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Design And Manufacture > National 5 > Flashcards

National 5 Flashcards

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1
Q

Name some idea generation techniques.

A

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

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2
Q

What is the function?

A

the purpose of the product (what it must do)

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3
Q

what is the primary function?

A

the main function of the product

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4
Q

what is the secondary function?

A

other functions that a product might have but they are less important than the primary function

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5
Q

what are the aesthetics of a product?

A

the appearance of a product

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6
Q

what should you consider when aesthetically designing a product?

A

the shape, proportion, size, colour, texture, contrast/harmony of the idea

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7
Q

what is ergonomics?

A

the study of how the human body interacts with products

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8
Q

what are the 3 factors of ergonomics?

A

Anthropometrics
Physiology
Psychology

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9
Q

what are anthropometrics?

A

making sure that the products are made to the correct size for the target market

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10
Q

what should u consider when figuring out the sizes of a product?

A

the reach, clearance, posture and the different percentiles; 0-5th, 5th-95th, 95th-100th

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11
Q

what is Physiology?

A

the understanding of human capabilities

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12
Q

Physiology; what should you consider when designing a product?

A

avoiding stress, strain, fatigue and possible injury

strength, posture, flexibility, joint movement and reaction times

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13
Q

what is Psychology?

A

how the human mind perceives the environment

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14
Q

psychology ; what should you consider when designing the product?

A

how the product appeals to the humans senses

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15
Q

environment; what should you consider when designing the product?

A

the location of where the product will be and the environmental impact that the product will have

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16
Q

performance; what should you consider when designing the product?

A

the durability, ease of maintenance, ease of use, running costs and is it value for money

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17
Q

what should you consider when deciding on the materials of a product?

A

who is the target market?,
what is the product going to be used for?
how and where will the products be used?

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18
Q

what are pure metals?

A

metals that have been mined from the earth

and extracted from the ore using a process called smelting

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19
Q

name some examples of pure metals.

A 
copper
iron
tin
lead
gold
silver
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20
Q

what is an alloy metal?

A

a mixture of pure metals
or
a metal with substance such as carbon added

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21
Q

name some examples of alloy metals

A

steel
duralumin
brass
bronze

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22
Q

what are ferrous metals?

A

metals that contain iron and are usually magnetic

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23
Q

name some examples of ferrous metals

A

cast iron
mild steel
high carbon steel

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24
Q

what are non-ferous metals?

A

metals that don’t contain iron, and are usually not magnetic

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25
Q

name some examples of non-ferous metals

A 
aluminium 
copper
brass
duralumin
lead
gold
silver
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26
Q

name some forms that you can buy metals in

A 
round rod
square rod
hexagonal rod
octagonal rod
a flat strip
a sheet
round tube
square tube
angle (equal)
channel (various)
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27
Q

what are the properties of cast iron?

A

smooth
soft core
strong when compressed
can’t be bent or forged

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28
Q

what are the uses of cast iron?

A

vices
lathe beds
garden bench ends
car brake drums

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29
Q

what are the properties of mild steel?

A 
ductile
malleable
tough
high tensile strength
corrodes easily
easily welded
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30
Q

what are the uses of mild steel?

A 
car bodies 
machine bodies
nuts and bolts
screws
nails and girders
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31
Q

what are the properties of high carbon steel?

A

very hard
rather brittle
difficult to cut
poor resistance to corrosion

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32
Q

what are the uses of high carbon steel?

A

tool blades;

saws, chisels, screwdrivers and centre punches

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33
Q

what are the properties of high speed steel?

A

very hard
heat resistant
remains hard when red

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34
Q

what are the uses of high speed steel?

A

drills
lathe cutting tools
milling cutters
power Hacksaw blades

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35
Q

what are the properties of stainless steel?

A 
tough
hard
corrosion resistant 
wears well
difficult to cut, bend and file
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36
Q

what are the uses of stainless steel?

A 
cutlery
sinks
teapots
kitchen Ware
saucepans
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37
Q

what are the properties of aluminium?

