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ZZ ENGINEERING > LO2 > Flashcards

LO2 Flashcards

1
Q

What is a standard component?

A
  • Standard components are used in a variety of products and made by a variety of manufacturers
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2
Q

Give examples of standard components

A
  • Tyres
  • Power supplies
  • Motors
  • Screws
  • Nails
  • Bolts
  • Cogs/ gears
  • Fuse
  • Bearings
  • Washers
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3
Q

What are the advantages of using standard components?

A
  • Available from a variety of suppliers
  • Inexpensive as mass produced
  • Can buy in bulk
  • Cheaper to buy than make
  • Saves production time
  • Likely to be very reliable as made by specialist
  • Easy to obtain parts for repair
  • Reduces production costs
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4
Q

Explain why using standard components is more sustainable

A
  • Products can be disassembled easily
  • Materials can be separated and recycle
  • Parts can be reused
  • You can fix or replace broken parts
  • They are durable
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5
Q

Why are standard components manufactured to certain tolerances?

A
  • People know the components will work or fit
  • Making components to be an exact size would be too expensive
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6
Q

What is a premanufactured component?

A
  • Pre-manufactured components are made by specialist manufacturers and used in just one product
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7
Q

Give examples of premanufactured components

A
  • Car windscreens
  • Engines
  • Touchscreens
  • Some electric motors
  • Circuit boards
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8
Q

What are the advantages of using pre-manufactured components?

A
  • Saves production time
  • Easier to assemble products
  • Quality of components is high
  • Likely to be very reliable as made by specialist
  • Reduces the range of manufacturing equipment needs
  • Outsourcing saves buying expensive machinery
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9
Q

Define manufacturing constraints

A
  • Are things which could stand in the way of manufacturing a product
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10
Q

List some manufacturing constraints

A
  • Costs
  • Availability of materials
  • Meeting laws/ safety legislation
  • Assembly time
  • Shipping/ distributing the products
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11
Q

What are the factors which influence design?

A

Safety:
* Strength, durability, stability, rounded edged/no small parts
Sustainability:
* Can it be recycled
Working environment
* Where the product will be used and what it will need to cope with
Cost of production
* Can it be produced in high volumes, if additional components needed, on single piece reduces cost to make each unit
Materials:
* Availability, colour, using plastics - self finishing, easy to mould

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12
Q

Define client requirements

A
  • What a client wants the product to do, be or have
  • What features the product will have to ensure the requirement is met
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13
Q

What is included in a client requirements?

A

*

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14
Q

Define ergonomics

A
  • How a product is designed to fit the user, be easy and comfortable to use
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15
Q

Why must ergonomics be considered when designing products?

A
  • So the user can easily use the product
  • So it functions correctly
  • Poor ergonomics can cause injuries
  • Consider ergonomics of target market, e.g. elderly
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16
Q

What do ergonomics consider?

A
  • Weight, height, hearing, sight & touch
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17
Q

Define anthropometrics

A
  • The study of different sizes of the human body, used to determine average ties when designing a product to suit a market
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18
Q

Define performance requirements

A
  • What a user wants the product to do, be or have
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19
Q

What might performance requirements relate to?

A
  • Durability - how long it will last
  • Energy efficiency
  • Weight (light)
  • Product having different functions/ settings
  • Safety
  • Noise produced (not loud)
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20
Q

What are the legal requirements of a product in terms of hygiene?

A
  • Some products must be hygienic for example, food related items.​
    ​* If a product was not hygienic it could lead to:​
  • Loss of customers​
  • Health risks to customers​
  • Contamination (food poisoning) if food related​
    ​* It is a legal requirement​
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21
Q

What are the advantages of using plastics over metals?

A
  • Easier to mould complex shapes​
  • Cheaper manufacturing​
  • Quicker production​
  • Plastic is easy to recycle​
  • No finish needed – plastic is self coloured​
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22
Q

Why is it important to consider the availability of materials when designing and making products?

A
  • If there are no materials, production stops which is expensive/looses money.​
  • Buying materials in bulk is cheaper.​
  • Just in time (JIT) manufacturing is used, so if materials don’t arrive on time, production stops.​
  • If a material is rare, it makes the selling cost more expensive.​
  • If a material isn’t available to meet demand (how much they need) a different material might need to be selected.​
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23
Q

Define supply chain

A
  • Where materials and components are being ordered from and when they are being delivered.​
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24
Q

What happens if the supply chain breaks down?

