PRODUCT DESIGN (EDEXCEL) 2016 SPEC. Flashcards
CAM
What does CAM do?
CAM converts drawings done on CAD to actual products
CAM
give a disadvantage of CAM
It can be expensive to set up
CAM
CAM involves a range of machines, name some of these machines
Laser cutter
Lathe
Milling machine
Routers
HARDENING
what is hardening?
Hardening is when the work is heated until red hot and then plunged into water
MILD STEEL
what is mild steel an alloy of?
Mild steel is an alloy of iron and carbon
MILD STEEL
what is the carbon content of mild steel?
0.15 - 0.30 % carbon
MILD STEEL
what are some properties of mild steel
Ductile
Malleable
Tough
High tensile strength
LCD
what are liquid crystals?
They are organic carbon-based compounds
LCD
what happens to liquid crystals when voltage is applied on them, and light falls onto it?
The LCD appears dark
LCD
what are LCD screens used in
Phones
Computers
TV’s
Smart watches
HEAT TREATMENT. ANNEALING
what does annealing do?
Annealing relieves internal stress in non-ferrous metals that allows them to work again
WORK HARDENING
What is work hardening?
Work hardening is when a non-ferrous metal is cold worked by being bent, hit or shaped over time
WORK HARDENING
After the desired shape is made. What needs to be done to harden the object?
The object needs to be plannished, this means to gently hit the work with a hammer
HEAT TREATMENT. ANNEALING
Give an advantage to annealing
The work is easily manipulated
HEAT TREATMENT. ANNEALING
Give a disadvantage of annealing
The material can be worked too much this can make the work split
ANNEALING ALUMINIUM
List the steps for annealing aluminium
1 - apply soap to the aluminium
2 - heat gently until the soap turns black
3 - remove from heat source using tongs and allow to cool
4 - run under water to remove the soap
ANNEALING ALUMINIUM
Why is soap applied to aluminium for annealing
Soap is applied as a temperature indicator
ANNEALING COPPER
list the steps for annealing copper
1 - heat in heat source until it turns dull red 2 - remove from heat source with tongs 3 - allow to cool 4 - place in acid bath to remove oxides 5 - run under tap to remove acid
TEMPERING
what is tempering?
Tempering is when the work is heated gradually until red hot then put into water
TEMPERING
What colour do the oxides go on the steel?
Yellow Dark yellow Brown Purple Dark purple Blue
TEMPERING
What temperate is it the hardest
230 degrees Celsius
TEMPERING
what temperate is it the toughest
300 degrees Celsius
CNC MACHINES
list the steps setting up a CNC machine
1 - clean all work surfaces 2 - load tools required 3 - set up vise 4 - set work fixture offsets 5 - set tool length by loading tool into spindle 6 - enter diameter offset if needed 7 - adjust coolant lines not too close 8 - start machine
KILN SEASONING
what does kiln seasoning do to the wood
It kills off any bugs and ensures the moisture content is the same throughout
KILN SEASONING
what is kiln seasoning
Kiln seasoning is the process of artificially removing excess moisture from planks of timber
KILN SEASONING
give an advantage of kiln seasoning
It’s quick controlled method
KILN SEASONING
give a disadvantage of of kiln seasoning
It can be expensive
ALLOYS
what are alloy metals?
Alloy metals are metals that have been created by mixing two or more metals
ALLOYS
what is the purpose of adding elements of other metals to another?
To enhance the properties
ALLOYS
what is the alloy of stainless steel?
Steel and chromium
QUALITY ASSURANCE
what is quality assurance?
Quality assurance is when the manufacturer monitors the quality of a product
QUALITY ASSURANCE
What is monitored during quality assurance?
The quality of the product from design and development stage to manufacture and end use
QUALITY CONTROL
what is quality control?
Inspecting and testing a product
QUALITY CONTROL
What is inspection?
Inspecting is inspecting products produced to specified tolerance during or after production
QUALITY CONTROL
give the three types of inspection and explain then briefly
100% inspection - whole batch is inspected
Normal inspection - sampling plan to inspect
Reduced inspection - sampling plan but with smaller sample size
COMPUTER-AIDED INSPECTION
What is computer-aided inspection?
A CMM mechanical system that measures sizes and proportions of features of mechanical parts
RISK ASSESSMENTS
List the steps to completing a risk assessment
Remember - IWAMR (I will always make risks)
1 - identify the hazards - anything hazardous
2 - who would be harmed - identify how it would happen
3 - assess risks and take action
4 - make record of findings
5 - review risk assessment
WORK HARDENING
is work hardening cold working or hot working?
Cold working
WORK HARDENING
What is work hardening?
When non-ferrous metals are cold worked by being bent, hit or shaped over a period of time
WORK HARDENING
after the desired shape is made, what needs to be done to harden the object?
The work needs plannished - this is gently hitting it with a hammer
WORK HARDENING
Give an advantage of work hardening
It can be easily manipulated
WORK HARDENING
Give a disadvantage of work hardening
The work can be hardened too much and eventually the work will split
HARDENING
give the process for hardening
1 - heat the work until red hot then plunge into water (making the steel cool quick)
2 - this makes the steel brittle
HARDENING
what is the procedure after hardening?
