Product Design Flashcards
1
Q
give me 5 polymers and there uses?
A
PET (plastic bottles) PVC (Windows) HDPE (Toys) Thermosets (mixed chemicals together, epoxy resin+aroldite) LDPE (plastic wallets)
2
Q
name 6 properties?
A
tensile stiff tough durable ductile bending
3
Q
name 5 non ferrous metals?
A
zinc gold aluminium platinum copper
4
Q
name 3 ferrous metals?
A
cast iron
steel (mild or medium carbon)
5
Q
what stock forms can you get metals in?
A
sheets ingots rods tubing bars
6
Q
what is a ferrous metal?
A
a metal that contains iron
7
Q
what are 4 manufacturing boards?
A
MDF
plywood
hardwood
chipboard
8
Q
give me 3 properties about hard woods?
A
expensive tighter grains thicker, so harder to get in longer pieces. only come to the size of the tree slow growing
9
Q
what happens within spinning?
A
there is two clamps on either side that holds the machine together, they use a stock form sheet of metal which Is spun around the mandrel which is turned by a specific roller which is an a forming tool, which pushed the sheet metal around the mould. it creates hollow products; like bowls and cups.
10
Q
what happens within deep drawing?
A
the “punch” is pushed onto the blank and the metal goes around the mould, a bit like punching. the mould pushes the metal to create a hollow can for like cans or tubing. wall thickness becomes less that a 1/3.
11
Q
what is punching and piercing metals?
A
punching is removing the specific moulded metal, it punches through the metal (holes created)
piercing is piercing holes through metals, it penetrates the metal.
12
Q
what is blanking?
A
blanking is keep the moulded shape, the specific mould is placed and punched out the object.
13
Q
explain the process of blow moulding?
A
the plastic pellets are put into the hopper, where they are vertically put onto the turning Archimedean screw which is turned by the gearbox. The polymers start going along the screw until they get to the heaters where they are softened to get extruded vertically down the extruder into the mould, by passing the parison. They enter the specific mould where hot air is blown up into the mould so that the polymers can make its shape. it’s then cooled down by removing ejector pins and removed any flash.
14
Q
what is compression moulding?
A
is where the mould is heated up and also uses forces to create the product. the top mould halve punches onto the “preformed slugs” where they are melted and made into the shape of the bottom mould half.
15
Q
what’s press forming?
A
press forming is where the die (top mould) used force to punch the “blank” into the bolster’s specific shape.
16
Q
What is an alloy?
A
A mixture of metals to use a variety of their different properties
17
Q
PET is a type of plastic, but what characteristics does it have and what is it used for?
A
good chemical resistance, it can be used within clothing for protection and also electrical plugs.
18
Q
What properties does LDPE have and what is it used for?
A
it has good chemical resistance and also low density (lightweight) it’s used for toys and carrier bags.
19
Q
what does HDPE stand for?
A
high density polyethylene
20
Q
What properties does HDPE have and what is it used for?
A
it has good stiffness, high density and good chemical resistance. it’s used for crates and buckets
21
Q
name 3 types of thermosets?
A
epoxy resins, urea formaldehyde and polyester resins
22
Q
Name 2 advantages of blow moulding?
A
once set up, blow moulding is a quick process so can be made in mass production and also non circular shapes can be produced.
23
Q
name 3 advantages of rotation moulding?
A
one-piece moulding can be produced.
a large range of sizes are available.
cheaper moulds allow lower production runs.
24
Q
what is extrusion?
A
is the process used where products with a continuous cross section are required.
25
name 1 advantage and 1 disadvantage or extrusion?
they are generally low costing and only requires one simple die.
it's main disadvantage it can only produce continuous cross sectional shapes.
26
what are the properties of aluminium?
good corrosion resistance, good surface finish, lightweight, its a relatively soft metal therefore can be bent into any shape and also it has good strength.
27
what are the properties of Carbon fibre?
lightweight, its a composite material therefore has uses of both properties, strength, high stiffness and used for like F1 cars.
28
what is a smart material?
is where the properties of a certain material can change due to a specific stimulus. e.g. thermo chromic- used for testing temperature of babies food bottle.
29
describe the 4 processes of steam bending?
1. the veneers of wood are stuck together by resin.
2. then they are CNC routered into it's specific shape.
3. it's then steam bent in the machine and wood becomes softened.
4. it's the put into a specific mould and dries Into that shape.
30
what are the properties of polypropylene?
food safe, good impact resistance, good chemical resistance and light weight. used for most polymer based products and also medical equipment.
31
how would you finish wood?
varnish, painting, waxing, removing dust (sanding) and also natural barriers such as oils.
32
how would you finish metals?
deburring, electroplating, powder coating, filing and painting e.g. spray painting.
33
what are the two ways of cutting wood?
quarter sawing- where you cut to the size you want.
| slab sawing- cutting to the size of the tree.
