GCSE - The WHOLE revision guide Flashcards
what is automation?
the use of machines to do a task automatically, without much human input
Give an example of automation
in the car industry, robots can be programmed to weld or do other processes
give 3 advantages of automation
robots can increase the speed of production
robots can work with high accuracy, therefore increasing quality
robots can work in dangerous situations
give 3 disadvantages of automation
robots can replace human workers
robots can be expensive to buy
can’t carry out tasks that require human judgement
what does smart technology do?
develops machines like CAD further by connecting them with other machines and sensors to share data. This creates ‘smart’ machines
what can ‘smart’ machines do?
use data to organise what tasks they need to do
work out when they will run out of a material by receiving stock level data.
what can ‘smart’ machines be a part of?
‘The Internet of Things’
What is the Internet of Things
describes the connection between technologies and the internet, for machines this could mean receiving and processing online customer orders.
What can the use of smart technology do?
make automated manufacturing very efficient.
what has been a key development in manufacturing?
tracking materials, tools, equipment and products in the factory
How can tracking be done?
automatically by tagging each necessary thing (e.g. box of material). These can then be scanned or detected as the item moves around the factory
Name some uses of tracking
monitoring stock levels
tracking the movement of the products
getting the number of finished products in stock
Give an example of workers using devices to receive information
warehouse workers can use things like tablet to give them the best/ efficient route to required items
What is a modular component in relation to factories?
components that can be moved, taken apart or added to. Like extra production space
what can technological advances lead to in relation to factories?
reduced need for room. e.g. 3D printing uses a small machine
What are flexible manufacturing systems?
they consist of a set of different machines which carry out different stages of production. Automated systems transport materials through the different processes and store the finished product. Fairly quick and easy to change the system
What is lean manufacturing?
manufacturing that minimises waste and resources used. Aims to reduce cost and increase efficiency
Give an example of Lean manufacturing
Just In Time (JIT)
Give 2 advantages of JIT
reduces need for space
less money needed
give 2 disadvantages of JIT
system relies on materials being delivered on time
money can be lost if there are faults with the delivery
What can CAD help designers do?
model and change their design quickly
experiment with different colours and forms
3D programs enable designers to view the product from all angles
What is CAM?
the process of using computers to manufacture products. Computer Aided Manufacture
what can CAM do?
follow the X,Y,Z coordinated, given by CAD, to move the tools and cut out or build up your design. They can do this because they are computer numerically controlled (CNC)
give an example of CAM
some milling machines, 3D computers, CNC routers and laser cutters
What are the two types of CAM machines
2 axis - only cut out 2D shapes
3 axis - can cut out 3D shapes
What can CNC routers be used for?
to engrave things on plastics, metals and wood
cut out either 2D or 3D shapes as they can be 2 or 3 axis machines
What can laser cutters be used for?
to cut out things from plastic, wood, cardboard, fabrics and some metals. On low power settings they can engrave things. Can only cut through sheet materials and they are 2 axis
What can 3D printers be used for?
rapid prototyping, can print with several different materials including plastic and wax. can manufacture final products
Why is CAD/CAM good for global companies?
saves shipping costs as designs can be sent electronically
saves labour costs as products can be manufactured in a country with cheap labour
name a disadvantage of CAD/CAM
computers can be affected by viruses, software problems and file corruption therefore slowing down production
what does sustainability mean?
not causing permanent damage to the environment
what does the sustainability of a product depend on?
what materials the product is made of
the processes involved in making the product
how long lasting and efficient the product is
define a carbon footprint
the amount of greenhouse gasses produced throughout the lifecycle of a product
what is ‘Design for Disassembly’?
a new product is designed so it can be easily taken apart at the end of its lifetime, allowing parts and materials to be reused/ recycled
what are up-to-the-minute designs?
designs that go out of fashion therefore become obsolete quickly (like mobile phones)
define ‘Design for Maintenance’
products that are designed to last and can be repaired or have parts that can be replaced (like washing machines)
what are modular electronics?
electronics made up of different parts that can then be replaced/ upgraded separately making the product more sustainable
why can continuous improvement be harmful?
can encourage users to replace existing products with new ones
leads to an increased usage of finite resources and environmental damage due to manufacturing, packaging, transportation etc.