Tempering is done after hardening
TEMPERING
what is tempering?
work is heated gradually until red hot then plunged into water. Becomes harder but more brittle
TEMPERING
what colours do the oxides go on the steel
Yellow Dark yellow Brown Purple Dark purple Blue
TEMPERING
what temperate is the steel the hardest
230 degrees Celsius
TEMPERING
what temperate is steel the toughest
300 degrees Celsius
EXTRUSION
explain the process of extrusion
When plastic is is pushed through a 2D die of a desired cross section
EXTRUSION/INJECTION MOULDING
What are some sections that can be made in extrusion / Injection moulding - draw these in 3D
T U L I
EXTRUSION
What products are made through extrusion
Bottles Bars Tubing / piping Rods Window frames
EXTRUSION
List 5 plastics that can be used for extrusion
Polyethylene Polystyrene Polypropylene Polyvinyl Chloride Polycarbonate
JUNIOR HACKSAW
how many teeth per 25mm do they usually have?
32 teeth
JUNIOR HACKSAW
what are junior hacksaws used for?
They are used for general use. Smaller objects
JUNIOR HACKSAW
how is the blade held in a junior hacksaw?
The blade is held in tension by a sprung steel frame
METAL WORKING SAWS - HACKSAW
how many teeth per 25mm do they usually have?
25 teeth
METAL WORKING SAWS - HACKSAW
What are hacksaws used for?
They are used for general purpose
METAL WORKING SAWS - HACKSAW
What way must the teeth face?
They must face away from the handle
CONVERSION - Through and through (slab) conversion
What is slab conversion?
After the tree has been felled it is when it is cut along the length of the log
CONVERSION - Through and through (slab) conversion
What is the result of slab conversion?
Parallel planks of timber
CONVERSION - Through and through (slab) conversion
Give an advantage of slab conversion
It is the cheapest method. There is little waste
CONVERSION - Through and through (slab) conversion
Give a disadvantage of slab conversion
The planks produced are prone to distorting and warping
PVC
what does PVC stand for?
Polyvinyl chloride
PVC
give some properties of PVC
It has good chemical resistance, it is weather resistant. It is stiff, tough, hard and lightweight
PVC
give some disadvantages
PVC becomes brittle. UV makes it brittle
PVC
give some applications of PVC
Pipes
Guttering
Floor covering
Electrical wiring covering
PVC
is it a thermoplastic or thermosetting?
Thermoplastic
CONVERSION - Quarter sawn conversion
What is quarter sawn conversion?
When the log is cut into annual rings which are short as possible
CONVERSION - Quarter sawn conversion
How is the wood cut?
The wood is cut in rings
CONVERSION - Quarter sawn conversion
Give an advantage of quarter sawn conversion
The wood produced is higher quality. The wood has a reduced chance of twisting and cupping
CONVERSION - Quarter sawn conversion
Give a disadvantage of quarter sawn conversion
It is expensive as there is more waste
DURALUMIN
what is it an alloy of
Copper
Aluminium
Manganese
DURALUMIN
give some properties
Lightweight but strong
DURALUMIN
give a disadvantage of duralumin
The work hardens
DURALUMIN
Give some applications
Aviation industry
Automobile industry
NORMALISING
what is normalising
It is the process of returning already hardened ferrous metals to their unhardened state
NORMALISING
To what degrees Celsius is the steel heated at
900 degrees Celsius
CONVERSION
what is conversion
Converting felled trees to usable planks of wood
CONVERSION
name the two types of conversion
Through and through conversion
Quarter sawn conversion
FERROUS METALS
what is a ferrous metal?
A ferrous metal is a metal that contains iron
FERROUS METALS
give some examples of ferrous metals
White cast iron Grey cast iron Mild steel Medium carbon steel High carbon steel
CARBON STEEL
what is the carbon content of medium carbon steel?
Medium = 0.30 - 0.70 %
CARBON STEEL
what is the carbon content of high carbon steel?
High = 0.70 - 1.40 %
PLYWOOD
what is plywood manufactured from?
Layers of veneers that are bonded with glue
PLYWOOD
how is plywood made to be strong / stable
It’s made to be strong by placing the veneers on top of each other with the grain at 90degrees above and below
PLYWOOD
what happens to plywood if it gets wet?
The veneers can delaminates and come apart
PLYWOOD
what are some applications of plywood?
Flat pack furniture
Flooring
School workshops
PLYWOOD
how thick are the veneers usually?
They are usually 1mm thick
NATURAL SEASONING
what is natural seasoning?
It is allowing the planks of timber to dry out at their own pace
NATURAL SEASONING
give an advantage of natural seasoning
It is the cheapest method
NATURAL SEASONING
give a disadvantage of natural seasoning
It takes a long time. Can take up to five years
SEASONING
what is seasoning?
The removal of excess moisture from timber after conversion
SEASONING
Give the two types of seasoning
Kiln
Natural
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Jigs, what are they used for?
Jigs are used for producing a hole in exactly the same position every time
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
why are jigs good? what is one of their advantages?
because if the markings were done manually, it would take a long time and inaccuracies would creep in
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Why are jigs used? Why are they useful when doing cutting processes?