A 
strong
light
malleable
ductile
difficult to weld
non-toxic 
resists corrosion 
conducts electricity and heat well
polishes well
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38
Q

what are the uses of aluminium?

A

kitchen foil
drinks cans
saucepans

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39
Q

what are the properties of duralumin?

A

stronger than pure aluminium

nearly as strong as mild steel but only a 3rd of the weight

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40
Q

what are the uses of duralumin?

A

greenhouses
window frames
aircraft bodies

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41
Q

what are the properties of copper?

A 
tough
ductile
malleable
conducts heat and electricity well
corrosion resistant
solder and polishes well
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42
Q

what are the uses of copper?

A

electrical wire
central heating pipes
circuit boards
saucepan bases

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43
Q

metalwork: what is a scriber used for?

A

marking metal

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44
Q

metalwork: what is a centre punch used for?

A

accurately punching holes

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45
Q

metalwork: what are old leg callipers used for?

A

marking straight lines parallel to the edge of the piece of metal

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46
Q

metalwork: what are spring dividers used for?

A

marking circles onto a piece of metal

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47
Q

what are outside callipers used for?

A

measuring the outside widths and diameters of metal, wood or plastic

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48
Q

what are inside callipers used for?

A

measuring the inside widths and diameters of metal, wood or plastic

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49
Q

what is a micrometer used for?

A

to very accurately measure the outside diameters of metal or plastic

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50
Q

metalwork: what could a Hacksaw be used for?

A

cutting think and large pieces of metal

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51
Q

metalwork: what could a junior Hacksaw be used for?

A

cutting small pieces of metal such as sheet metal and wire

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52
Q

metalwork: what could a power Hacksaw be used for?

A

it’s a bandsaw type machine
used for heavy cutting of large pieces of metal
such as round bar or square bar

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53
Q

metalwork: what are vernier callipers used for?

A

measuring very accurate sizes, both internal and external sizes

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54
Q

metalwork: what are folding bars used for?

A

used when folding sheet metal in order to obtain a straight, neat bend
they are usually held in a vice for small scale work

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55
Q

metalwork: what are hand vices uses for?

A

holding small and irregular shaped parts while drilling or riveting

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56
Q

metalwork: what are machine vices used for?

A

to hold heavier pieces of metal whilst drilling

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57
Q

metalwork: what are engineer’s vices used for?

A

to hold metal while cutting, sawing, filling is being carried out

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58
Q

metalwork: what are toolmaker’s clamps used for?

A

to hold parts together while marking out, shaping and drilling

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59
Q

metalwork: what mallet should be used if you don’t want to make any marks on the metal?

A

the raw hide mallet

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60
Q

metalwork: what is a general use hammer but is also specifically used to round the heads of the snap head rivet?

A

the ball pein hammer

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61
Q

what are files used for?

A

to shape metal or plastic

they are available with a range of shapes and degrees of roughness

62
Q

how do you cross file?

A

you move the file across the work piece using the full length of the blade

63
Q

what is cross filing used for?

A

to remove alot of material with every stroke applied

64
Q

how do you draw file?

A

you move the file sideways along the work piece

65
Q

what is draw filling used for?

A

to obtain a smooth finish after cross filling

draw filling doesn’t remove as much material

66
Q

name some shapes of files

A 
round file
rectangular file
square file
triangular file
half round file
67
Q

metalwork: what are screw threads used for?

A

to hold parts together and to transmit power

68
Q

metalwork: what is internal screw cutting?

A

it’s when a whole is drilled and the a tool called a Tap is used to cut a thread within the whole

69
Q

metalwork: what are the 3 types if Taps?

A
  1. taper tap
  2. second tap
  3. plug tap
70
Q

metalwork: what is a blind hole?

A

a hole which has a bottom to it

71
Q

metalwork: how can you ensure that you won’t break the tap when threading a blind hole?

A

you could attach a bit of tape to the tap to indicate the depth of the blind hole

72
Q

metalwork: what is a die used for?