A

​* If the supply chain breaks down or cannot provide the materials or deliver them on time, manufacturing will stop.​
​
​

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25
Q

Why should manufacturers should consider the supply chain when developing a new product?

A
  • Check the supply can meet the demand (how much the company need)​
  • Check the materials and components are actually available​
  • To work out costs to make the product​
  • To work out delivery times and dates​
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26
Q

What are composites?

A
  • Composites are a mixture of 2 or more materials to give a material with combined and improved properties
    e.g. stronger, attractive.​
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27
Q

Give examples of composites materials

A
  • Kevlar
  • Carbon fibre/ fibre glass
  • Glass reinforced plastic
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28
Q

What is kevlar and what is it used for?

A
  • Artificial fibre​ woven together to create a very light and strong material.​
  • Strong and tough material​
  • Used for body armour​
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29
Q

What is carbon fibre/ fibre glass and what is it used for?

A
  • Fibre woven into a textile material and epoxy resin is applied (glue) and left to dry.​
  • Very strong, has the best weight to strength ratio.​
  • Used for fighter planes, sports cars.​
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30
Q

What is glass reinforced plastic and what is it used for?

A
  • Strands of glass are woven to form a flexible fabric. which is placed in a mould with resin (glue) and left to dry.​
  • Strong and light material​
  • Used for canoes, surf boards, swimming pools.​
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31
Q

What are smart materials?

A
  • Smart materials have a reactive capability.
  • Their properties change when in contact with things like heat or pressure.​
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32
Q

What does polymorph come in?

A

​* Polymorph comes in plastic granules.

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33
Q

What is the function of polymorph?

A
  • Has the reactive capacity to change from a solid to mouldable when heated. ​
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34
Q

How do polymorphs work?

A
  • Heat granules with boiling water and they’ll melt and can be moulded.​
  • Once the plastic cools, it sets into a solid plastic.​
  • Can be re-heated with hot water and re-moulded.​

​
​

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35
Q

What are polymorphs useful for?

A
  • Useful for making unusual shaped items, ergonomic handles or modelling. ​
    ​
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36
Q

What is the function of thermochromic pigments?

A
  • Thermochromic pigments are added to plastics to make them change colour when heated to a certain temperature. ​

​

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37
Q

Give examples of thermochromic pigments

A
  • Baby spoons - change colour if the food is too hot​
  • Kettle - changes colour when the water is boiled. ​
38
Q

When would the thermochromic pigments be added to the product?

A
  • The thermochromic pigments would be added when the product was being made
    e.g. with plastic powder when being injection moulded.​
39
Q

What does a thermochromic sheet consist of?

A
  • Thermochromic sheets consist of a thin layer of liquid crystal which has been printed onto a black background.​
    ​

​

40
Q

What happens when you place your hand on a thermochromic sheet?

A
  • When you place your hand on the strip, the print will appear in a range of colours which represent different temperatures on parts of the hand. * Can be reused.​
41
Q

What is the function of photochromic sheets and inks?

A
  • Photochromic sheets and inks react to UV light​

​

42
Q

What is the function of hydrochromic sheets and ink?

A
  • Hydrochromic sheets and ink which react to water and liquids.​
43
Q

What is a shape memory alloy?

A
  • Shape Memory Alloys have a reactive capability to change their shape when heated. ​
    ​
44
Q

Give examples of shape memory alloys

A
  • Nitinol
  • Memoflex glasses
    ​
45
Q

What is nitinol? Name an example

A
  • Nitinol is a type of smart wire which changes length when heat is applied to it.
    e.g. Braces for teeth are made from Nitinol – your body heat will have attempted to shorten the length of the wire which then pulled your teeth into shape.​
    ​
46
Q

What are memoflex glasses?

A
  • Memoflex glasses are made from a shape memory alloy
  • Once shaped into the design of the glasses frame, they will continue to return to this original shape even after being badly bent.
47
Q

What does FSC stand for? And what is its purpose?

A
  • Forest Stewardship Council
  • To make sure more trees are replanted than are cut down so we don’t run out.​
48
Q

How are FSC forests managed?