They ensure that components are all the same size and are all identical
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Patterns - what are patterns?
patterns are replicas of products
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Patterns - what kind of of job is it to produce patterns? and why?
it is a highly skilled job, this is because many factors need to be considered when making patterns
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Patterns - what should be taken into consideration when making patterns?
consideration of cores and holes that may be required in the finished product
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Patterns - what are they usually made from?
wood
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Formers - what are formers used for?
they are used for processes such as vacuum forming and laminating
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Formers - what are formers?
formers are shapes that a material can be bent or formed around to create components
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Formers - when are formers used? and how?
they are used in vacuum forming. the former is placed into the vacuum and a thermoplastic is heated and then atmospheric pressure forces the plastic around the former
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Formers - what is an advantage of using formers?
they can be used to create innovative work
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Formers - what is a disadvantage of formers?
using formers for complex constructions can be difficult to handle
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - what are moulds described as in processes of casting, injection moulding and blow moulding?
moulds are the ‘negative’ in these processes
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - what is a mould?
a mould is where a molten metal or plastic is poured or forced in to make the desired shape
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - how do moulds work?
molten metals or plastics are poured of forced into the mould, creating the desired shape
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - what are moulds made from in casting?
sand or hardened steel
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - how many times are moulds used in sand casting?
they are used once, then are reconstituted or discarded
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - how many times are moulds used in die casting and injection moulding
it is used over and over again
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - what is a disadvantage of using the moulds again?
if mistakes are made, then the process of manufacturing will have to be repeated and will cost the business a lot of money
MANUFACTURING TECHNIQUES FOR MASS PRODUCTION
Moulds - what kind of job is producing and designing moulds for die casting and injection moulding?
it is a highly skilled job as it is complex
JOINING TECHNIQUES
Nuts, bolts and washers - what sizes are bolts?
bolts come in various sizes, length and diameter wise
JOINING TECHNIQUES
Nuts, bolts and washers - how are bolts tightened and undone?
they are tightened and undone using a spanner
JOINING TECHNIQUES
Nuts, bolts and washers - what are washers?
thin disks of metal usually, but sometimes they are made from plastic
JOINING TECHNIQUES
Nuts, bolts and washers - what is the other name for a washer?
a spacer
JOINING TECHNIQUES
Nuts, bolts and washers - what are washers used for?
they are used for methods of sealing in liquid and gases. they can also be used for locking nuts into position
JOINING TECHNIQUES
Rivets - what are rivets?
rivets are permanent mechanical fasteners
JOINING TECHNIQUES
Rivets - what are the two forms of rivets?
solid rivets and pop rivets
JOINING TECHNIQUES
Rivets - snap rivets, what are these?
snao rivets are round head rivets, they come with a snap and a set
JOINING TECHNIQUES
Rivets - what are the 6 steps to snap riveting?
1 - mark out all positions. drill the holes in material in these positions
2 - clean off any burrs and waste material
3 - place rivet through holes, support round head of rivet in snap which has been secured in vice
4 - check length of shaft of the rivet. there should be 1 1/2 times the diameter above the work to be joined
5 - using ball pein hammer to shape rivet into round head
6 - finish off using snap and hammer to make the rivet a smooth round shape
JOINING TECHNIQUES
Rivets - countersunk head rivets, when are these used?
they are used when it is important for the head of the rivet to be flush to the material it is joining
JOINING TECHNIQUES
Rivets - what are the 7 steps to countersunk riveting?
1 - drill holes through material in desired positions on both outside faces of the join
2 - remove burrs and waste
3 - place rivets into hole and press metal to be joined together
4 - place countersunk head on flat metal surface
5 - hit rivet with flat surface of hammer, to swell the rivet
6 - using ball pein hammer, force rivet into countersunk
7 - finish off with flat face of hammer, smooth off with file
JOINING TECHNIQUES
Rivets - pop rivets, when is pop riveting used?
when both sides of the work is either unpractical to get to or impossible
JOINING TECHNIQUES
Rivets - how does pop riveting work?
pop rivet guns are used.
a pop rivet is placed in the holes in the work, and the gun is used to pull the mandrel through the rivet, as this is being pulled the inner side of the rivet is begins to expand, pulling the two sheets of metal together
JOINING TECHNIQUES
Rivets - what are the two forms of solid rivets?
snap (round head) and countersunk head
JOINING TECHNIQUES
Rivets - pop rivets, only come in one form, what size are they?
they are various sizes
JOINING TECHNIQUES
Rivets - what is a mandrel?
a mandrel is a piece of wire running through the centre of a pop rivet
JOINING TECHNIQUES
Welding - what is welding?
a method to join metal
JOINING TECHNIQUES
Welding - what are the two types of welding?
oxyacetylene welding and arc welding
JOINING TECHNIQUES
Welding - what material is the most commonly welded?
steel
JOINING TECHNIQUES
Welding - what does MIG welding stand for?
