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product design paper 1 > important stuff > Flashcards

important stuff Flashcards

1
Q

what is the izod test

A

a test for toughness.
a pendulum swings down and breaks the test piece which is clamped. the toughness judged by how far the pendulum swings after breaking the test piece.

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2
Q

what are mechanical properties

A 
how a material reacts to an external force 
•compressive strength 
•tensile strength
•bending strength 
•shear strength 
•torsion strength 
•hardness
•toughness
•plasticity
•ductility
•malleability 
•elasticity
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3
Q

what is malleability

A

ability to withstand deformation by compression without cracking
mechanical property

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4
Q

what is ductility

A

ability to withstand being drawn out under tension without cracking
mechanical property

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5
Q

what is elasticity

A

ability to be deformed and then return to it’s original shape when the force is removed
mechanical property

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6
Q

what are physical properties

A 
associated with the actual structure or makeup of the material
•electrical conductor
•electrical insulator
•thermal conductor
•thermal insulator 
•thermal expansion
•opaque 
•transparent 
•translucent 
•density
•fusibility 
•magnetism 
•corrosion/degradation resistance
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7
Q

what is fusibility

A

the ability of the material to be fused or converted from a solid to a liquid or molten state
physical property

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8
Q

what is thermal expansion

A

the increase in material volume in response to heat

physical property

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9
Q

what is non destructive testing and what are some examples

A

tests that don’t involve damaging the product
•ultrasonic testing
•x-ray testing
•electrical conductivity using a 4 point probe
•thermal conductivity using a heat flow meter

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10
Q

what is an elastomer

A

a material that, at room temperature, can be deformed under pressure and upon release will return to it’s original shape

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11
Q

what is a smart material

A

a material whose physical properties change in response to an input or change in environment

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12
Q

what is a modern material

A

a material developed through the invention of new or improved processes

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13
Q

what is layout paper

A

thin translucent paper with a smooth surface

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14
Q

what is tracing paper

A

translucent paper slightly thicker than layout paper

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15
Q

what is tessellation

A

cutting out shapes on the material in a way that makes them fit together and waste less materials

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16
Q

what is duplex card and what is it used for

A

it is card with two layers with the exterior often coated to make it waterproof
used for food packaging such as juice cartons

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17
Q

what is foil backed card and what is it used for

A

it is card with polymer film or foil applied to one or more layer to make it water resistant and/or heat insulating
used for food packaging such as juice cartons

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18
Q

why is fluted PP sheet lightweight and strong

A

due to the flutes or corrugations

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19
Q

what is air seasoning

A

a traditional way of drying wood that involves stacking wood under a shelter protected from rain. air circulates between the planks to slowly remove the moisture. usually used for outdoor products as the wood is seasoned to the same moisture content as the surroundings
inexpensive

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20
Q

what is kiln seasoning

A

a quicker and controlled method of seasoning wood. may take only a few weeks but more expensive. temperature and humidity controlled. planks stacked on trolleys.

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21
Q

what does a BSI mark mean for a product

A
  • the product is safe to use
  • the product has been tested
  • the safety checks are up to date
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22
Q

what are examples of hardwoods

A
  • oak
  • ash
  • mahogany
  • teak - suitable for outdoor furniture, natural oils resistant to moisture, weather resistant, aesthetically pleasing, dark brown/red straight grain, natural oils resistant to acid and alkali (bird droppings), hard (peoples buttons wont scratch it)
  • birch
  • beech
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23
Q

what are examples of softwoods

A
  • pine
  • spruce
  • douglas fir
  • larch
  • cedar
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24
Q

what are examples of manufactured boards

A
  • plywood
  • marine plywood
  • aeroply
  • felxible plywood
  • chipboard
  • MDF
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25
Q

under COSHH regulations 2002 what is the wood dust exposure limit in a work shop

A

5 mg per cubic metre

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26
Q

what are stock forms of wood

A
  • rough sawn
  • planed square edge (PSE)
  • planed all round (PAR)
  • natural wood
  • mouldings
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27
Q

what are non-ferrous metals and examples

A 
metals with no iron 
•aliminium
•copper
•zinc
•silver
•gold
•titanium
•tin
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28
Q

what are ferrous metals and examples

A

metals with iron
•low carbon steel
•medium carbon steel
•cast iron

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29
Q

what are examples of ferrous alloys

A
  • stainless steel - steel with chrome and nickel
  • high speed steel
  • die steel (tool steel)
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30
Q

