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Resistant Materials > Industrial and Commercial Processes > Flashcards

Industrial and Commercial Processes Flashcards

1
Q

What is one-off production?

A

The design and manufacture of a single item or product

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2
Q

Name 3 advantages of one-off production

A
  • Unique product each time
  • High quality product as high level of skill is needed
  • Products can be made to measure
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3
Q

Name 2 disadvantages of one-off production

A
  • Labour-intensive = takes a long time to produce, so you may have to wait a long time for the product to be produced
  • Very expensive
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4
Q

What is batch production?

A

System of manufacturing used to produce a fixed quantity of ‘batch’ of identical products

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5
Q

Name 3 examples of one-off products

A
  • Wedding dress
  • Stadiums
  • Ships
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6
Q

Name 3 characteristics of one-off production

A
  • Highly skilled workers
  • Constant discussion with client
  • Specialist area of work (e.g. jewellery)
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7
Q

Name 3 characteristics of batch production

A
  • Production-line set-up
  • Workers semi-skilled and flexible
  • Parts often bought from other companies and assembled
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8
Q

Name 2 advantages of batch production

A
  • Quick response to customers’ demands
  • Production line can be changed quickly
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9
Q

Name a disdvantage of batch production

A

Tools need to be reset for new production run

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10
Q

What is mass production?

A

Making the same product continuously

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11
Q

Name 2 characteristics of mass production

A
  • Semi-automated with much computer control
  • High level of investment in machinery
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12
Q

Name 2 advantages of mass production

A
  • Low unit costs
  • Can operate 24/7
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13
Q

Name a disadvantage of mass production

A

Initial machinery and tooling costs are very high

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14
Q

Give 3 examples of products that are produced by batch production

A
  • Clothes
  • Watches
  • Baked goods
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15
Q

Give 3 examples of products that are produced by mass production

A
  • Cars
  • Televisions
  • iPhones
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16
Q

When is sand casting used?

A

When producing complex shapes

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17
Q

Give 3 examples of products that are sand casted

A
  • Car engine parts
  • Kitchen and bathroom taps
  • Screws
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18
Q

Describe how sand casting works

A
  1. Encase a mould pattern (usually made from wood) in moulding sand = relief pattern
    1. Consists of 2 parts: cope and drag
    2. Cope contains 2 taper tubes (act as delivery tubes for the metal): runer and riser
  2. Remove pattern to leave an empty cavity
  3. Drag and cope placed together
    1. Sand tightly packed around them (to prevent air being trapped inside/metal getting out)
  4. Pour molten metal into riser to fill the tubes
  5. When metal solidified and cooled, sand removed and taper tubes cut
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19
Q

Name 3 advantages of sand casting

A
  • Any waste can be reused
  • Complex shapes and forms can be achieved
  • Hollow products can be achieved with the use of cores
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20
Q

Name 3 disadvantages of sand casting

A
  • Consumes great deal of energy in order to melt metal
  • New sand cast has to be packed each time the product has to be made
  • Time-consuming to pack sand each time
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21
Q

Name the tool

A

Pillar drill

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22
Q

Name the tool

A

Hand drill

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23
Q

Name the tool

A

Cordless drill

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24
Q

Name 3 advantages of a pillar drill

A
  • Can be used continuously
  • Chuck can be removed to accept larger drill bits
  • Speed can be varied
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25
Q

Name 2 disadvantages of a pillar drill

A
  • Fixed in one position
  • Can be dangerous
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26
Q

Name an advantage of a hand drill

A

Portable

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27
Q

Name 2 disadvantages of a hand drill

A
  • You need to provide the power
  • Will only hold bits up to 10 mm
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28
Q

Name 3 advantages of a cordless drill

A
  • Portable
  • Generally has a variable speed control
  • Can be made to reverse direction
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29
Q

Name 3 disadvantages of a cordless drill

A
  • Power limited by battery type and size
  • Charging batteries can take some time
  • Will only hold bits up to 10 mm
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30
Q

What does wood turning allow?

A

Allows circular wooden products to be made

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31
Q

Name 2 products that can be made using wood turning

A
  • Fruit bowls
  • Stair spindles
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32
Q

What are lathes used for?