Metal inert gas
JOINING TECHNIQUES
Welding - what is MIG welding?
form of electric arc welding. an electric current is started, an arc is struck between the work and electrode, and used as a hear source, gas is flowed onto the work to keep oxygen away from the joint to prevent oxidation
JOINING TECHNIQUES
Welding - during welding, why is inert gas flowed into the work?
to prevent oxygen from getting to the joint, essentially preventing oxidation
JOINING TECHNIQUES
Welding - what gas is ‘inert gas’ usually?
argon
JOINING TECHNIQUES
Brazing - what is joined using brazing?
mild steel to mild steel
JOINING TECHNIQUES
Brazing - how does brazing work?
Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint
JOINING TECHNIQUES
Brazing - what is spelter an alloy of?
copper and zinc
JOINING TECHNIQUES
Brazing - what is the melting point of spelter?
875 degrees Celcius
JOINING TECHNIQUES
Brazing - before brazing, what should the engineer do?
clean the joint area with an emery cloth, and then apply a flux where the join will be
JOINING TECHNIQUES
Nuts and bolts - give an advantage and disadvantage of nuts and bolts
They can be applied and removed an infinite number of times
they are prone to vibration
JOINING TECHNIQUES
Nuts and bolts - give an application to nuts and bolts
they are used in engineering situations when a joint needs to be undone
JOINING TECHNIQUES
Pop and snap rivets - give an advantage and disadvantage of snap rivets
they are a good strong joint
there needs to be access to both sides of the work for the join to be created
JOINING TECHNIQUES
Pop and snap rivets - give an advantage and disadvantage of pop rivets
can be applied from one side of the work
they are weak compared to snap rivets
JOINING TECHNIQUES
Pop and snap rivets - give an application of snap rivets
enigneering situations whenva permanent join is required
JOINING TECHNIQUES
Pop and snap rivets - give an application of pop rivets
joining thin sheets of metal
JOINING TECHNIQUES
Brazing - when preparing the metal for brazing, a flux is applied, what are the 2 purposes of applying a flux?
it prevents oxidation, by forming a barrier between the work and the atmosphere
a flux also breaks down the tension on the molten spelter and allows it to flow between the two pieces being joined
JOINING TECHNIQUES
Brazing - when a metal is undergoing brazing, what is the degrees Celsius when the joint starts to form?
875 degrees
JOINING TECHNIQUES
Brazing - when the brazing is finished, what is cleaned and removed?
the joint, traces of the flux needs to be removed
JOINING TECHNIQUES
Hard Soldering - what is hard soldering similar to?
brazing
JOINING TECHNIQUES
Hard Soldering - when is hard soldering used most commonly?
when joining copper and jewelry
JOINING TECHNIQUES
Hard Soldering - why is a flux required for hard soldering?
to allow the solder to flow and help prevent oxidation
JOINING TECHNIQUES
Hard Soldering - what is the melting temperature of hard soldering?
625 - 800 degrees Celsius
JOINING TECHNIQUES
Welding - give an example of oxyacetylene welding
oxygen and acetylene gases are mixed in a gas torch and then ignited as a source of heat. a filler rod of the same material is added to complete the joint.
JOINING TECHNIQUES
Welding - give an example of arc welding
using an electric current, an arc is struck between the work and the electrode and is used as a heat source. a flow of inert gas is blown over the joint area to keep oxygen away
JOINING TECHNIQUES
Welding - give an advantage and disadvantage of welding
the weld is as strong as parent metal.
there can be safety issues with gas welding and MIG welding
JOINING TECHNIQUES
Welding - give two applications of welding
general engineering
automotive engineering
JOINING TECHNIQUES
Brazing - give an advantage and disadvantage to brazing
it makes a good general purpose joint
care is needed when undertaking the braze to ensure the joint is clean and oxides do not form, creating a weak joint
JOINING TECHNIQUES
Brazing - give an application of brazing
general engineering
JOINING TECHNIQUES
Hard Soldering - give an advantage and disadvantage of hard soldering
relatively low temperatures needed
it is a weak joint, it does not withstand stress
JOINING TECHNIQUES
Hard Soldering - give an application of hard soldering
decorative metalworking
JOINING TECHNIQUES
Chemical Joints - what are the 2 types of chemical joints
tensol cement
polystyrene cement
JOINING TECHNIQUES
Chemical Joints - tensol cement, what is it used to join?
thermoplastics
JOINING TECHNIQUES
Chemical Joints - what happens when tensol cement comes into contact with a thermoplastic?
the tensol cement literally melts the material
JOINING TECHNIQUES
Chemical Joints - how does joining materials work with tensol cement?
tensol cement is applied to both joining areas and then they are pushed together
JOINING TECHNIQUES
Chemical Joints - how long should a join be clamped together with tensol
24 hours
JOINING TECHNIQUES
Chemical Joints - what does a tensol cement join result in?
a permanent joint
JOINING TECHNIQUES
Chemical Joints - how should tensol cement be used and why?
it should be used with caution as it gives off fumes it can be regarded as a hazardous substance
JOINING TECHNIQUES
Chemical Joints - polystyrene cement, how does polystyrene cement work?
it melts the surface of the plastic being joined and it allows for the two components to be joined together
JOINING TECHNIQUES
Chemical Joints - what can only be joined using tensol cement and polystyrene cement?