why can continuous improvement be good for the environment?
products can be changed to be more efficient therefore having a lower carbon footprint as it uses less energy
name 3 other aspects of products that have a positive impact on the environment
avoiding the use of harmful chemicals
making products from materials that can be recycled
minimising the amount of material used.
name the 6 Rs
Repair Reuse Recycle Rethink Reduce Refuse
Define Reuse
passing on a product e.g. tyre for a swing
Define Rethink
thinking about the design from an environmental perspective
name 2 impacts a product can have on people
safe working conditions health impacts (harmful pollutants)
What is innovation?
when an entrepreneur or business come up with a something new
Name 3 innovations in business
crowdfunding, virtual marketing/ retail, co-operatives and fairtrade
Define crowdfunding
using websites to raise money for an idea. Backers give money/ invest and often get a reward for their investment
Define virtual marketing and virtual retail
promoting and selling products on the iternet
Define co-operatives
a type of business that is run and owned by its members. Profits are shared out. they can have higher negotiating powers.
Define fairtrade
a scheme that ensures farmers are paid a fair price
define market pull
designing for what the customer wants/ needs
define technology push
the development of new technologies that then drive the design of new products
How does burning fossil fuels power a system?
power stations burn fossil fuels to produce heat
water then turns into steam
steam drives a turbine
this turns a generator, generating electricity
name 2 arguments for using fossil fuels
they are reliable
fairly cost effective as extraction and running costs are low
name 3 arguments against using fossil fuels
they are finite
extraction of fossil fuels have environmental and social impacts
they release greenhouse gases when burnt contributing to global warming
How does nuclear power stations work?
in a similar way to burning fossil fuels but nuclear fission is used to create heat instead
name 3 arguments for using nuclear power
reliable
quite cheap
produces low levels of greenhouse gases
name 3 arguments against using nuclear power
uses finite fuel sources (uranium)
nuclear power plants cost a lot to build and maintain
waste produced is dangerous and difficult to dispose of
risk of major catastrophe
name 3 arguments for using renewable energy
generally have a smaller environmental impact
after initial set up costs, the energy provided is usually free
name 3 arguments against using renewable energy
set up costs are quite high
less reliable as depend upon external factors (wind)
spoil landscapes
habitat loss
name 2 systems that are used to store extra energy
kinetic pumped storage system
batteries
how does a hydro electric power station work?
‘spare’ energy pumps water up from a lower reservoir to an upper reservoir. In peak demand, water from the upper reservoir can flow through turbines, generating electricity.
what kind of energy do batteries store and how do they work
chemical energy
chemical reactions are used to generate an electric voltage
name the 2 types of batteries
alkaline
rechargeable
name properties of alkaline batteries
they’re recyclable
last a long time
leak less than some disposable batteries
power output gradually decreases over time
name properties of rechargeable batteries
can be charged when it goes flat
more expensive than alkaline batteries
can be used again and again - makes them more environmentally friendly
power output remains constant until they go flat
define an alloy
a mixture of two or more metals
what are alloys useful for?
they are developed to have a specific set of properties as they have different properties from their individual metals
why would you use cartridge paper?
as it is textured, it is good for sketching with different drawing materials
what is layout paper good for?
thin and translucent and use for general design work
what is tracing paper used for?
semitransparent so can copy images
what is grid paper used for?
useful for orthographic and scale drawings
what is bleed proof paper used for?
designing with felt tips and marker pens
why is carboard used in packaging?
low cost and has a high strength to weight ratio
what is solid white board used for?
ideal for printing and primary packaging (individual items)
what is ink jet card used for?
ink jet printing, printed image is sharply defined and of a high quality
what is corrugated card used for?
secondary packaging (items all in one box) as it is strong and rigid
what is duplex board used for?
when only one side is seen like food packaging.
what is foam core board used for?
good for making models and mounting posters as it is stiff, lightweight and can be scored
what is foil lined board used for?