A
  • FSC forests are managed with consideration for people, wildlife and the environment. ​
49
Q

Where is the FSC logo found?

A
  • Logo is found on wooden and paper products.​
50
Q

What does the FSC logo show (to the user)?

A
  • As trees are chopped down, they are replaced.​
  • Parts of the forest are untouched to protect animals and plants.​
  • Once a section of the forest has been cut down, it is left for 20 years so the trees can re-grow.​
  • Local workers run the forest, get a fair wage and safe conditions.
51
Q

What are the advantages of mass/volume production?

A
  • Cost savings​
  • Once set up, cost per product/component is very low​
  • Less skilled workers needed = cheaper​
  • Efficient​
  • Material costs are cheaper the more you make​
52
Q

What are the disadvantages of mass/volume production?

A
  • High setup costs​
  • Lots of specialist equipment needed​
  • Storing materials for large numbers of products​
53
Q

Define Just In Time production

A

​* Just in time production is where parts/materials/components arrive just as they are needed.​
a.k.a lean manufacturing

54
Q

What are the advantages of JIT production?

A
  • Less storage space needed = Lower costs​
  • Used in car manufacturing as the parts are large.​
55
Q

What are the disadvantages of JIT production?

A

​* If materials/parts don’t arrive on time, production stops

56
Q

When is JIT production used?

A
  • Used when making large products like cars to save money on warehouse space.
57
Q

What is one-off production used for?

A
  • One-off items or prototypes – individual.
    e.g. bespoke item of clothing, football stadium etc. ​
58
Q

What is batch production used for?

A
  • Used for limited production runs like books and bread up to 10,000 products made.​​
59
Q

What is mass production used for?​

A
  • Used to make millions of products at the same time like mobile phones and standard components.​
60
Q

What is continuous production used for?

A
  • Production 24 hours a day, 7 days a week – makes products like paper, glass and cans.​
    ​
61
Q

How does the scale of production impacts material selection?

A
  • When using plastics, a large scale of production is needed to offset/counteract the high setup costs and machinery.​
  • Using modern materials is expensive and are not used for mass production.​
    ​* The sustainability of mass produced products must be considered.​
    ​* We must consider how the materials and components will be reused or recycled.​
    ​* One-off or custom products are more expensive for a customer to buy. It also often uses more expensive materials.​
    ​* Mass production processes like injection moulding, casting or CNC require parts to be designed with geometry so they are easier to produce.​
62
Q

What is design for manufacturing & assembly? (DFMA)

A
  • DFMA is designing a product in such a way as it is as easy and inexpensive as possible to manufacture
63
Q

What are the characteristics of DFMA?

A
  • Consideration of the design to optimise manufacturing or assembly time.​
  • Designed so it can be manufactured efficiently.​
  • Components allow them to be assembled effectively.​
  • Minimal parts are used​
64
Q

Why do designers consider DMFA when designing products?

A
  • Speed up assembly​
  • Increase production​
  • Reduce making costs​
  • They need less skilled workers (cheaper)​
65
Q

How could a design be optimised for DFMA?

A
  • Make it easy to assemble
  • Use standard components where possible
  • Consider pre-manufactured components
  • Error-proofing
  • Reduce number of components
  • Design to assemble using standard tools where possible
  • Removing unnecessary material from the design
66
Q

Why is design for disassembly important?

A
  • Components or materials can be easily separated at the end of the products life
  • Allows components or materials to be recycled or reused
  • Allows parts to be replaced
  • Allows the user to carry out maintenance & cleaning
  • Easier to transport or store if not in use
67
Q

How could a design be optimised for maintenance?

A

Make the products easy to disassemble and maintain by:
* Using clips or other non-permanent fixings
* Reducing number of parts
* Using standard parts where possible
* Making components easy to clean

68
Q

Define tolerances

A
  • Tolerance is the amount a product/component can be too big or too small (than its intended size) before it is discarded (thrown away). ​
    ​
69
Q

What symbol is used to indicate tolerance for parts?

A
  • The tolerance for parts of a product is recorded using this plus or minus symbol.​
    +
    -
    ​
70
Q

Why are tolerances important?

A
  • Tolerance is important for safety and quality– if parts aren’t the right size, accidents could happen. Also, if products don’t fit, customers would complain.​
71
Q

How can designers improve the reliability of a product?