only thermoplastics
JOINING TECHNIQUES
Chemical Joints - why can only thermoplastics be joined with tensol and polystyrene cement, and not thermosetting?
thermosetting plastics will not melt so cannot be joined with a chemical weld
JOINING TECHNIQUES
Chemical Joints - tensol cement, give an advantage and disadvantage
it gives an excellent bond when joining acrylic
it gives off strong fumes
JOINING TECHNIQUES
Chemical Joints - tensol cement, give an application
joining acrylic
JOINING TECHNIQUES
Chemical Joints - polystyrene cement, give an advantage and disadvantage
gives an excellent bond when joining two pieces of polystyrene
it must be applied with care to avoid melting the polystyrene
JOINING TECHNIQUES
Chemical Joints - polystyrene cement, give an application
joining polystyrene
JOINING TECHNIQUES
Adhesives - what are 4 types of adhesives
PVA
Epoxy resin
hot melt glue
contact adhesives
JOINING TECHNIQUES
Adhesives - what is the most widely used wood glue?
PVA
JOINING TECHNIQUES
Adhesives - what does PVA stand for?
polyvinyl acetate
JOINING TECHNIQUES
Adhesives - what does PVA look like?
a thick white viscous liquid
JOINING TECHNIQUES
Adhesives - before applying PVA, what issues need to be addressed?
the wood surfaces need to be cleaned and they need to match each other with no gaps
JOINING TECHNIQUES
Adhesives - what may happen if PVA gets on some wood accidentally?
it will stain the wood
JOINING TECHNIQUES
Adhesives - how long does PVA take to harden?
approximately 24 hours
JOINING TECHNIQUES
Adhesives - when using a clamp, what should be put in between the jaw and the work?
a piece of scrap wood
JOINING TECHNIQUES
Adhesives - what are the 2 most common clamps used in woodworking?
G clamps and sash clamps
JOINING TECHNIQUES
Adhesives - epoxy resin, what is this used on?
almosy any material
JOINING TECHNIQUES
Adhesives - epoxy resin is mixed with another element, what is this called?
a catalyst
JOINING TECHNIQUES
Adhesives - what happens when the resin and catalyst is mixed together?
a chemical reaction occurs
JOINING TECHNIQUES
Adhesives - when epoxy resin and a catalyst is mixed together, a reaction occurs, is this reaction reversible?
no it is not reversible
JOINING TECHNIQUES
Adhesives - using epoxy resin, what is the method for using it?
equal quantities of the epoxy resin and the catalyst and squeezed out and mixed together. a paste is made. then it is applied to the material and the join is made. pressure has to be applied to joint area
JOINING TECHNIQUES
Contact Adhesives - what are they made from?
a natural rubber and polychloroprene (neoprene)
JOINING TECHNIQUES
Contact Adhesives - when are these useful?
in situations where ,materials like laminates need to be glued to flat surfaces
JOINING TECHNIQUES
Contact Adhesives - before using contact adhesives what has to be checked?
the surfaces being bonded are clean and free from dust
JOINING TECHNIQUES
Contact Adhesives - how should contact adhesives be applied?
they should be applied thinly and onto both joining surfaces
JOINING TECHNIQUES
Contact Adhesives - how can you tell if it is dry enough to start the bonding
it will feel dry to the touch
JOINING TECHNIQUES
Contact Adhesives - why must contact adhesives be used in well-ventilated areas?
they give off toxic fumes
JOINING TECHNIQUES
Hot melt glue - what material is the glue?
thermoplastic adhesive
JOINING TECHNIQUES
Hot melt glue - what form does the glue come in?
cylinders that are various sizes
JOINING TECHNIQUES
Hot melt glue - what are glue guns useful for?
small model making tasks
JOINING TECHNIQUES
Hot melt glue - what is one safety hazard of using hot glue guns?
the glue is very hot when melted and will stick to skin if it comes into contact and will cause blistering
HEAT TREATMENTS
Normalising - what metals undergo normalising?
ferrous metals
HEAT TREATMENTS
Normalising - what does normalising do?
returns already hardened metals to their unhardened state
HEAT TREATMENTS
Normalising - when medium/high carbon steel has been hardened, how will it be brought back to its unhardened state?
the steel is heated until cherry red 900 degrees hot. it is then allowed to cool down
HEAT TREATMENTS
Normalising - when normalising metals, the ‘redness’ from heating the metal will quickly go away, what is the safety hazard surrounding this?
the metal will still be very hot from heating it up
FAULTS IN WOOD
Cupping - when does cupping occur?
when the timber is bent across the grain
FAULTS IN WOOD
Cupping - why does cupping occur?
the varying length of annual rings causes the wood to dry out at varying speeds
FAULTS IN WOOD
Twisting - when does twisting occur?
when timber is taken from the centre of the tree, there is a spiral grain
FAULTS IN WOOD
Splitting - when does splitting occur?
when the grain of the timber seperates
FAULTS IN WOOD
Splitting - where does splitting occur?
it is usually at the end of the plank of wood
FAULTS IN WOOD
Knots - what is a knot in timber?
knots are where the branches were attached to the tree
FAULTS IN WOOD
Knots - what sometimes happens with the knots in timber?
sometimes they become loose and fall out
COMPUTER AIDED DESIGN
What is the short term for Computer Aided Design?