A

to cut an external thread on a metal rod

73
Q

what is the most common type of die used in a school workshop?

A

a circular slit die

- it can open slightly therefore cutting a shallower cut

74
Q

metalwork: what do heat treatments envolve?

A 
processes such as; 
annealing
normalising 
forging
hardening 
tempering
75
Q

metalwork: what does work hardened mean?

A

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

76
Q

metalwork: what is annealing?

A

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.

77
Q

metalwork: what does the annealing process do?

A

it makes the metal soft as possible to relieve the internal stresses and to make it easier to shape

78
Q

metalwork: tempering?

A

the process which involves heating the metal to various temperatures and then immediately quenching it in water.

79
Q

metalwork: what is case hardening?

A

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

80
Q

metalwork: what is the hardening process?

A

the metal is heated and then quenched in oil or tepid water, then before the tool can be used it must be tempered

81
Q

metalwork: what tool ensures that the metal being joined and the rivet are being held together firmly?

A

the rivet and snap tool

82
Q

name some examples of rivets

A

snaphead
panhead
mushroom
countersunk

83
Q

what is popped riveting?

A

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

84
Q

metalwork: what is welding used for?

A

joining thin sheets of metal together

85
Q

metalwork: how do you weld metal together?

A

an electrical current is passed through the copper rods and the metals being joined,
causing heat to build up and melt the metal

86
Q

metalwork: what is arc welding used for?

A

to join thick metals together including bar and round form

87
Q

metalwork: how does arc welding work?

A

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

88
Q

metalwork: what is soldering used for?

A

joining a thin sheet of metal and a thin bar

89
Q

metalwork: how does soldering work?

A

a solder bolt is heated in the forge,

once hot enough it is used to melt a filler metal along the joint

90
Q

metalwork: what is brazing used for?

A

joining sheet metal and a thin metal bar/rod

91
Q

metalwork: how does brazing work?

A

a gas air torch is used to melt the metal filler along the joint

92
Q

metalwork: name non permanent fixing methods

A

nuts and bolts

available in a range of diameters

93
Q

metalwork: name some ways of joining metals without heat

A

adhesives:
steel epoxy
steel putty
plastic metal cement

94
Q

metalwork: what are the properties of steel epoxy?

A

very strong
durable
heat and water resistant

95
Q

metalwork: what are the uses of steel epoxy?

A

patching gutters, and gas tanks
sealing pipes
filling rust holes

drying time 12hrs
curing time 1-2 days

96
Q

metalwork: what are the properties of steel putty?

A

strong

water resistant bond

97
Q

metalwork: what are the uses for steel putty?

A

patching and sealing pipes (that aren’t under pressure)
ceramic
masonry

curing time 30mins

98
Q

what are the properties of plastic metal cement?

A

moisture resistant

99
Q

what are the uses of plastic metal cement?

A

use on metals, glass, concrete and wood where strength is not required

100
Q

metalwork: what is sand cast moulding?

A

the process of making metal shapes (components) using pre-shaped objects and sand

101
Q

metalwork: what are the 4 stages of sand casting?

A

look in the metal booklet

102
Q

how are plastics usually supplied?

A

moulding powder
granules
chips which have been procesed

103
Q

what does processing plastics include?

A

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

104
Q

Give some examples of plastic processes

A 
injection moulding
compression moulding
extrusion
vacuum forming
blow moulding
rotational moulding
calendaring
bending
fabrication 
coating
forming
105
Q

plastic: what is injection moulding?

A

a process which allows large quantities of plastic compounds to be made quickly

106
Q

plastic: how does injection moulding work?

A

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

107
Q

plastic: what is the process of injection moulding?

A

look in plastics booklet

108
Q

plastic: name some examples of injection moulding products

A 
small containers
computer shell
golf Tees
spoons wash basins
buckets
109
Q

plastic: how would you know that a product has been injection moulded?

A 
sprue marks
draw angles
mould split lines
ejection pin marks
injection mark
110
Q

plastic: what is compression moulding?