A

Used to ‘turn’ materials = to make round objects

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33
Q

Describe how you use a lathe (include safety things)

A
  1. Piece of material is held and rotated by the lathe, while a tool or bit is pressed onto the material to cut it
  2. Before using it, check all guards are in place & aren’t cracked
  3. Keep your hands away from moving pieces
  4. Make sure lathe is set to rotate at the correct speed for the material being cut + tool used
  5. Make sure material is held tightly and straight
    1. Long pieces of material needed to be held securely at both ends (stops it from wobbling)
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34
Q

Describe how you prepare wood for a lathe and explain why you do this

A

Make saw cuts and remove corners by planing = allows wood to fix onto lathe without slipping

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35
Q

Name part A

A

Drive centre

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36
Q

Name part B

A

Tailstock

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37
Q

Name the turning process

A

Facing

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38
Q

Name the turning process

A

Parallel turning

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39
Q

Name the turning process

A

Taper turning

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40
Q

Name the turning process

A

Parting

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41
Q

Name the turning process

A

Drilling

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42
Q

Name the turning process

A

Knurling

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43
Q

Describe the turning process facing

A

Tool moved at right angles to axis, facing end surface

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44
Q

Describe the turning process parallel turning

A

Tool moved parallel to axis to form a cylinder, reducing the diameter

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45
Q

Describe the turning process taper turning

A

Tool moved at angle to axis to produce a taper

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46
Q

Describe the turning process parting

A

Narrow tool fed into work to trim, to length or part work from stock bar

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47
Q

Describe the turning process drilling

A
  • Tail stock used to hold chuck into which a dril can be placed
  • As work rotates, drill is fed into the work
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48
Q

Describe the turning process knurling

A

Hardened steel wheel pressed into the rotating work to produce straight or diamond pattern

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49
Q

Name 3 advantages of metal turning

A
  • Chuck can hold a variety of sizes and lengths
  • Very accurate sizing can be achieved with fine adjustments of the cross slide
  • Drilling and tapping can be carried out
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50
Q

Name 3 disadvantages of metal turning

A
  • Very difficult to set up non-cylindrical items
  • Long objects can flex if not correctly supported along their length
  • Once an object has been removed, it is difficult to reset it to centre
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51
Q

Name 3 products made by blow moulding

A
  • Shampoo bottles
  • Water butts
  • Milk containers
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52
Q

Describe how blow moulding works

A
  1. Tube (parison) of softened plastic is inserted into a solid mould
  2. Air is then injected which forces the plastic to expand to the shape of the mould
  3. Product dropped out of machine as two halves open
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53
Q

Name 3 advantages of blow moulding

A
  • Very cheap unit costs
  • Produces high volume - can run 24/7
  • Not very labour-intensive
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54
Q

Name 3 disadvantages of blow moulding

A
  • Initial costs of machine and tooling very high
  • Sometimes a seam if left around product where mould closes
  • Products sometimes need to have flashing removed
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55
Q

Describe vacuum forming

A
  1. Sheet of thermoplastic (e.g. HIPS) is heated until it goes soft
  2. A mould is put onto the vacuum bed & bed is then lifted close to the heated plastic
  3. Air is sucked out from under the plastic = creating a vacuum
  4. Air pressure from outside the mould then forces the plastic onto the mould
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56
Q

Name 3 examples of product made from vacuum forming

A
  • Yoghurt pots
  • Trays
  • Masks
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57
Q

Name 3 products made by injection moulding

A
  • Buckets
  • Bottle caps
  • Wheelie bins
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58
Q

Describe injection moulding

A
  1. Hopper filled with plastic pellets
  2. Which are then fed along the machine by a large screw & are heated as move through it
  3. Once the plastic is fully melted, the molten plastic is injected into a mould
    1. Mould made out of 2 separating halves which come together to from whole shape of product
  4. Cools in the mould until solid and then is released
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59
Q

Name 3 advantages of injection moulding

A
  • High level of accuracy
  • Little or no secondary surface finishing required
  • Identical components formed each time
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60
Q

Name 3 disadvantages of injection moulding

A
  • Initial machine and mould costs high
  • Some flashing may have to be removed
  • Sprue pins need to be cut off
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61
Q

Name 3 things you need to do before vacuum forming

A
  • All vertical surfaces need to be slightly tapered = so product can easily removed from mould
  • Round off sharp corners = don’t puncture or rip the plastic
  • Incorporate vent holes to avoid pockets of aire becoming trapped
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62
Q

Name 3 advantages of vacuum forming

A
  • Lightweight, hollow products can be made
  • Relatively cheap moulds can be made from MDF in school workshop for a one-off item
  • Surface textures can be moulded into products
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63
Q

Name 3 disadvantages of vacuum forming

A
  • Thermoplastic material sometimes thins too much and may burst/pop
  • Webs sometimes form between items = product formed cannot be used
  • Products need to be trimmed and cut out
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64
Q

What is wood laminating used for?

A

To produce the desired shape or curve

65
Q

Describe wood laminating

A

Thin strips of wood (2-6 mm) are glued together and held in a jig, which keeps them in the right shape till the glue has dried = strips of wood stay bent

66
Q

Name 3 products made from wood laminating

A
  • Rocking chair runners
  • Table legs
  • Roof beams
67
Q

Name 3 examples of products made by extrusion

A
  • Plastic-covered wire
  • Rain water guttering
  • Copper pipes
68
Q

What is type of products is extrusion used to make?