CAD
COMPUTER AIDED DESIGN
Give 2 advantages of 2D design
any modifications to a 2D design can be done quickly.
various components can be drawn and joined together on screen, enabling in-depth design
COMPUTER AIDED DESIGN
How can 2D designs be stored?
they are stored electronically
COMPUTER AIDED DESIGN
Give 2 disadvantages of 2D design
they are expensive
the people who use the CAD systems been extensive training before they can understand and operate the system
3D MODELLING
Why is 3D modelling used?
3D models can give more realistic impressions than a 2D design
3D MODELLING
Give an advantage of 3D modelling
you can see clearly around an object at 360 degrees
3D MODELLING
Give a disadvantage of 3D modelling
the cost to set up is expensive
MODELLING AND PROTOTYPING
Block Modelling - why is block modelling useful?
it helps determine the shape, dimension and surface of the product by constructing an accurate representation of a final product
MODELLING AND PROTOTYPING
Block Modelling - when is it often used?
often used in advertising and photographs in brochures
MODELLING AND PROTOTYPING
What does block models not have compared to the real product?
they have no working or moving parts
MODELLING AND PROTOTYPING
How are block models produced? what is an advantage of this?
they are produced using cells and sub-cells. this means they can be produced to a very high level of detail
MODELLING AND PROTOTYPING
what is block modelling useful for?
they are useful when determining the ergonomic factors to products
MODELLING AND PROTOTYPING
What is the main disadvantage of block modelling?
the set up cost
MODELLING AND PROTOTYPING
Give an advantage and disadvantage to 2D designing and mortification
highly accurate drawings
hoever high set up costs
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality assurance - what are quality assurance systems?
quality assurance systmes are activities used bu the manufacturer to monitor the quality of a product from its design to development stage
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality assurance - what is the short term for quality assurance?
QA
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality assurance - quality assurance ensures what?
it ensures aproduct is fit-for-purpose
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality assurance - what does quality assurance give to customers and external stakeholders?
it supplies then with fact-based evidence so they know the product meets their neefs and expectations
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - what is quality control?
quality control i a part of quality assurance that involves inspection and testing of a product, during or immediately after production
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - when is quality control done?
during prduction or immediately after
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, what is checked through inspection?
inspection is when the manufactured products are inspected to see if they have been produced to specified tolerance.
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, what are the three main levels of inspection?
100%
normal inspecton
reduced inspection
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, what is 100% inspection?
100% inspection is when the whole batch is inspected
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, what is normal inspection?
there is a sampling plan for inspection
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, what is reduced inspection?
there is another sampling plan used, it is smaller sample sizes
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - inspection, computer aided inspection, what is this?
CAM is when a coordinate measuring machinr is used to measure the dimensions of the product
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - Testing, what is testing concerned with?
it is concerned with the products performance
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - Testing, what are the two main types of testing?
non-destructive testing
destructive testing
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - Testing, non-destructive testing, what happens during this type of testing?
the product is tested until is shows signs of failing, for example the material cracks
it is used to determine how much force is needed to deform it
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control - Testing, destructive testing, what happens during this type of testing?
when the product is destroyed under controlled conditions to gather valuable data
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - what is flat pack furniture manufactured from?
sheet material such as chipboard
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - what can flat pack furniture be affected by?
damp or humid conditions
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - before manufacturing, how must the chipboard be stored?
chipboard must be stored in a stable environment
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what is this in short term?
TQM
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what is this also sometimes referred as?
Total Quality Control
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what is this?
it is a strategic integrated system for achieving customer satisfaction by applying quality assurance procedures at every stage of the production process
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - give an example of TQM
a production team must produce a high-quality component that the assembly team know is quality assured and will fit perfectly
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - what is the possible quality control check for veneer bubbles?
when veneer is put onto sheet material there is a chance that the veneer does not stick and bubbles will occur between the sheet and veneer of chipboard.
QC = check and make sure the glue covers the whole surface of the chipboard and when placed in vacuum pack, the vacuum is complete
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - what is the possible quality control check for cut edges that are not straight?
it is vital that the furniture fits together, so all the edges need to be straight, if they are not the edges will not butt up to each other.
QC = periodically check that all guides and fences on machines are set to correct size and distance
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Quality control in production of flat pack furniture - what are the possible quality control checks for holes that are not positioned?
if holes are not positioned correctly n flat pack furniture then nothing will fit together properly
QC = checking jigs are vital for accurate assembly of the product
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what is the British Standards Institute?
in the UK, the British Standards are developed together with the UK Government, businesses and society. Some are enforced by regulation but most standards are voluntary
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what is the short term for the British Standards, Institute?
BS
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what are the benefits of the BSI for owners and investors?
increased return on investment
improved operational results
increased profits
QUALITY ASSURANCE AND QUALITY CONTROL SYSTEMS
Total quality management - what are the benefits of the BS for society?
improved health and safety
reduced environmental impact
increased security
HEALTH AND SAFETY
when was the Health and Safety at Work Act brought out?