what are examples of non-ferrous alloys

A
  • bronze - copper and tin
  • brass - copper and zinc
  • duralumin - copper, magnesium and manganese
  • pewter - copper and tin
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31
Q

examples of thermoplastics

A
  • low density polyethylene (LDPE) - squeezy detergent bottles and carrier bags
  • high density polyethylene (HDPE) - chemical drums
  • polypropylene (PP)
  • high impact polystyrene (HIPS)
  • ABS
  • rigid polyvinyl chloride - gutters
  • flexible polyvinyl chloride - hose pipes
  • PMMA - car light casing
  • nylon - cable ties
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32
Q

examples of thermoset polymers

A
  • urea formaldehyde - electrical fittings and adhesives
  • melamine formaldehyde MF - decorative laminates e.g. fake kitchen tops
  • polyester resin
  • epoxy resin - adhesives
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33
Q

examples of biodegradable polymers

A
  • oxy-degradable polymer
  • photodegrdable polymer
  • hyrdo-degradable polymer
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34
Q

examples of elastomers

A
  • natural rubber
  • butadiene rubber
  • neoprene - wetsuits, laptop cases
  • silicone - wristband, flexible ice trays
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35
Q

examples of composites

A
  • CFRP - easily moulded, tourque resistant, lightweight
  • GRP
  • concrete
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36
Q

examples of smart materials

A
  • thermochromic pigment
  • phosphorescent pigment
  • photochromic pigment
  • electroluminescent pigment
  • piezoelectric material - gives off a small electrical charge when deformed e.g. air bag sensors in cars
37
Q

examples of modern materials

A
  • kevlar
  • precious metal clay
  • high density modelling foam
  • polymorph
38
Q

examples of paper and board finishes

A
  • laminating (by encapsulation and by surface coating)
  • embossing - creates a raised design by pressing the paper in between a male and female die
  • debossing - instead of raised, debossing creates a depression
  • foil blocking
  • screen printing
  • flexogrpahic printing - uses cylinders
  • offset lithography
39
Q

examples of polymer finishes

A
  • adding colour to the moulding process
  • acrylic spray paints
  • overmouldings e.g. toothbrushes
40
Q

examples of metal finishes

A
  • cellulose and acrylis paints
  • electroplating - invloves and anode and a cathode
  • dip coating (metals or polymers)
  • powder coating
  • varnishing
  • sealants
  • preservatives
  • anodising
  • cathodic protection
41
Q

examples of wood finishes

A
  • polyurethane varnish and acrylic varnish
  • water-based paints
  • stains
  • colour wash
  • wax
  • pressure treating
  • yacht varnish
  • danish oil
  • teak oil
42
Q

advantages of CAD

A
  • cad speed up the design process
  • less physical storage space for designs
  • less waste of paper
  • easy to change designs
  • completed cad drawings can be downloaded to cam
43
Q

what is CFD

A

computational fluid dynamics
•is a tool available on some 3d cad packages
•shows the flow of gas or fluid around a product
•can use results to change designs
•save time and money (otherwise would have to use wind tunnels or wave tanks)
•could test a boat
•can simulate lots of conditions

44
Q

disadvantages of CAD

A
  • some platforms may require training or getting used to
  • initial set up cost can be expensive
  • requires electricity
  • software must be updated
45
Q

what is FEA

A

finite element analysis
•uses computer modelling to carry out component stress analysis
•can simulate vibrations or shock
•can highlight weak points before further development

46
Q

what is rapid prototyping

A

the process of downloading a 3d cad drawing to a machine that will produce a 3d model of the drawing. makes realistic models quickly. example is sterolithography. uses a vat of polymer resin solidified layer by layer using a UV laser

47
Q

what is epos

A

a system of capturing date when consumers buy goods

electric point of sale

48
Q

what is a master production schedule

A

a plan that determines how many products will be made in a given time

49
Q

what is a kanban

A

a system used to control the movement of materials and components from suppliers and through a factory

50
Q

what are radio fequency identification (RFID) tags

A

small electronic devices that can be scanned and used to track items as they move through a factory and into dispatch

51
Q

what is an automatic guided vehicle (AGV)

A

robots, similar to forklift trucks, used to carry materials and finished goods around a factory

52
Q

what is computer numerically control (CNC)

