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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
under COSHH regulations 2002 what is the wood dust exposure limit in a work shop
5 mg per cubic metre
26
what are stock forms of wood
* rough sawn * planed square edge (PSE) * planed all round (PAR) * natural wood * mouldings
27
what are non-ferrous metals and examples
``` metals with no iron •aliminium •copper •zinc •silver •gold •titanium •tin ```
28
what are ferrous metals and examples
metals with iron •low carbon steel •medium carbon steel •cast iron
29
what are examples of ferrous alloys
* stainless steel - steel with chrome and nickel * high speed steel * die steel (tool steel)
30
what are examples of non-ferrous alloys
* bronze - copper and tin * brass - copper and zinc * duralumin - copper, magnesium and manganese * pewter - copper and tin
31
examples of thermoplastics
* 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
32
examples of thermoset polymers
* urea formaldehyde - electrical fittings and adhesives * melamine formaldehyde MF - decorative laminates e.g. fake kitchen tops * polyester resin * epoxy resin - adhesives
33
examples of biodegradable polymers
* oxy-degradable polymer * photodegrdable polymer * hyrdo-degradable polymer
34
examples of elastomers
* natural rubber * butadiene rubber * neoprene - wetsuits, laptop cases * silicone - wristband, flexible ice trays
35
examples of composites
* CFRP - easily moulded, tourque resistant, lightweight * GRP * concrete
36
examples of smart materials
* 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
examples of modern materials
* kevlar * precious metal clay * high density modelling foam * polymorph
38
examples of paper and board finishes
* 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
examples of polymer finishes
* adding colour to the moulding process * acrylic spray paints * overmouldings e.g. toothbrushes
40
examples of metal finishes
* 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
examples of wood finishes
* polyurethane varnish and acrylic varnish * water-based paints * stains * colour wash * wax * pressure treating * yacht varnish * danish oil * teak oil
42
advantages of CAD
* 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
what is CFD
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
disadvantages of CAD
* some platforms may require training or getting used to * initial set up cost can be expensive * requires electricity * software must be updated
45
what is FEA
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
what is rapid prototyping
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
what is epos
a system of capturing date when consumers buy goods | electric point of sale
48
what is a master production schedule
a plan that determines how many products will be made in a given time
49
what is a kanban
a system used to control the movement of materials and components from suppliers and through a factory
50
what are radio fequency identification (RFID) tags
small electronic devices that can be scanned and used to track items as they move through a factory and into dispatch
51
what is an automatic guided vehicle (AGV)
robots, similar to forklift trucks, used to carry materials and finished goods around a factory
52
what is computer numerically control (CNC)
using a program to convert CAD drawings to drive CAM equipment
53
what does FMS stand for
flexible manufacturing systems
54
what does JIT stand for
just in time
55
what does HSWA stand for
health and safety work act
56
what is intellectual property
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
what is copyright
unregistered rights that protect original works such as books photographs or plays
58
what is patent
legal protection for a product based on how it functions
59
what is registered design
a product whose appearance or decoration has been legally protected to counter copying
60
what is trademark
a unique combination of words, sounds, colours and logos for marketing and the legal protection of brand identity
61
what is open design
not protected by IPR (interlectual property rights) can be used and developed freely by others
62
what is the process of injection moulding
* 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
What does UPS stand for
Unit production systems | Overhead transporters used for component transfer between workers to improve factory efficiency
64
What is modular/cell production
The use of groups of CNC machines, robots and AGVs to facilitate efficient, flexible manufacturing
65
What are satandardised components
Parts such as screws and lightbulbs that are made to a common standard to ensure interchangeability
66
What is sub assembly
A self contained element of production that is made separately and incorporated into the final assembly stages
67
What are examples of additives for polymers
* 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
what is the process of anodising
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
what is the process of dip coating
* 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
what is the process of galvanisation
* 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
what is the process of electroplating
* 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
what is the process of screen printing
ink is forced through a mesh screen and onto the surface of a material to create and image or pattern
73
what is the difference between embossing and debossing
embossing sticks up, debossing is the opposite (depression)
74
what is sterolithography
a vat of polymer resin which solidifies layer by layer using a UV laser
75
what is annealing
makes metal easier to work with by making in less brittle and more ductile changing of crystal structure
76
what is the toxic liquid created by landfill
leche
77
key words in blow moulding
parison, flash, mould halves,
78
how quickly is the polymer rotated in rotational moulding
slow, around 20 rotations per minute
79
what must be broken down to create fibres for paper and board
lignin
80
what is the main industrial paper test
elemendorf
81
what is special about kevlar
high tensile strength to weight ratio
82
what is the process of calendaring
smoothening a material through rolls
83
key words for compression molding
pre weighted slug mold heated to allow cross links to form any excess pushed out product ejected whilst still warm
84
metal sealants process
often silicone based
85
metal varnishing
clear can remove grease
86
what does anodising enhance
the natural oxide layer
87
what does polyeurathane varnish or acrylic varnish do to wood
provides a hard, tough, heatproof, waterproof finish, | clear finish allows the grain to be seen
88
what does wax do to wood
provides a high gloss finish, clear allows the grain to still be viewed. increases the hardness and toughness of surface
89
teak oil
enhances grain, improves weather resistance and resistance to fungal/insect attack

product design paper 1 (1 decks)

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