34
what are the properties of plywood?
layers are each at a 90' angle, therefore strong as it's all equal, it has on the outer face an odd number of layers, therefore the grain would be exactly the same on both sides, it's made from veneers of wood stuck together by resin, and also it can come in many sizes as its man made
35
what attacks each wood?
hardwood- "death wood beetle" which lays it's eggs In the wood and they crawl out, leaving holes.
softwood- "woodworm" which eats through the wood.
36
what defects can wood have?
warping- is where the wood becomes damp and dried again, it caused the wood to curl at the ends.
bowing- same process but the wood becomes like a U shape.
knots- where branches have began to come out of the wood, it reduces the woods strength.
37
give 2 positives about timber (wood)?
its sustainable as we can grow more
| they are renewable.
38
what is the thermoset "Ureaformaldhyde. used for and it's properties?
used for plug sockets- as it's a good insulator and good stiffness.
39
what is foam board used for?
making models, as its cheap, recyclable and also easily to mould into shapes.
40
what is biodegradable?
e.g. plastic bags, the polymers break down due to natural barriers.
..its environmentally friendly
.. saves cost in landfills
.. however, If someone wanted to use them in the future and went to get it, it would have been in pieces. (not long lasting)
41
what is a memory shape alloy?
where a metal remembers it's specific original shape due to the design of it, e.g. bending glasses back to shape.
42
what is the material used for smart materials? and why It is used?
thermo chromic- pigments, sheets etc.
| its used because its a visual indicator.
43
advantages and disadvantages of rotational moulding?
start up costs are expensive, moulds are expensive, can create many sized containers and also makes one piece products.
44
adv/ disadvantages of injection moulding?
makes complex 3D shapes, moulds are expensive, mass produced quickly and also initial start up costs are high.
45
what is meant by CNC?
where a computer controls equipment such as machinery and tools. it is controlled by numeric data. e.g. CNC router.
46
what is a screw called?
archimedean.
47
describe the process of vacuum forming?
there are clamps on either side, and the plastic is placed on top of the mould, where it is softened and compressed air is pulled from the mould so that the plastic takes the shape of the mould. (comes fro, the vents). a draft angle of 3/5' is on the mould, so that the plastic can be easily removed.
48
what are the properties of PVC?
used for window frames, it has good stiffness, good chemical resistance and lightweight.
49
what are 3 ways of joining metals?
brazing
welding
soldering
50
what does the glass symbol stand for?
fragile.
51
what does the fish and tree symbol stand for?
harmful to the environment.
52
what does the X symbol stand for (orange and black)?
harmful
53
what is epoxy resin used for? (thermoset)
it's used for surface finishes as it has good wear resistance and also tough.
54
what are some types of knock down fittings (wood)?
corner plate
block connector
chipboard fastener
55
what does the CE symbol stand for?
european standards
56
what is laminating?
where layers of extra material are put into the original for strength and finish. (plastic layer)
57
2 types of wood joinings?
dowel joint and finger joint.
58
what does the recycle symbol mean with numbers and letters mean?
specific plastic recyclable.
59
describe the process of extrusion?
plastic pellets are put into the hopper (vertically), then moved along the archimedean screw which is turned by the gearbox. Then the polymers are pushed along the screw to the heaters where the polymers are softened and entered into the die where the polymers are extruded out of the die and cooled down, then cut to specific lengths.
60
what is a jig used for?
holding into place and cutting.
61
what is CNC bender used for?
bending pipes etc.
62
what is flash?
excess of plastic, it needs removing.
63
properties of acrylic?
can come in any thickness, transparent and also easy to mould into shape.
64
name 2 types of composite materials?
GRP (glass reinforced plastic)
| Carbon Fibre
65
what is an alloy?
a mixture of 2 properties for the usage of both.
66
what is ductile?
bending, twisting and pulling forces.
67
what is sustainable?
how well it meets the needs of the environment. e.g environmentally friendly.
68
what are thermoplastics?
where they can be reheated or reshaped. save costs and environmentally friendly
69
what are the properties of PET and what is it used for?
good water/moisture barrier, good chemical resistance, and also lightweight. used for packaging and fruit packaging.
70
what are knots in woods?
is where branches have started to grow into the wood, it's made the wood weak as it's harmed it's natural structure.
71
name 4 types of man made boards?
MDF
PLYWOOD
CHIPBOARD
HARDBOARD.
72
what are the properties of MDF?
is in many sizes as it's man made, smooth on both sizes, it is dense and also good strength.
73
what processes are blanks used for?
press forming and deep drawing.
74
describe the process of deep drawing?
two mould halves are used, the top one punches the metal "blank" with a compression force which makes the blank create into the shape of the bottom one. it makes like cans and hollow objects.
75
Which one of the following pressing process used both heat and pressure?
Compression moulding
76
Which 2 processes uses blanks?
Compression moulding and deep drawing
77
Which process used a bolster and die?
Press Forming
78
Name 2 safety checks you could do when manufacturing?
Make sure all of the components are there.
| Wear appropriate equipment when manufacturing. Eg. Goggles when sanding.
79
what manufacturing process uses a hydraulic ram to push the pellets?
injection moulding
80
examples of compliant materials?