A
  • Use components that are easily replaceable by the user
  • Rigorously test a product to ensure it will last for desire product life span
  • Choose high quality material and components
72
Q

Why do designers use general tolerances?

A
  • When making components, there are always slight variations in sizes.​
  • Creating products to an exact size is expensive​
  • Using a small tolerance means cheaper production​
  • Products will work and be safe​
73
Q

Define specific or close tolerances

A
  • A specific or close tolerance is used for specific parts of a design where the size may be more critical.​
    ​
74
Q

Why are specific or close tolerances used?

A
  • Safety reasons​
  • So parts fit​
  • So they are accurate​
  • So they function correctly​
  • Used for location and fit​
75
Q

How might copyright, patents, registered designs, and trademarks influence the design of new products?

A
  • Designers will avoid copying product features that are protected
  • Alternatively, manufacturers may have to pay a license fee to use the feature
76
Q

What is one-off production used for?

A
  • One-off production is used for prototypes and commissioned custom products
  • Requires highly skilled workers
  • Slow
  • Expensive
  • Hand tools
  • Rapid prototyping e.g. 3D printer
77
Q

What are the features of batch production?

A
  • Used for relatively smaller fixed numbers of products. Typically 10-200
  • Middle-ranged cost and speed per copy
  • Workers specialise in a few processes
  • Little automation
    *Uses manufacturing aids:
    -templates
    -jigs
    -fixtures
78
Q

What are the features of mass production?

A
  • Used for high volume production
  • Highly automated, robotic manufacture
  • Assembly lines
  • Design optimised for mass production
  • Employment is in maintaining machines or in simple, repetitive assembly
  • Lowest cost per copy
  • Expensive set up cost
79
Q

What is the difference between durability and reliability?

A
  • Durability is a measurement of how long a products entire life is
  • Reliability refers to how likely the product will fail within a specific time period
80
Q

Define engineering tolerance

A
  • Tolerance is an acceptable amount of variation from the design - usually applies to sizes
81
Q

Why do designers need to specify manufacturing tolerance?

A
  • It is not possible to manufacture a component with complete accuracy
  • A tolerance is used to state the amount of accuracy required
  • Essential to ensure components fit together
82
Q

What is intellectual property?

A
  • Intellectual property is the idea that a person or company owns their creative work and it should not be freely copied
  • Laws can be used to protect designs/ideas
  • Copyright (written and art work)
  • Patents (mechanisms)
  • Registered designs (product shape)
  • Trademarks (logo etc)
83
Q

Draw the “UKCA” and “British Standards” quality symbol?

A

UKCA
- required in the UK
- Manufacturer declares product meets all applicable laws
- UK version of “CE” mark
British Standard
- optional
- product is independently tested by British Standards Institution
- Common on safety equipment

84
Q

What are the 5 main parts of a design specification?

A
  • Users needs
  • Product requirements
  • Manufacturing considerations
  • Consideration of production costs
  • Regulations and safeguards
85
Q

What are the different types of user needs?

A
  • Aesthetics
  • Ergonomics
  • Anthropometrics
  • Benefits and features
  • Product safety
86
Q

What are the different types of product requirements?

A
  • Function
  • Features
  • Performance
  • Target group/intended users
  • Working environment
  • Limitation and constraints, size, weight, functional limitations
  • Appearance
  • Ergonomics
  • Lifecycle
87
Q

What are the main types of manufacturing considerations

A
  • Materials availability & supply chain
  • Ease of manufacture
  • Production method (batch, mass, one-off)
  • Manufacturing process (must match production method)
  • Durability & reliability
  • Tolerances
88
Q

What might influence production costs?

A
  • Scale of production
    Materials cost
  • Production method
  • Tolerance needed
  • Manufacturing process cost
89
Q

Which regulations and safeguards would be considered?

A
  • Copyright
  • Patents
  • Registered designs
  • Trademarks
  • British Standards
  • European Conformity (CE)
90
Q

Explain what a supply chain is

A
91
Q

Why might an engineer specify an older traditional material rather than an innovative new one with better properties?

A
  • If traditional material is likely to be available from any suppliers
  • A failure on one supplier would not stop production as the material could be sourced elsewhere

ZZ ENGINEERING (3 decks)

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