1974
HEALTH AND SAFETY
The Health and Safety Act ensures employers are legally required to do what?
they are legally required to do all that is reasonably practicable to ensure health and safety and welfare at work of employees. and the health and safety of visitors and students etc
HEALTH AND SAFETY
What does PPE stand for?
Personal and Protective equipment
HEALTH AND SAFETY
what does the PPE act state?
employers have basic duties concerning the provision and use of personal protective equipment
HEALTH AND SAFETY
when was the PPE act brought out?
1992
HEALTH AND SAFETY
how is the PPE act defined?
it is defined as “ all equipment (including clothing providing protection against the weather) which is intended to be worn or held by a person at work which protects them against one or more risk to their health or safety”
HEALTH AND SAFETY
what do the regulations of PPE require?
they require that PPE is properly assesses to ensure it is suitable.
maintained and stored properly
provided with instructions on how to use it safely
used correctly by employees
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for eyes?
Hazards: chemical or metal splash, dist, projectiles, gas, vapor and radiation
PPE: safetly spectacles, goggles, face shields, visors
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for your head?
Hazards: impact from falling or flying objects, risk if head bumping, hair entanglement
PPE: range of helmets and bump caps
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for breathing?
Hazards: dust, vapour, gas, oxygen-deficient atmospheres
PPE: disposable filtering face piece, respirator, breathing apparatus
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for protecting the body?
Hazards: temperature extremes, weather, chemical and metal splash, spray from pressure leaks, impact or penetration
PPE: conventional or disposable overalls, boiler suits, high visibiltiy clothing
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for for hands and arms?
Hazards: abrasion, temperature extremes, cuts, punctures, chemicals, electrical shock
PPE: gloves, gauntlets, mitts, wrist cuffs
HEALTH AND SAFETY
There are some risks at work, these have hazards and some PPE to help reduce the risks, what is this for feet and legs?
Hazards: wet, slipping, cuts, falling objects, chemical splash
PPE: safety boots, shoes with toe caps, gaiters, spats, leggings
HEALTH AND SAFETY
When were the Safety Signs regulations brought out?
1996
HEALTH AND SAFETY
what do health and safety sings ensure?
employers are informed of a risk or harm, a sign means that the risk cannot be avoided
HEALTH AND SAFETY
What are prohibition signs?
they are signs to prohibit the actions to prevent personal injury and the risk of fire
HEALTH AND SAFETY
what are mandatory sings?
mandatory signs, convey action that must be taken for example procedures in case of a fire
HEALTH AND SAFETY
what are warning signs?
warning signs are signs to warn personnel of possible dangers in the workplace
HEALTH AND SAFETY
what are safe condition signs?
they show directions to areas of safety and medial assistance and indicate a safe area or where medical equipment is located
HEALTH AND SAFETY
what are fire equipment signs?
show the location of fire equipment and compliance with fire precautions
HEALTH AND SAFETY
warning symbols, what are the importance of these?
they tell employees clearly what needs to be done so there are no accidents and risks are reduced
HEALTH AND SAFETY
where do some warning signs appear?
packaging of adhesives and domestic cleaning products
HEALTH AND SAFETY
What dies the Health and Safety Executive lay down?
the HSE lays down government guidelines to health and safety issues within the work place
HEALTH AND SAFETY
What is the short term of the Health and Safety Executive?
HSE
HEALTH AND SAFETY
what does the HSE stand for?
Health and Safety Executive
HEALTH AND SAFETY
what does the HSE state?
it states that all places to work must carry out risk assessment of their facilities to identify any hazards
HEALTH AND SAFETY
what does the HSE outline as its 5 steps to a risk assessment?
1 - identify the hazard 2 - identify the people at risk 3 - evaluate the risk 4 - decide upon suitable control measure 5 - record risk assessment
HEALTH AND SAFETY
using computers, what are computers used as?
a design tool
HEALTH AND SAFETY
using a computer, what are some potential hazards?
typing and using a mouse
HEALTH AND SAFETY
What is Repetitive strain injury?
Medical condition affecting muscles, tendons and nerves
HEALTH AND SAFETY
what does RST stand for?
repetitive strain injury
HEALTH AND SAFETY
define a hazard
potential risk from a substance, machine or operation
HEALTH AND SAFETY
define a risk
a reality of farm from the hazard
HEALTH AND SAFETY
define a control measure
an action taken to minimize the risks to people
HEALTH AND SAFETY
there is guidance for working safely at a computer, what is the guidance for working safely concerning the environment?
there must be adequate lighting and hat the heat produced by equipment must not cause discomfort to user
HEALTH AND SAFETY
there is guidance for working safely at a computer, what is the guidance for working safely concerning the chair?
the chair must be stable and allow for freedom of movement. the height of the chair and the backrest must be fully adjustable
HEALTH AND SAFETY
there is guidance for working safely at a computer, what is the guidance for working safely concerning the workstation?
the workstation must provide sufficient space for the user to change position and vary movements
HEALTH AND SAFETY
there is guidance for working safely at a computer, what is the guidance for working safely concerning the screen?