```
Layout paper
Extruded polystyrene foam (styrofoam)
Polypropylene
Acetate
carton board
Bleed proof paper
```
81
what is a compliant material?
A compliant material is a material that conforms to regulations or even a building code. It is a material that has recognised, predictable and consistent properties. A material is a compliant material, if it conforms to a known performance criteria.
82
what are compliant used for?
packaging, designing of a product ie. model making (styrofoam)
83
name 3 permanent fixings you can use on metals?
welding, brazing and soldering
84
name 3 temporary fixings you can use on metals?
nuts/bolts, screws (tap in or threading)
85
what is a thermoset plastic?
a plastic that cannot be reheated or reshaped.
86
give a good example of a thermoset plastic on a product?
a kettle handle, when the water is boiling you do not want the handle above to become hot and disfigure
87
properties and uses of HDPE?
good chemical resistance, high density, light weight. used for crates or plastic containers
88
after manufacturing a plastic product, what is excess called?
flash
89
in plastic what are additives used for, and name 2?
they are used to protect the plastic, against the environment or usage. examples are: UV stabilizers, i.e. if the product was placed outside, and also pigments- builds up the layer.
90
which manufacturing process of plastics, uses a dye?
extrusion.
91
name all manufacturing processes you can use for plastics?
extrusion, compression moulding, rotational moulding, blow moulding and injection moulding
92
when the plastic product is complete, how can you remove/ cool the product?
remove ejector pins, let it cool down naturally, or use of cold water
93
name a specific product that can be made when blow moulding?
bottles
94
describe the process of compression moulding?
the preformed "plastic slugs" are put into the bottom half of the mould, which is heated up. then the specific top half of the mould, compresses the preformed slugs to take the shape of the bottom half mould.. this process uses both compression and heat
95
3 examples of soft woods?
spruce, scotts pine and balsa
96
name 3 ways you can protect woods?
wax, varnish, natural oxides
97
name 3 quality control methods?
... check the material for any defects.
... make sure all the machines are fully function and safe to use.
... check the product after manufacturing.
98
what is sustainability?
how well the product meets/interacts with the environment.
99
what are the 4 R's for sustainability?
reduce
recycle
reuse
refuse
100
what is a jig?
holds something into place.
101
name a smart material and its application?
thermochromic, and used in measuring baby food temperature as it changes colour when hot
102
what is oxo degradable polymer and biopol?
they are biodegradable plastics. it breaks down the natural oxides, it saves cost and renewable.
103
what process is used for metals that is similar to injection moulding(plastics)?
die casting
104
what are the two types of die casting?
hot chamber
| cold chamber
105
in die casting, what metals are usually used?
non ferrous- as it's usually the iron in ferrous metals, that needs heat to melt the metal.
106
what is duplex board usually used for? how it's made? and what are it's properties?
cardboard packaging. (cereal boxes) it will be die cut and it has white outer layer, and a brown inside. the white can easily be printed onto.
107
when rendering what paper would you use?
bleed proof paper/ layout paper.
108
what is Ureaformaldhyde used for? (thermosetting polymer)
used for plug sockets- it is a very good insulator, and good stiffness.
109
describe 5 points about plywood?
...veneers of wood.
... alternative layers at a 90 degree angle.
... alternative faces on outer side.
... can be steam bent.
... can be laminated, for protection.
... man made, so can be made into much bigger sections.
110
what does FSC stand for, with the tree symbol?
Forest Stewardship Council, showing that these trees have been protected and planting more.
111
describe the process of Press forming?
the metal sheet is held into place by clamp plates. The top section (Die) is pressed onto the sheet to take up the shape of the bottom section (Bolster).
112
properties of polypropylene?
food safe, impact resistant, light weight, good chemical resistant.
113
what polymer would you use for food packaging I.e. fruit and why?
PET- food safe, good moisture/water barrier, good chemical resistance.
114
describe the process of sand casting?
it creates clamps, vices, and metal (it has a rough finish). there are two halves, which combined to become one. there is highly impacted sand in both, as it is an insulator to heat. the wooden "pattern" which acts as the mould for the molten metal. there is then molten metal poured into the riser which flows vertically down into the pattern. there is also a runner where excess metal comes out of, it is then cooled down and both of these are snapped off.
115
give 2 applications why plastics are biodegradable?
...natural recyclable, no excess costs in needed to decompose of the material (i.e. no energy required).
... reusable, plastics can be made into something else..
116
what can an application be for a thermo chromic sheet (smart material)?
baby bath indicator
| measuring someone's temperature
117
give 3 example of what stainless steel could be used for?
cutlery, kitchen sink etc.
118
give an example of what the hazardous to health symbol could be (fish and tree)?
mainly dangerous chemicals such as solvents, paints, varnishes etc.
119
give 2 reasons why rotational moulding is good?
creates large hollow products.
can be made in mass production.
no waste involved, as polymers are put straight into the mould.
120
if you were making a sink or a similar product out of metal (stainless steel) how would it be manufactured?
it would be press formed. the blank would be created, and then pressed into the shape of the sink.
