCD
Use tools correctly
Select the correct drill bit for the task
Always use the guards provided
Check that the machine is securely mounted
Check the condition of the guards
Adjust the machine correctly prior to use
Only drill suitable materials
Use correct drilling speeds
Use appropriate cutting fluid
Clean the machine after use
It is relatively hard and strong.
Spring steel
Taps
is designed to cut internal threads into a hole in metal objects,
allowing bolts or studs to be fitted.
Uses in the motor industry include: coil and leaf springs.
Spring steel
Dies
A die is designed to cut external threads
Its rust resistant and hard wearing.
Stainless steel
Thread files
A thread file is used to repair an external thread.
Uses in the motor industry include: exhaust system components and some body parts.
Stainless steel
Sleeve
thread
inserts
A thread insert is used when there is not enough material around the
hole or when a specific thread is required.
Its very ridged and strong in compression. Cast into intricate shapes and forms a good wearing surface.
Cast iron
Outline the procedure involved when cutting a thread in a blind hole
using taps.
Step 1 Consult with the manufacturer’s tapping and drilling chart and
select the appropriate drill bit and tap.
Step 2 Drill the tapping hole.
Step 3 Using the taper tap and carry out steps 3 - 6 as above. Do not
force the taper tap at the bottom of the hole as the tap may
break off.
Step 4 Remove the taper tap and clean out the hole.
Step 5 Install the intermediate tap and repeat steps 3 – 4.
Step 6 Install the bottoming tap and repeat steps 3 – 4.
Uses in the motor industry include: cylinder blocks, cylinder heads and other housing.
Cast iron
Outline the procedure involved when installing a thread insert.
- Select a thread insert kit to suit the thread diameter and pitch
required. - Select the correct drill bit from the kit.
- Drill out the original thread.
- Select the appropriate tap.
- Tap the new thread.
- Fit the Heli-coil onto the installation tool supplied in the kit ensuring
that the tang on the Heli-coil is firmly inserted into the slot of the
installation tool. - Screw in the Heli-coil into the tapped hole. This reduces the diameter
of the Heli-coil allowing it to be threaded into place. - When the Heli-coil is in place, break off the tang.
Its strong and can be forged.
Medium carbon steel
Cable ties
Can be used when securing wiring harnesses, steering rack boots
and wheel covers
Uses in the motor industry include: crankshafts, connecting rods, gears and camshafts.
Medium carbon steel
Clamps
To secure exhaust pipes and radiator hoes
Its hard and strong
High carbon steel
Double sided
tape
Can be used when securing exterior protective mouldings, decals
and badges.
Uses in the motor industry include: cutting tools, files, taps dies and punches.
High carbon steel
Lockwire
To secure c.v. boots and rack and pinion boots
Studs
Dave, nah just kidding. Use to securely clamp components together