to package food as it keeps flavor in and air and moisture out
define timber
sawn chunks of solid wood that are used as building materials
name 3 softwoods
pine
larch
spruce
give some properties of pine
strong, cheap, knotty. used for telegraph poles, fences and cheap furniture
name some properties of larch
attractive yellow/ red colour
harder, tougher and more durable than most soft woods
resistant to rot
used for decking
name some properties of spruce
reddish/ brown colour hard good strength to weight ratio knotty not durable used for structural purposes
name 4 hardwoods
oak
beech
ash
mahogany
name some properties of oak
tough durable very strong corrodes steel used for interior panelling, flooring and furniture
name some properties of beech
hard
can be bent using steam
used for chairs and toys
name some properties of ash
tough
absorbs shock well
used for tool handles, some furniture
name some properties of mahogany
durable
easy to work with
expensive
used for good quality furniture
what do ferrous metals contain?
iron
name 3 ferrous metals
cast iron
low carbon steel (mild steel)
high carbon steel (tool steel)
name properties and uses of cast iron
strong if compressed
brittle
not malleable
bench vices, car brake disks
name properties and uses of low carbon steel
quite strong cheap rusts easily can't be hardened car bodies, screws, washing machines
name properties and uses of high carbon steel
harder than low carbon steel can be hardened not as easy to work with rusts tools like files, saws and drills
define a non ferrous metal
a metal that doesn’t contain iron so they don’t rust
name 5 non ferrous metals
aluminum, brass, copper, tin, zinc
name properties and uses of aluminum
lightweight corrosion resistant expensive not as strong as steel airplanes, cans, ladders
name properties and uses of brass
quite strong corrosion resistant malleable ductile good electrical conductor electrical parts, door handles, taps
name properties and uses of copper
relatively soft malleable ductile very good electrical conductor electrical wiring, pipes
name properties and uses of tin
soft corrosion resistant malleable ductile low melting point foil, tin cans, alloying metal in solder
name properties and uses of zinc
not very strong
corrosion resistant
coating steel
name 3 useful alloys
high speed steel, brass, stainless steel
name some properties of high speed steel
contains iron and 0.6% of carbon
keeps its hardness when heated
used in high speed cutting tools
state what brass is made of
copper and zinc
state properties of stainless steel and what it is made of
iron, carbon, chromium, nickel strong tough ductile decreases rust used in surgical equipment, sinks and cutlery
name the two main sorts of plastics
thermoforming and thermosetting plastics
name properties of thermoforming plastics
recyclable, bendy, doesn’t resist heat, easily formed into shapes
name 6 thermoforming plastics
acrylic (PMMA), HDPE, PET, HIPS, PVC, PP
Name properties of acrylic (PMMA)
hard, stiff, shiny, resists weather well, brittle
used for motorcycle helmet visors, baths, signs
name properties of high density polyethylene (HDPE)
stiff, strong, lightweight,
used for washing up bowls, baskets, folding chairs, gas and water pipes
name properties of polyethylene terephthalate (PET)
polyester that is light, strong, tough
used to make see through water bottles and fibres for clothing
name properties of high impact polystyrene (HIPS)
rigid, fairly cheap
used for smoke detector cases and CD cases
name properties of polyvinyl chloride (PVC)
quite brittle, cheap, durable
used for window frames, vinyl records, some clothing
name properties of polypropylene (PP)
quite tough, flexible, can be made into bright colours
used for plastic chairs
name properties of thermosetting plastics
non-recyclable, rigid, resist heat, permanently become hard and rigid
name 5 thermosetting plastics
ER, UF, MF, PF, PR
name properties of epoxy resin (ER)
rigid, durable, corrosion- resistant, good electrical insulator
used for circuit boards and wind turbine rotor blades
name properties of urea-formaldehyde (UF)
hard, brittle, good electrical insulator
used for plug sockets and cupboard handles
name properties of melamine-formaldehyde (MF)
strong and scratch-resistant
used to laminate chipboard and for plates and bowls
name properties of phenol-formaldehyde (PF)
hard, heat resistant, very easily moulded
used for bottle caps, snooker balls and to form composites
name properties of polyester resin (PR)
hard, stiff, cheap, good electrical insulator
can form glass reinforced plastic e.g. for kayaks
waterproof so used for shower stalls and garden furniture
name general properties of natural fibres
absorbent, strong when dry, poor resistance to biological damage like moths
name 3 natural fibres
cotton, wool, silk
name 3 advantages and disadvantages of cotton
hard wearing, doesn’t cause allergies, washes easily
creases easily, poor elasticity, can shrink when washed
what is cotton used for?