A

using a program to convert CAD drawings to drive CAM equipment

53
Q

what does FMS stand for

A

flexible manufacturing systems

54
Q

what does JIT stand for

A

just in time

55
Q

what does HSWA stand for

A

health and safety work act

56
Q

what is intellectual property

A

a novel, physical creation that is entitled to protection for its originator in the form of copyright, design rights, patent, registered design or trademark

57
Q

what is copyright

A

unregistered rights that protect original works such as books photographs or plays

58
Q

what is patent

A

legal protection for a product based on how it functions

59
Q

what is registered design

A

a product whose appearance or decoration has been legally protected to counter copying

60
Q

what is trademark

A

a unique combination of words, sounds, colours and logos for marketing and the legal protection of brand identity

61
Q

what is open design

A

not protected by IPR (interlectual property rights) can be used and developed freely by others

62
Q

what is the process of injection moulding

A
  • thermoplastic granules poured into the hopper
  • archemedes screw pushes the granues through the chamber past electric heaters
  • heaters melt the polymer
  • liquid polymer injected into the mould
  • polymer cools
63
Q

What does UPS stand for

A

Unit production systems

Overhead transporters used for component transfer between workers to improve factory efficiency

64
Q

What is modular/cell production

A

The use of groups of CNC machines, robots and AGVs to facilitate efficient, flexible manufacturing

65
Q

What are satandardised components

A

Parts such as screws and lightbulbs that are made to a common standard to ensure interchangeability

66
Q

What is sub assembly

A

A self contained element of production that is made separately and incorporated into the final assembly stages

67
Q

What are examples of additives for polymers

A
  • pigments - mixed into the molten state and can change the aesthetics
  • antistatics - improve the conductivity of electricity
  • flame retardants
  • plasticisers - added to plastics such as pvc to make them less hard and brittle at room temp
  • uv stabilisers - prevents the polymer from being broken down by sunlight
  • antioxidants - help to reduce environmental deterioration from oxygen
  • biodegradable plasticisers - makes polymer faster to break down
68
Q

what is the process of anodising

A

enhances the natural oxide layer of the metal making it more hard and tough. a current is passed through a sulfuric acid electrolyte solution making the metal the anode. can can provide a colour

69
Q

what is the process of dip coating

A
  • metal heated to approximately 230 degrees c
  • metal then dipped into a fluidisation tank full of fine powder polymer
  • fluidisation (air running through)
  • provides an even coat
  • air cooled
  • provides a corrosion resistant layer, better grip and aesthetic properties
70
Q

what is the process of galvanisation

A
  • involves dipping metal into molten zinc at approximately 460 degrees c
  • often used on steel to protect from rust
  • protective layer and improves the durability
71
Q

what is the process of electroplating

A
  • coating a usually cheaper metal with another metal from improved aesthetic or protection
  • e.g. metal tea pots plated with silver
  • involves the metal being submerged in an acid electrolyte solution
72
Q

what is the process of screen printing

A

ink is forced through a mesh screen and onto the surface of a material to create and image or pattern

73
Q

what is the difference between embossing and debossing

A

embossing sticks up, debossing is the opposite (depression)

74
Q

what is sterolithography

A

a vat of polymer resin which solidifies layer by layer using a UV laser

75
Q

what is annealing

A

makes metal easier to work with by making in less brittle and more ductile
changing of crystal structure

76
Q

what is the toxic liquid created by landfill

A

leche

77
Q

key words in blow moulding

A

parison, flash, mould halves,

78
Q

how quickly is the polymer rotated in rotational moulding

A

slow, around 20 rotations per minute

79
Q

what must be broken down to create fibres for paper and board

A

lignin

80
Q

what is the main industrial paper test

A

elemendorf

81
Q

what is special about kevlar

A

high tensile strength to weight ratio

82
Q

what is the process of calendaring

A

smoothening a material through rolls

83
Q

key words for compression molding

A

pre weighted slug
mold heated to allow cross links to form
any excess pushed out
product ejected whilst still warm

84
Q

metal sealants process

A

often silicone based

85
Q

metal varnishing

A

clear can remove grease

86
Q

what does anodising enhance

A

the natural oxide layer

87
Q

what does polyeurathane varnish or acrylic varnish do to wood

A

provides a hard, tough, heatproof, waterproof finish,

clear finish allows the grain to be seen

88
Q

what does wax do to wood

A

provides a high gloss finish, clear allows the grain to still be viewed. increases the hardness and toughness of surface

89
Q

teak oil

A

enhances grain, improves weather resistance and resistance to fungal/insect attack

product design paper 1 (1 decks)

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