Past Papers Flashcards
Problems with painting
Paint would scratch more easily than zinc and offer no protection Polymer powder coating is more wear-resistant than paint
Hazards of powder coating / zinc galvanising and solutions
• Fumes – wear mask and use fume extraction
• Airborne particles – wear eye protection
How is CAD used?
CAD software is used to draw the exact shape and dimensions of the component to be machined; this information is then converted to a Part Program that can be downloaded on to a CNC machine for the manufacture of the component.
What should you do before doing a batch of a product in a CNC machine?
• To confirm that the program produces a product that meets the specification
• To check for possible collisions with ancillary equipment (clamps etc)
• To confirm cutting parameters are correct (speeds, feeds, depth of cut etc)
2 industrial uses of robots in manufacturing
• Pick and Place for automated assembly from circuit boards to cars
• Processes – welding, painting, etc
Explain the difference between CIM and CAD
CIM is the integration of all the functions in a manufacturing enterprise from product concept to sale and dispatch. CAD/CAM is part of a CIM system, concerned only with the design and production element of a manufacturing enterprise.
2 uses of Industrial Control Systems in a modern factory
• Monitoring and adjusting environmental temperature in the workplace
• Planned maintenance procedures
2 examples of smart materials in engineering
• Shape memory – simple bi-metal strip such as in Kettle or Iron
• Chromic materials – colour change in response to pressure or
temperature
Properties of rubber
Grippy
Washable
Comfortable
Sweatproof
Advantages of composite materials
Lightweight
Strong
Can be moulded into complex shapes
No finish required
Disadvantages of composite materials
Time
Expensive
Can’t be recycled
Dangers of lathe
Spinning fast
Swarf
PPE
Personal Protection Equipment
Tools for casting
Cope, split pattern, runner, sprue, crucible
Tools for making holes
Centre punch
Drill
Twist drill
Tools for deburring holes
Pillar drill
Countersink bit
What is deburring
Remove sharp edges by drilling the holes
Tools for finish surface
Abrasive sheets and buffing wheel
Why finish surfaces?
Remove scratched and polish
Why is steel hardened?
Wear resistance and increases usefulness
Disadvantage of hardening steel
Makes it brittle
Describe hardening low carbon steel
Heat to cherry red, dip in carbon, cool, repeat.
Information client needs to give the designer
Colour
Price
Storage capacity
Why are micrometers good?
Faster and more accurate
Industrial method for cutting
- Stamping
- Press forming
- Plasma cutting
- CNC milling machine
2 environmental impacts of plastic
Crude oil
Non-biodegradable
2 features for a successful vacuum formed product
Draft angle
No sharp corners
2 health and safety risks when working with GRP
- Toxic fumes
- Irritation from fibres
- Explosion/fire risk
- Storage leaks/contamination
Advantages to basically anything
Accurate and easy
Advantages of a just in time system
- less stock storage
* Less time required to locate parts
Disadvantages of just in time system
- Needs a highly coordinated work force
- Sharing of data
- Dependant on reliable supply chains
- Production may stop due to stock shortages
- Less flexibility if customers require customized items
How are robots used
Pick and place
Simple processes such as spot welding
How do robots reduce health and safety risks
Lift heavy weights
Carry out processes in hazardous environments
Alloy
Metallic material consisting of multiple metals
Reasons why metals are alloyed
- Corrosion resistance
- Improving material properties
- fluidity
- Improving machining characteristics
- Hardness
- Elasticity
- Change melting point
How can costs change
- Change in materials based on supply and demand
- Energy costs
- Transport costs
- Unforeseen maintenance costs
- Unforeseen quality control issues
- Improved performance due to experience
Fixed production costs
- Set up costs
- Machinery
- Rates/rents for a year
- Labour rates agreed for fixed periods of time
