Jan 2015 - mock exam

Question 0

Name some examples of synthetic plastics?

Answer 0

• Acrylonitrile butadiene styrene

- or most polymers e.g. Polystyrene

Question 1

What is the definition of ergonomics?

Answer 1

The interactions between the human body and the design

Question 2

Name some natural plastics?

Answer 2

• Latex
• Rubber
• Shellac
• Glue
• Cellulose

Question 3

If a material is UV stable, what does that mean?

Answer 3

That the structure does not change under UV light (the suns rays)
E.g. That the flexibility is not altered or that the colour does not fade

Question 4

Name an example of a UV stable plastic and explain why

Answer 4

Urea Polyvinyl chloride, as the ‘Urea’ has been added to polyvinyl chloride to make it UV stable

Question 5

What is an example of a product made from polyvinyl chloride (PVC)?

Answer 5

The seat on a plastic chair

Question 6

What is a thermoplastic?

Answer 6

A plastic the can be repeatedly related and remoulded

Question 7

What is a thermosetting plastic?

Answer 7

A plastic which once it has been heated is chemically altered becoming permanently rigid

Question 8

What is an Elastomer?

Answer 8

A plastic which has polymers with good elasticity allowing it, when distorted under pressure, to return to its original shape (after pressure has been removed)

Question 9

Name some examples of elastomers?

Answer 9

• natural rubbers
• silicone rubbers
• nitrile rubbers
• neoprenes

Question 10

Name some examples of both thermoplastics and thermosetting plastics?

Answer 10

Thermosetting plastics = - urea formaldehyde

                                     - silicones
                                     - polyesters 

Thermoplastics = - cellulose acetate

                         - polyethylene 
                         - polycarbonate 
                         - polypropylene 
                         - polyvinyl chloride

Question 11

What is plastic guttering most commonly made out of and what manufacturing process is used?

Answer 11

• Polyvinyl chloride and the process is called extrusion

Question 12

What plastics are best suited for making safety hats and why?

Answer 12

Acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) as ABS has a high impact strength and PC has a good chemical resistance

Question 13

What are the 5 general properties of plastics?

Answer 13

• low melting point
• lightweight
• good electrical insulator
• good thermal insulator
• chemically resistant

Question 14

Summarise the process of sand casting

Answer 14

1. A pattern is made
2. Each half pattern placed on base board with a mould box over it
3. Green sand is tampered around mould followed by backing sand
4. Pattern removed, riser + runner gates cut in top half
5. Mould halves fitted together
6. Molten metal poured into runner, riser used to see when mould is full
7. Metal solidifies, sand mould broken away, gates left in mould

Question 15

Give 2 advantages and disadvantages for the process of sand casting?

Answer 15

Advantages, - complex 3d mould produced - good for short runs
Disadvantages, - poor surface finish - low rate of output

Question 16

Name 2 advantages and disadvantages of CAD

Answer 16

Advantages, - accurate - you can modify existing ideas (time saving)
Disadvantages, - training required - expensive equipment/ software

Question 17

Name 2 advantages and disadvantages of CAM

Answer 17

Advantages, - less waste created - precise

Disadvantages, - expensive equipment - high maintenance costs

Question 18

What is the definition of anthropometrics?

Answer 18

The measurements and properties of the human body

Question 19

Describe the process of laser cutting

Answer 19

Laser cutting involves using an intense beam of light to cut out a pattern, shape or even lettering which has been designed using a CAD (computer aided manufacturing) design software.

Question 20

Describe the process of injection moulding

Answer 20

Involves granules of plastic being fed into a hopper which is then heated by 2 heaters, the melted plastic is then moved by a screw that was activated by the heat and the plastic is forced into a mould where it will harden in a set shape

Question 21

What is reverse engineering?

Answer 21

Involves taking apart an object to see how it works in order to duplicate or enhance the object

Question 22

What is Hardware reverse engineering?

Answer 22

Involves taking apart an object to see how it works

Question 23

Name an example of hardware reverse engineering?

Answer 23

A manufacturer disassembling a competitors product to see how it works to copy certain aspects of the design

Question 24

State some advantages and disadvantages of hardware reverse engineering?

Answer 24

Advantages
- useful to stay ahead of the competition

Disadvantages

• illegal in some countries
• requires a great deal of expertise
• quite expensive

Question 25

What is an open loop system?

Answer 25

Set up to achieve desired results however it does not use feedback to monitor the output which it is controlling

Question 26

What is a closed loop system?

Answer 26

Uses feedback in order to correct mistakes to achieve the desired result

Question 27

What is a Gantt chart?

Answer 27

Uses a series of horizontal lines to show the amount done or production completed I certain periods of time

Question 28

What is a flow chart?

Answer 28

Diagram showing the sequence of movements or actions a person takes while involved in a complex sequence or activity

Question 29

What is solid modelling?

Answer 29

Consists of a set of principles for mathematical and computer modelling of 3d solids

Question 30

Name some examples of primary research?

Answer 30

• questionnaires
• interviews
• observations
• surveys
• pictures
  I

Question 31

Name some examples of secondary data?

Answer 31

• books
• Internet
• newspapers
• pictures

Question 32

What is the difference between primary and secondary research?

Answer 32

Primary research is new information which you collect and secondary research is existing information which you use as evidence

Question 33

What is fabrication?

Answer 33

A process in which an item is made from raw of semi-finished materials instead of being assembled from ready made parts

Question 34

What is a patent?

Answer 34

Protects your design for the first 5 years then you must apply annually for a maximum of the next 15 years - only gives you the right in 1 country

Question 35

What is copyright?

Answer 35

Protects the expression of an idea not the idea itself

Question 36

What is a trade mark and a registered trade mark?

Answer 36

A trade mark is a sign which can distinguish your goods/services from other traders, it’s used as a marketing tool for recognition

A registered trade mark gives you and only you the right to use your mark on the goods and services in the classes for which its registered

Question 37

What does a trade mark have to meet to be registered?

Answer 37

• distinctive

- not the same as any previous product

Question 38

What is a registered design?

Answer 38

A design which visual appearance is protected throughout the uk, not how it works

Question 39

What is an IP?

Answer 39

An intellectual property which includes patents, trade marks, copyrights and design
If you own it you can rent it, sell it or licence it etc.

Question 40

Name some advantages and disadvantages of global manufacturing

Answer 40

Advantages

• sourcing from abroad = cheaper labour costs
• developed trade links
• reduces overall production time

Disadvantages

• travel costs
• expensive equipment
• different quality control processes/checks