A

Products that have a regular, fixed cross-sectional profile

69
Q

Describe extrusion

A
  1. Process similar to injection moulding - used for some metals and thermoplastics
  2. Material is melted and forced under pressure through a die
  3. Produces long, continous strips of moulding exactly the same shape as the the exit hole
70
Q

What’s the difference between plastic and metal extrusion?

A

Plastic extrusion uses plastic pellets & metal extrusion starts with a billet (large lump of metal) that’s heated up before placed into the extrusion machine

71
Q

Name 3 advantages of extrusion

A
  • Continuous lengths can be produced
  • Complex profiles can be achieved
  • Seamless tibes can be produced
72
Q

Name 3 disadvantages of extrusion

A
  • Initial set-up costs of machinery and upkeep are high
  • Die costs can be very high
  • Hot extrusion of metals e.g. steel can leave oxidised surface finish
73
Q

Name 4 temporary joining methods

A
  • Tapping and threading
  • Nuts, bolts and washers
  • Screws
  • Knock-down fittings
74
Q

Name 4 permanet joining methods

A
  • Nails
  • Dowel joints
  • Welding
  • Rivets - snap and pop
75
Q

Tapping and threading can be carried out on both ___ and ___

A

metals and plastics

76
Q

What is tapping?

A

The process of cutting and internal (female) screw thread

77
Q

What is threading?

A

Cutting of an external (male) screw thread

78
Q

Describe how tapping and threading is done

A
  • Hole is drilled and ‘tap’ is used to cut a female thread in the hole
    • Screw is inserted into it and tightened until it stops
  • You can make round rod fit a threaded hole by cutting a male thread onto the ouside it, using a ‘split die’ ot on a lathe
79
Q

Name the tool

A

Tap

80
Q

Name the tool

A

Split die

81
Q

Name?

A

‘Drunken’ Thread

82
Q

Name 3 advantages of tapping/threading

A
  • Can be carried out in plastic and metal
  • Size of thread can be varied slightly by adjusting the pressure on the split die
  • Nuts and bolts widely available for use with tapped or threaded components
83
Q

Name 3 disadvantages of tapping/threading

A
  • Boths taps and die made from high-speed steel = easy to break if dropped/too much pressure applied
  • Taps are easily broken when threading blind holes
  • Difficult to start threading and to make the thread parallel to axis of rod or hole being threaded
84
Q

Name?

A

Nut

85
Q

Name?

A

Washer

86
Q

Name?

A

Bolt

87
Q

Name 3 advantages of nuts, washers and bolts

A
  • Can be undone so items can be taken apart
  • Come in various lengths and sizes
  • Lock nuts can be used for a firm fixing
88
Q

Name 2 disadvantages of nuts, washers and bolts

A
  • Can work loose with vibration
  • If correct size is not used you can wear the head down
89
Q

Name part 1)

A

Countersunk hole

90
Q

Name part 2)

A

Clearance hole

91
Q

Name part 3)

A

Pilot hole

92
Q

Name?

A

Round head

93
Q

Name?

A

Countersunk head

94
Q

Name 3 tips to follow to avoid splitting the wood or damaging the screw head

A
  • Screw through the thinner piece into the thicker one
  • The screw should be three times as long as the piece being fixed
  • Drill a clearance hole slightly bigger than the shank of the screw
95
Q

Name 3 advantages of using screws

A
  • Can be easily removed
  • Some new types of screws don’t need clearance and pilot hole drilling
  • Can be used to join dissimlar materials
96
Q

Name 3 disadvantages of using screws

A
  • Steel screws will rust if used outside
  • Some screws can be quite hard to remove
  • It is difficult to get screws of it they shear off
97
Q

What do knock-down fittings allow?

A

Allow joints to be made & taken apart easily and quickly

98
Q

What are knock-down fittings used in?

A

Construction of furniture and kitchens

99
Q

Name?

A

Round wire (nail)

100
Q

Name?

A

Oval wire (nail)

101
Q

Name?

A

Panel pin (nail)

102
Q

What are round wire nails used for?

A

General-purpose joinery

103
Q

Name 2 advantages of round wire nails

A
  • Big, flat head makes it easy to hit
  • Sometimes serrated which helps them to grip
104
Q

Name a disadvantage of round wire nails

A

Longer nails can bend when hammering them in

105
Q

What are oval wire nails used for?

A

Fixing floorboards to joists and general joinery

106
Q

Name an advantage of oval wire

A

Head can be punched below surface and hole filled

107
Q

Name a disadvantage of oval wire

A

Very difficult to get out as head goes below the surface

108
Q

What are panel pins used for?

