National 5 Flashcards
Revise the course
Name some idea generation techniques.
Morphological analysis: you use a table to organise different options for how the product is going to be made
Thought showers: you write down different ideas and explore them through notes or a mind map
Lifestyle boards: you make up a board of images related to your target market
Take your pencil for a walk: you scribble lots of squiggly lines in a box and then follow a line around until you get an outline for a possible idea
SAM: you subtract, add and/or multiply 2,3 or more basic shapes
What is the function?
the purpose of the product (what it must do)
what is the primary function?
the main function of the product
what is the secondary function?
other functions that a product might have but they are less important than the primary function
what are the aesthetics of a product?
the appearance of a product
what should you consider when aesthetically designing a product?
the shape, proportion, size, colour, texture, contrast/harmony of the idea
what is ergonomics?
the study of how the human body interacts with products
what are the 3 factors of ergonomics?
Anthropometrics
Physiology
Psychology
what are anthropometrics?
making sure that the products are made to the correct size for the target market
what should u consider when figuring out the sizes of a product?
the reach, clearance, posture and the different percentiles; 0-5th, 5th-95th, 95th-100th
what is Physiology?
the understanding of human capabilities
Physiology; what should you consider when designing a product?
avoiding stress, strain, fatigue and possible injury
strength, posture, flexibility, joint movement and reaction times
what is Psychology?
how the human mind perceives the environment
psychology ; what should you consider when designing the product?
how the product appeals to the humans senses
environment; what should you consider when designing the product?
the location of where the product will be and the environmental impact that the product will have
performance; what should you consider when designing the product?
the durability, ease of maintenance, ease of use, running costs and is it value for money
what should you consider when deciding on the materials of a product?
who is the target market?,
what is the product going to be used for?
how and where will the products be used?
what are pure metals?
metals that have been mined from the earth
and extracted from the ore using a process called smelting
name some examples of pure metals.
copper iron tin lead gold silver
what is an alloy metal?
a mixture of pure metals
or
a metal with substance such as carbon added
name some examples of alloy metals
steel
duralumin
brass
bronze
what are ferrous metals?
metals that contain iron and are usually magnetic
name some examples of ferrous metals
cast iron
mild steel
high carbon steel
what are non-ferous metals?
metals that don’t contain iron, and are usually not magnetic
name some examples of non-ferous metals
aluminium copper brass duralumin lead gold silver
name some forms that you can buy metals in
round rod square rod hexagonal rod octagonal rod a flat strip a sheet round tube square tube angle (equal) channel (various)
what are the properties of cast iron?
smooth
soft core
strong when compressed
can’t be bent or forged
what are the uses of cast iron?
vices
lathe beds
garden bench ends
car brake drums
what are the properties of mild steel?
ductile malleable tough high tensile strength corrodes easily easily welded
what are the uses of mild steel?
car bodies machine bodies nuts and bolts screws nails and girders
what are the properties of high carbon steel?
very hard
rather brittle
difficult to cut
poor resistance to corrosion
what are the uses of high carbon steel?
tool blades;
saws, chisels, screwdrivers and centre punches
what are the properties of high speed steel?
very hard
heat resistant
remains hard when red
what are the uses of high speed steel?
drills
lathe cutting tools
milling cutters
power Hacksaw blades
what are the properties of stainless steel?
tough hard corrosion resistant wears well difficult to cut, bend and file
what are the uses of stainless steel?
cutlery sinks teapots kitchen Ware saucepans
what are the properties of aluminium?
strong light malleable ductile difficult to weld non-toxic resists corrosion conducts electricity and heat well polishes well
what are the uses of aluminium?
kitchen foil
drinks cans
saucepans
what are the properties of duralumin?
stronger than pure aluminium
nearly as strong as mild steel but only a 3rd of the weight
what are the uses of duralumin?
greenhouses
window frames
aircraft bodies
what are the properties of copper?
tough ductile malleable conducts heat and electricity well corrosion resistant solder and polishes well
what are the uses of copper?
electrical wire
central heating pipes
circuit boards
saucepan bases
metalwork: what is a scriber used for?
marking metal
metalwork: what is a centre punch used for?
accurately punching holes
metalwork: what are old leg callipers used for?
marking straight lines parallel to the edge of the piece of metal
metalwork: what are spring dividers used for?
marking circles onto a piece of metal
what are outside callipers used for?
measuring the outside widths and diameters of metal, wood or plastic
what are inside callipers used for?
measuring the inside widths and diameters of metal, wood or plastic
what is a micrometer used for?
to very accurately measure the outside diameters of metal or plastic
metalwork: what could a Hacksaw be used for?
cutting think and large pieces of metal
metalwork: what could a junior Hacksaw be used for?
cutting small pieces of metal such as sheet metal and wire
metalwork: what could a power Hacksaw be used for?
it’s a bandsaw type machine
used for heavy cutting of large pieces of metal
such as round bar or square bar
metalwork: what are vernier callipers used for?