A

the process used most often for shaping thermosetting plastics

111
Q

plastic: how does compression moulding work?

A

the plastic is placed into a mould cavity where it in heated and plasticised
it is then compressed into shape by a heated punch

112
Q

plastic: what is the process of compression moulding?

A

look in plastics booklet

113
Q

plastic: name some examples of products that have been made from compression moulding

A 
camera cases
electrical wall sockets
handles
door knobs 
light switches
114
Q

plastic: what is extrusion?

A

a process used for products with long uniform cross sections

115
Q

plastic: what are the 2 types of extrusion?

A

forward extrusion

backward extrusion

116
Q

plastic: what is forward extrusion used for?

A

long continuous lengths

117
Q

plastic: how can you forward extrude a metal or plastic?

A

a heated billet is forced through a die

118
Q

plastic: what is backwards extrusion used for?

A

for short lengths

119
Q

plastic: how can you backwards extrude a metal or plastic?

A

a heated billet is forced backwards by a smaller diameter punch

120
Q

plastic: what is the extrusion process?

A

look in plastics booklet

121
Q

plastic: name some examples of products made from extrusion

A 
curtain rails
drainpipes
electric cable sheathing 
florescent light covers
fibre for fabrics or hose pipes
122
Q

plastic: what are the 7 steps of vacuum forming?

A

look in plastics booklet

123
Q

plastic: name some examples of where products have been made from vacuum forming

A

packaging items; trays, dishes, margarine tubs

toys
light panels

124
Q

plastic: what is blow moulding?

A

when a softened thermoplastic is forced into the mould using compressed air

125
Q

plastic: what are the 5 steps of blow moulding?

A

look in plastics booklet

126
Q

plastic: name products that have been made by blow moulding

A

bottles

liquid containers

127
Q

plastic: what are the 5 steps of rotational moulding?

A

look in plastics booklet

128
Q

plastic: name some examples of where products have been made from rotational moulding

A 
plastic toys
play equipment 
Road markers
buoys
large tanks
129
Q

what is the process of calendaring plastic?

A

where thermoplastics are squeezed between hot rollers forming thin sheets or film

130
Q

what is the process of casting plastics?

A

when molten plastic is poured into a mould

useful for thermosetting plastics

131
Q

what is the process of bending plastics?

A

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

132
Q

what is the fabrication process of plastic?

A

when you join plastic together using a variation of fixings and adhesives

133
Q

what is the coating process of plastic?

A

when powered thermoplastic melts on a surface of a heated product (dip coating)

134
Q

what is the process of forming plastic?

A

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

135
Q

wood: what is the gouge used for?

A

rapid removal of waste

used for turning a square blank on round

136
Q

wood: what is a scraper used for?

A

finishing off products

137
Q

wood: what is the parting off tool used for?

A

commonly used for notching and grooving

138
Q

wood: what is the skew chisel used for?

A

smoothing or shaping

139
Q

wood: what are the 6 steps for preparing the blank for the wood lathe?

A

look in wood lathe booklet

140
Q

what is the ergonomist?

A

the person who ensures that all the aspects of ergonomics are addressed in the design

141
Q

what does the manufacturer do?

A

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

142
Q

what does the electronic engineer do?

A

responsible for designing all the electrical components for the design

143
Q

what does the lawyer do?

A

to make sure that products comply with safety regulations,

to protect the company from any legal issues

144
Q

who are the consumer/client or user?

A

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

145
Q

who is the retailer?

A

the people who sell the product once it has been made

146
Q

what does the accountant do?

A

controls all the costs relating to the product,
makes sure the company with profit from the product,
staff, material costs
advertisement and electricity costs

147
Q

what does the production specialist do (manufacturing engineer)?

A

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

148
Q

what does the marketing team do?

A

promoting the product

149
Q

what does the market researcher do?

A

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

150
Q

what does the materials technologist do?

A

ensuring that the correct material is selected for the product

responsible for making sure that the product is successful in operation

151
Q

what does the project manager do?

A

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

Design And Manufacture (1 decks)

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