A

Finer work e.g. mitre joints

109
Q

Name an advantage of a panel pin

A

Small heads can be punched below the surface with a nail punch

110
Q

Name a disadvantage of a panel pin

A

They bend more easily due to their thinness

111
Q

Name the wood joint

A

Halving joint

112
Q

Name the wood joint

A

Butt joint

113
Q

Name the wood joint

A

Rebate joint

114
Q

Name the wood joint

A

Housing joints

115
Q

Name the wood joint

A

Mortise and tenon joint

116
Q

Name the wood joint

A

Dowel joint

117
Q

Describe a halving joint

A

Made by cutting away half thickness of material on each half of the joint

118
Q

What are halving joints used for?

A

Corners

119
Q

Halving joint - pro

A

Fairly strong

120
Q

Butt joint - pro

A

Very easy

121
Q

Butt joint - con

A

Very weak

122
Q

Butt joint - use

A

Cheap furniture

123
Q

Describe a rebate joint

A

One part is left plain and other has rebate cut into it

124
Q

Rebate joint - pro

A

Easy

125
Q

Rebate joint - con

A

Average strength

126
Q

Housing joint use?

A

Shelves

127
Q

Mortise and tenon joints use?

A

Construction of furniture frames

128
Q

Name 4 metal joints

A
  • Soft soldering
  • Brazing
  • Welding
  • Rivets
129
Q

Describe soft soldering

A
  1. Thin layer of solder applied to each piece
  2. Both pieces then brought together
  3. Gentle flame applied so 2 pieces become 1
130
Q

Name 2 advantages of soft soldering

A
  • Can be used on various metals
  • Relatively low temperatures involved
131
Q

Name a disadvantage of soft soldering

A

Can take a long time to set up

132
Q

Describe brazing

A

Bonding materials (usually metals) by melting a filler metal or alloy between the components you want to join

133
Q

Name an advantage of brazing

A

Creates a strong joint

134
Q

Name a disadvantage of brazing

A

Fumes given off due to flux buring

135
Q

Describe welding

A

Uses very high temperatures to melt edges of joint = flow together, fuse together as it cools

136
Q

Name 2 advantages of welding

A
  • Creates strong, fused joint
  • Some devices are portable and can be easily transported
137
Q

Name 2 disadvantages of welding

A
  • Need to wear very dark goggles
  • Can only be used to join similar materials
138
Q

When are rivets used?

A

In sheet metals

139
Q

When is a pop rivet used?

A

When there’s only access to one side of material

140
Q

Describe how pop rivets work

A
  1. Metal pin inserted through hole in centre of pop rivet
  2. Both rivet and pin = placed in hole in material
  3. Pin is pulled tight with a riveter (or pop gun) till it snaps off
  4. Pulling pin tight = makes end of rivet expand = forming head on ‘blind’ side
141
Q

Name 3 advantages of rivets

A
  1. Fast and easy method of joining thin sheet metal (pop riveting)
  2. Joint can be created as hinges
  3. Little specialist equipment required
142
Q

Name a disadvantage of rivets

A

Can be time-consuming when snap riveting

143
Q

What is PVA glue used for?

A

Gluing wood

144
Q

Describe how you use PVA glue

A

Put on joint and must be held together while glue dries

145
Q

Name 3 advantages of PVA glue

A
  • Strong joint
  • Does not stain
  • Long shelf life
146
Q

Name a disadvantage of PVA glue

A

Most types are not waterproof

147
Q

What is contact adhesive used for?

A

Glueing large sheet materials - e.g. Sticking down floor tiles

148
Q

Describe how you use contact adhesive

A
  • You apply it to both surfaces and keep surfaces apart until glue goes tacky
  • When surfaces brought into contacts sticking is pretty instant
149
Q

Name 3 advantages of contact adhesive

A
  • Sets in 20-30 minutes
  • Gives very strong bond
  • Can be used to join dissimilar materials
150
Q

Name 2 disdvantages of contact adhesive

A
  • Does not allow repositioning
  • Gives off harmful fumes
151
Q

Describe how you use epoxy resin

A

Two separate substances are mixed together in equal parts = starts to harden due a chemical reaction

152
Q

What will epoxy resin stick to?

A

Almost anything

153
Q

Name 3 advantages of epoxy resin

A
  • Very strong
  • Waterproof
  • Takes about 15 minutes to harden
154
Q

Name a disadvantage of epoxy resin

A

Expensive (to use on large-scale work)

155
Q

What is acrylic cement used for?

A

Used to join plastics together

156
Q

Describe how you use acrylic cement

A

Two plastic surfaces need to be clamped together for 24 hours so permeant bond can form

(dissolves surfaces - “fusing” surfaces together)

157
Q

Name an advantage of acrylic cement

A
  • Waterproof
158
Q

Name 2 disadvantages of acrylic cement

A
  • Gives off harmful fumes
  • Very smooth surfaces need to be roughened a bit
  • (Takes 3-24 hours)
159
Q
A

Resistant Materials (4 decks)

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