measuring very accurate sizes, both internal and external sizes
metalwork: what are folding bars used for?
used when folding sheet metal in order to obtain a straight, neat bend
they are usually held in a vice for small scale work
metalwork: what are hand vices uses for?
holding small and irregular shaped parts while drilling or riveting
metalwork: what are machine vices used for?
to hold heavier pieces of metal whilst drilling
metalwork: what are engineer’s vices used for?
to hold metal while cutting, sawing, filling is being carried out
metalwork: what are toolmaker’s clamps used for?
to hold parts together while marking out, shaping and drilling
metalwork: what mallet should be used if you don’t want to make any marks on the metal?
the raw hide mallet
metalwork: what is a general use hammer but is also specifically used to round the heads of the snap head rivet?
the ball pein hammer
what are files used for?
to shape metal or plastic
they are available with a range of shapes and degrees of roughness
how do you cross file?
you move the file across the work piece using the full length of the blade
what is cross filing used for?
to remove alot of material with every stroke applied
how do you draw file?
you move the file sideways along the work piece
what is draw filling used for?
to obtain a smooth finish after cross filling
draw filling doesn’t remove as much material
name some shapes of files
round file rectangular file square file triangular file half round file
metalwork: what are screw threads used for?
to hold parts together and to transmit power
metalwork: what is internal screw cutting?
it’s when a whole is drilled and the a tool called a Tap is used to cut a thread within the whole
metalwork: what are the 3 types if Taps?
- taper tap
- second tap
- plug tap
metalwork: what is a blind hole?
a hole which has a bottom to it
metalwork: how can you ensure that you won’t break the tap when threading a blind hole?
you could attach a bit of tape to the tap to indicate the depth of the blind hole
metalwork: what is a die used for?
to cut an external thread on a metal rod
what is the most common type of die used in a school workshop?
a circular slit die
- it can open slightly therefore cutting a shallower cut
metalwork: what do heat treatments envolve?
processes such as; annealing normalising forging hardening tempering
metalwork: what does work hardened mean?
that the molecules that make up the metal have been pushed and twisted out of their original position, making the metal more liable to breaking.
this can be fixed by annealing the metal
metalwork: what is annealing?
when you heat up the metal to a certain temperature and then allow it to cool either by air or water depending on the material.
metalwork: what does the annealing process do?
it makes the metal soft as possible to relieve the internal stresses and to make it easier to shape
metalwork: tempering?
the process which involves heating the metal to various temperatures and then immediately quenching it in water.
metalwork: what is case hardening?
the low carbon content metal is heated to a bright red heat and then rolled in carbon riched powder, the carbon is absorbed into the skin of the metal, therfore making a hard outer skin
metalwork: what is the hardening process?
the metal is heated and then quenched in oil or tepid water, then before the tool can be used it must be tempered
metalwork: what tool ensures that the metal being joined and the rivet are being held together firmly?
the rivet and snap tool
name some examples of rivets
snaphead
panhead
mushroom
countersunk
what is popped riveting?
once the rivet is placed in the holes of the metal being joined, the rivet gun is then placed over the rivet and the handles squeezed together
as you apply more pressure the rivet expands in the hole until the pin breaks away
metalwork: what is welding used for?
joining thin sheets of metal together
metalwork: how do you weld metal together?
an electrical current is passed through the copper rods and the metals being joined,
causing heat to build up and melt the metal
metalwork: what is arc welding used for?
to join thick metals together including bar and round form
metalwork: how does arc welding work?
a metal filler is pushed through the electrode holder using gas,
the heat melts the metals being joined,
the metal filler then fills the gap to create a solid weld together
metalwork: what is soldering used for?
joining a thin sheet of metal and a thin bar
metalwork: how does soldering work?
a solder bolt is heated in the forge,
once hot enough it is used to melt a filler metal along the joint
metalwork: what is brazing used for?
joining sheet metal and a thin metal bar/rod
metalwork: how does brazing work?
a gas air torch is used to melt the metal filler along the joint
metalwork: name non permanent fixing methods
nuts and bolts
available in a range of diameters
metalwork: name some ways of joining metals without heat
adhesives:
steel epoxy
steel putty
plastic metal cement
metalwork: what are the properties of steel epoxy?
very strong
durable
heat and water resistant
metalwork: what are the uses of steel epoxy?
patching gutters, and gas tanks
sealing pipes
filling rust holes
drying time 12hrs
curing time 1-2 days
metalwork: what are the properties of steel putty?
strong
water resistant bond
metalwork: what are the uses for steel putty?
patching and sealing pipes (that aren’t under pressure)
ceramic
masonry
curing time 30mins
what are the properties of plastic metal cement?
moisture resistant
what are the uses of plastic metal cement?
use on metals, glass, concrete and wood where strength is not required
metalwork: what is sand cast moulding?
the process of making metal shapes (components) using pre-shaped objects and sand
metalwork: what are the 4 stages of sand casting?
look in the metal booklet
how are plastics usually supplied?
moulding powder
granules
chips which have been procesed
what does processing plastics include?