used in denim, corduroy and calico
used for jeans, t-shirts, blouses and soft furnishings
name 3 advantages and disadvantages of wool
warm, crease-resistant, good elasticity
can shrink, itchy, fairly expensive
what is wool used for?
used in felt, knitted fabrics and Harris Tweed
used for suits, jumpers, carpets
name 3 advantages and disadvantages of silk
resistant to shrinking/ stretching, good drape, lightweight
creases easily, weak when wet, expensive
what is silk used for?
used in chiffon, satin
used for ties, shirts, dresses
name general properties of synthetic fibres
less sustainable than natural fibres, resistant to biological damage, can be changed by heating, not very absorbent so hard to dye
name 3 synthetic fibres
elastane, polyester, polyamide
name 3 advantages and disadvantages of elastane
extremely elastic, lightweight, hard wearing
not absorbent, high flammability, not biodegradable
what is elastane used for?
used in lycra
used for sportswear, underwear and added to other fibres to add stretch
name 3 advantages and disadvantages of polyester
cheap, resists creasing, hard wearing
damaged by strong acids, melts as it burns, not absorbent
what is polyester used for?
used in dacron
used for bed sheets, curtains, tablecloths, sportswear
name 3 advantages and disadvantages of polyamide
warm, fairly cheap, crease resistant
not very absorbent, damaged by sunlight, melts as it burns
what is polyamide used for?
used in nylon
sportswear, tights, furnishings, carpet
what are yarns?
threads that are woven or knitted to make fabrics
what are yarns made of?
fibres. short fibres are staple fibres. long fibres are filaments
what are yarns made from filaments like?
smooth
what are yarns made from staple farmers like?
hairier than yarns made from filaments
name the three main ways to turn yarns/ fibres into a fabric
weaving, knitting, bonding
How are woven fabrics made?
by interlacing two sets of yarn
How are knitted fabrics made?
by interlocking one or more yarns together using loops. The loops trap air, so they insulate. They stretch more than woven fabrics
How are non-woven fabrics made?
layers of fibre held together by bonding or felting. They don’t fray and can be cut in any direction, little waste when laying out a pattern. They don’t stretch and aren’t very strong
what is the weft?
the yarn in woven fabrics travelling from right to left
what is the warp?
the yarn in woven fabrics travelling up and down
what are the properties of plain weave fabrics?
hard wearing, strong, holds its shape, smooth finish, cheapest weave to produce. used to make fabrics like cotton based one
What are woven fabrics used for?
shirts, upholstery and trousers
What are the 2 types of knitted fabrics?
weft-knitted and warp-knitted
how are weft knitted fabrics made?
yarn runs across the fabric, making interlocking loops with the row beneath
what are weft knitted fabrics used for and why?
they stretch but can lose their shape and if the yarn breaks it can unravel. used for jumpers, socks and t shirts
how are warp knitted fabrics made?
yarn runs up the fabric in loops which interlock vertically.
what are warp knitted fabrics used for and why?
they stretch and keep their shape and are hard to unravel. made by machines
used for tights, swimwear and fleeces
what are bonded fabrics?
‘webs’ of synthetic fibres glued, needle punched, stitched or melted together. they are used for interfacing, artificial leathers and disposable cloths
what are felted fabrics?
made by combining pressure, moisture and heat to interlock a mat of wool fibres. used for carpet underlay, craft material, hats and snooker table coverings.
name the two ways of combining fibres to get fabrics with different properties.
blending or mixing
what is the difference between blending and mixing?
blending combines two fibres into one yarn but mixing combines two yarns to make one fabric
name benefits of blending cotton and polyester fibres together
strong and hardwearing, less absorbent so dries quickly, soft, comfortable, resists creasing, doesn’t shrink, but is highly flammable
name properties of MDF
tiny fibres of softwood timber held together with glue. no natural grain, cheap, dense, smooth uniform surface, damaged by moisture. used for shelves and flat pack furniture
name properties of plywood
several layers of soft or hardwood, glued together with grains at right angles. very strong for its weight. used for building and furniture.
