Designs, materials and manufacturing

Question 1

Name 4 thermosetting plastics

Answer 1

Melamine Formaldehyde
Polyester resin
Urea Formaldehyde
Epoxy resin

Question 2

Name 5 thermoplastics

Answer 2

Acrylic
PVC
ABS
Nylon
Rigid polystyrene

Question 3

Name 3 hardwoods

Answer 3

Mahogany
Beech
Ash

Question 4

Name 2 softwoods

Answer 4

Pine

cedar

Question 5

Name 3 manufactured boards

Answer 5

Plywood
MDF
Chipboard

Question 6

Name 3 ferrous metals and alloys

Answer 6

Mild steel
Carbon steel
Stainless steel

Question 7

Name 3 non ferrous metals and alloys

Answer 7

Aluminium
Copper
Brass

Question 8

Why do most CAD softwares enable the design to be tested on a computer?

Answer 8

To prevent the waste of materials - make it and realise it is wrong
To make sure all measurements are right
To check that it would work

Question 9

What is a thermoplastic?

Answer 9

A plastic which can be reshaped with heat

Question 10

2 methods that are used to shape a sheet of thermoplastic material.

Answer 10

Line bending

Vacuum forming

Question 11

Why is a jig used in shaping thermoplastics?

Answer 11

To keep the shape while cooling

To hold it I’m position while it cools.

Question 12

3 CNC Machines that may be used in a school workshop

Answer 12

Laser cutter
3D printer
Milling machine

Question 13

Stages in CNC Process: (6)

Answer 13

• Upload lid design to computer
• Acrylic is taped to black of wood
• Place inside CNC machine, tighten with clamps
• lock guard in position- for operator protection
• Turn on CNC Machine + shape will be cut from acrylic
• when the cutter is stopped the material is removed

Question 14

What material could be used for hedge shears?

Answer 14

• Blade
  high carbon steel
  Strong
• Handle
  Polyester resin
  Durable to wear and tear

Question 15

Advantages of using hedge shears with longer handles?

Answer 15

To give more leverage so it will require less force

You will be able to reach higher

Question 16

What is the purpose of a countersink bit?

Answer 16

To taper the hole to allow it to sit flush

Question 17

Two advantages of a manufactured board compared to timber?

Answer 17

Doesn’t warp

Stronger

Question 18

Difference between aluminium and aluminium alloy?

Answer 18

Aluminium is pure, alloy is a mixture of 2 or more metals

Question 19

What is the function of a ‘computer file’ in a CNC machine?

Answer 19

Tells computer what to do

Question 20

Give two examples of how CAM helps the manufacturing process

Answer 20

It is more precise than human hand

You can mass produce/it’s quicker

Question 21

Name an appropriate hand tool that could be used to cut aluminium tubes

Answer 21

Hacksaw

Question 22

Name a tool or machine that could be used to cut the circular wooden beech top

Answer 22

Coping saw / scroll saw

Question 23

Is aluminium alloy a ferrous or non ferrous metal?

Answer 23

Non - ferrous

Question 24

2 reasons why a round steel tube is more suitable than a square tube for the frame of an extension cable reel

Answer 24

It is easier to shape

Stronger on bends + more comfortable to hold

Question 25

3 design criteria which should be considered in relation to the reel of the extension cable

Answer 25

Is it able to easily rotate without rotating accidentally
Is it durable
How many sockets