mixing adhesives to produce plastic compounds
by using adhesives a relatively small no. of plastics can be transformed into a wide range of versatile materials
Give some examples of plastic processes
injection moulding compression moulding extrusion vacuum forming blow moulding rotational moulding calendaring bending fabrication coating forming
plastic: what is injection moulding?
a process which allows large quantities of plastic compounds to be made quickly
plastic: how does injection moulding work?
thermosetting granules are heated until soft,
the material is then forced under pressure into a tampered mould,
when cool the mould is opened and a component is extracted
plastic: what is the process of injection moulding?
look in plastics booklet
plastic: name some examples of injection moulding products
small containers computer shell golf Tees spoons wash basins buckets
plastic: how would you know that a product has been injection moulded?
sprue marks draw angles mould split lines ejection pin marks injection mark
plastic: what is compression moulding?
the process used most often for shaping thermosetting plastics
plastic: how does compression moulding work?
the plastic is placed into a mould cavity where it in heated and plasticised
it is then compressed into shape by a heated punch
plastic: what is the process of compression moulding?
look in plastics booklet
plastic: name some examples of products that have been made from compression moulding
camera cases electrical wall sockets handles door knobs light switches
plastic: what is extrusion?
a process used for products with long uniform cross sections
plastic: what are the 2 types of extrusion?
forward extrusion
backward extrusion
plastic: what is forward extrusion used for?
long continuous lengths
plastic: how can you forward extrude a metal or plastic?
a heated billet is forced through a die
plastic: what is backwards extrusion used for?
for short lengths
plastic: how can you backwards extrude a metal or plastic?
a heated billet is forced backwards by a smaller diameter punch
plastic: what is the extrusion process?
look in plastics booklet
plastic: name some examples of products made from extrusion
curtain rails drainpipes electric cable sheathing florescent light covers fibre for fabrics or hose pipes
plastic: what are the 7 steps of vacuum forming?
look in plastics booklet
plastic: name some examples of where products have been made from vacuum forming
packaging items; trays, dishes, margarine tubs
toys
light panels
plastic: what is blow moulding?
when a softened thermoplastic is forced into the mould using compressed air
plastic: what are the 5 steps of blow moulding?
look in plastics booklet
plastic: name products that have been made by blow moulding
bottles
liquid containers
plastic: what are the 5 steps of rotational moulding?
look in plastics booklet
plastic: name some examples of where products have been made from rotational moulding
plastic toys play equipment Road markers buoys large tanks
what is the process of calendaring plastic?
where thermoplastics are squeezed between hot rollers forming thin sheets or film
what is the process of casting plastics?
when molten plastic is poured into a mould
useful for thermosetting plastics
what is the process of bending plastics?
when thermoplastics are heated along a line using a strip heater, then folded to the desired angle
a bending jig is sometimes used to hold the plastic in place
what is the fabrication process of plastic?
when you join plastic together using a variation of fixings and adhesives
what is the coating process of plastic?
when powered thermoplastic melts on a surface of a heated product (dip coating)
what is the process of forming plastic?
when layers of glass fibre matting and polyester resin form over a mould.
thermoplastic is formed by heating the whole sheet until soft and then pressed between 2 formers
wood: what is the gouge used for?
rapid removal of waste
used for turning a square blank on round
wood: what is a scraper used for?
finishing off products
wood: what is the parting off tool used for?
commonly used for notching and grooving
wood: what is the skew chisel used for?
smoothing or shaping
wood: what are the 6 steps for preparing the blank for the wood lathe?
look in wood lathe booklet
what is the ergonomist?
the person who ensures that all the aspects of ergonomics are addressed in the design
what does the manufacturer do?
works with the design team to ensure that the product can be manufactured,
makes decisions on the equipment, machinery and finishing that the product will require
what does the electronic engineer do?
responsible for designing all the electrical components for the design
what does the lawyer do?
to make sure that products comply with safety regulations,
to protect the company from any legal issues
who are the consumer/client or user?
the people who want to buy the product,
consumer/user are the people that identified the need for the product
the client could be a company who commissioned the design
who is the retailer?
the people who sell the product once it has been made
what does the accountant do?
controls all the costs relating to the product,
makes sure the company with profit from the product,
staff, material costs
advertisement and electricity costs
what does the production specialist do (manufacturing engineer)?
ensuring that parts of the product can be manufactured
tells the company + designers what machines and special requirements to make sure the product is successfully manufactured
sometimes has to be realistic about the limitations of machinery to manufacture the product
give advice to the design engineer
what does the marketing team do?
promoting the product
what does the market researcher do?
they do surveys, focus groups
identify problems with existing products and what changes could be made
help to identify the target market
makes sure that the marketing teams knows the target market
what does the materials technologist do?
ensuring that the correct material is selected for the product
responsible for making sure that the product is successful in operation
what does the project manager do?
leads the design team
make sure that the product is designed and manufactured within a certain time period
divides up the tasks
organises regular meetings for the team to discuss the progress of the design