name properties of chipboard
made by compressing wood chips, shavings and sawdust together with glue. cheap but not very strong, absorbent, damaged by moisture. used in cheap self assembly furniture
what are printed circuit boards (PCB)
boards with thin copper tracks connecting components. They are used to reduce the size and manufacturing costs of electronic systems
what do input devices do?
they change the electrical current in a circuit by receiving an external signal. Examples include switches and variable resistors
how does a thermistor function?
when conditions are hot the resistance falls increases
used in central heating
how do LDRs function?
in brighter light the resistance falls
used in automatic night lights
how do pressure sensors function?
depending on the type of pressure sensor, resistance can be increased or decreased
used in equipment where gases or liquids are monitored.
what are integrated circuits?
tiny self contained circuits, they simplify a circuit and make a circuit cheaper, smaller and use less power
name advantages and disadvantages of a micro controller
+they can do the job of multiple ICs
+they can be reprogrammed
- more expensive than other ICs
How are timers and counters different?
timers add a a time delay to a process and generate a pulse after a certain amount of time. counters count the pulses made by an input device
how does a microcontroller use a timer?
microcontrollers controlling flashing lights like car indicators use timers to set how long the light is on/ off
microcontroller controlling microwave uses a timer
what does a mechanical system do?
changes the magnitude and direction of a force
what do levers do?
make it easier to lift loads
What is in the middle in a first order leaver?
The pivot between the effort and the load.
picture it like a seesaw
What is in the middle in a second order leaver?
the load, like a wheelbarrow. the closer together the load and the pivot, the easier it is to lift
What is in the middle of a third order leaver?
the effort, like a fishing rod and garden spade. moving the effort and the pivot further apart makes it easier to lift
name 2 types of linkage
bell crank, push/pull linkages
what does a bell crank linkage do?
changes the direction of a force through 90 degrees
what do gear trains do?
transmit or change rotary motion
How do you make gears turn in the same direction?
use a third gear called an idler
How do you half the force needed to lift a load?
use one fixed pulley and one moving pulley (a block and tackle)
what do belt drives do?
transfer movement. They are used in things like pillar drills and washing machines. they are made up of a driver (motor), belt and the driven shaft.
what do cams do and what can they be used for?
they change rotary motion to reciprocating motion
changing the size and shape of the cam can be used to change the magnitude of the output motion
name 4 basic cam shapes
pear, circular, snail and four-lobed
name properties of metal foam
contain many gas filled spaces so are lightweight
stiff, tough and strong under compression. used in lightweight car parts and in bone implants
name properties of titanium
corrosion resistant, high strength: weight, used in aerospace, difficult to machine
name properties of liquid crystal displays
when an electric current is applied, the crystals change shape so the image changes. used in flat screen displays and calculators
name properties of coated metals
galvanising and electroplating can prevent rust, anodised aluminium is harder and resistant to corrosion, coating with PVC makes it corrosion resistant and can be coloured
name properties of carbon nanotubes
very high strength : weight, are good conductors of heat and electricity. can strengthen materials. used in electronics and tennis racquets
name properties of self cleaning fabrics
they have a nanoparticle coating that removes odours and stains upon exposure to light
name properties of antibacterial fabrics
use nanoparticles of silver to kill bacteria. they have medical uses like face masks and dressings.
name some smart materials
shape memory alloys (nitinol), photochromic pigments, thermochromic pigments
what are technical textiles?
made to just be functional
what does batch production do?
makes a certain amount of products.
batches can be repeated
one process is done on the whole batch and then another
the machinery and workforce need to be flexible so they can be quickly changed
down time wastes money
what does mass production do?
making loads of the same product
used for mass-market products each worker does a small part of the process
uses CAD/CAM
how does continuous differ from mass production?
it runs all the time as it would be too expensive to keep stopping
almost entirely automated
makes huge amounts of only one thing
cost per item is cheap
name some quality control tests
go/no go fixtures, registration marks, checking against original
what do registration marks do?
they check that the printing plates are aligned
name ways to achieve consistency during manufacture
depth stops, laser cutters, PCBs
what do depth stops do?
create exact depths, they are long rods clamped close to the drill bit