the screen must swivel and tilt easily. glare from the screen should be easily adjusted using brightness and contract controls, an anti-glare screen must be fitted
HEALTH AND SAFETY
there is guidance for working safely at a computer, what is the guidance for working safely concerning the keyboard?
the keyboard should be able to tilt to provide a comfortable typing position
HEALTH AND SAFETY
give one example of a risk assessment for using a computer
Hazard: using a computer
Risk: Repetitive strain injury
People at risk: user
Control measure:keyboard should tilt to provide a comfortable typing position
use an ergonomic keyboard with wrist support
use an ergonomic mouse
HEALTH AND SAFETY
give one example of a risk assessment for using a pillar drill
Hazard: using a pillar drill Risk: damage to eyes from flying debris people at risk: user / people in close area control measure: use appropriate PPE User fully briefed on use of machine
HEALTH AND SAFETY
Workshop practices, what would of happened for schools and colleges to ensure the equipment is safe?
they will of carried out a detailed risk assessment for each piece of equipment, this should be clearly displayed for their information
HEALTH AND SAFETY
Control of Substances Hazardous to Health regulations, what is the short term for this?
COSHH
HEALTH AND SAFETY
Control of Substances Hazardous to Health regulations what is this?
regulations place a duty on employers to make an assessment of risk for work involving exposure to substances
HEALTH AND SAFETY
Control of Substances Hazardous to Health regulations, hazardous substances include..
Substances used directly in work activities such as adhesives paints and cleaning agents
Substances generated during work activities such as fumes from soldering or welding
Naturally occurring substances such as dust
Biological agents such as bacteria and other microorganisms
HEALTH AND SAFETY
what does COSHH stand for?
Control of Substances Hazardous to Health regulations
HEALTH AND SAFETY
what is the HSE guidance on COSHH regulations, give the steps, the step and the action
1 - assess risks - assess risks to health from hazardous substances used in or created by workplace activities
2 - decide what precautions are needed -do not carry out work that could expose employees to hazardous substances with out first considering risks and necessary precautions and what else is needed to comply with COSHH
3 - prevent or control exposure - prevent employees being exposed to hazardous substances
4 - ensure control measured are used and maintained - ensure that control measures are used and maintained properly and that safety procedures are followed
5 - monitor exposure - monitor exposure of employees to hazardous substances
6 - carry out appropriate health surveillance - carry out appropriate heath surveillance where assessment has shown is necessary or where COSHH sets specific requirements
7 - prepare plans to deal with accidents and emergencies - carry out appropriate plans to deal with accidents involving hazardous substances
8 - ensure employees are properly informed, trained ans supervised - provide employees with suitable and sufficient information and training
HEALTH AND SAFETY
What does VOC’s stand for?
volatile organic compounds
HEALTH AND SAFETY
Volatile organic compounds give off vapours that can cause what?
dizziness and nausea
HEALTH AND SAFETY
are VOC’s dangerous or not?
yes
HEALTH AND SAFETY
give an example of part of a risk assessment for storage and use of solvent-based adhesives
hazard: use of solvent-based adhesives
Risk: burns from corrosive adhesives
people at risk: user
Control measure: use appropriate PPE including gloves and eye protection. wash area immediately with warm soapy water and seek medical attention
HEALTH AND SAFETY
give an example of part of a risk assessment for storage and use of solvent-based adhesives
hazard: use of solvent-based adhesives
Risk: burns from corrosive adhesives
people at risk: user
Control measure: use appropriate PPE including gloves and eye protection. wash area immediately with warm soapy water and seek medical attention
MATERIALS AND COMPONENTS
define Aesthetic properties
the sensory qualities of a material
MATERIALS AND COMPONENTS
define functional properties
the qualities a material must possess in order to be fit for purpose
MATERIALS AND COMPONENTS
give an example of functional propeties
correct weight and size
MATERIALS AND COMPONENTS
define mechanical properties
A materials reaction to physical forces
MATERIALS AND COMPONENTS
Give an example of mechanical properties
Strength. Plasticity. Ductility. Hardness. Brittleness. Malleability.
MATERIALS AND COMPONENTS
Define plasticity
The ability of a material to return to its original shape once the deforming force has been removed
MATERIALS AND COMPONENTS
Define ductility
The ability of a material to be drawn or stretched
MATERIALS AND COMPONENTS
Define hardness
The ability of a material to withstand indentation, abrasion or scratching
MATERIALS AND COMPONENTS
Define brittleness
The tendency of a material to fracture under stress
MATERIALS AND COMPONENTS
Define malleability
The ability of a metal to be deformed by compression without being torn or cracked
METALS
What are the three main categories that metals can be divided into
Ferrous
Non ferrous
Alloys
METALS
What are ferrous metals?
Metals that contain iron or ferrite
METALS
Give an example of a ferrous metal and what is it made out of
Steel. It is made up from iron with various amounts of carbon
METALS
Why do ferrous metals sometimes have other substances added to them?
To enhance their properties
METALS
Do ferrous metals rust? And are they magnetic?
Ferrous metals rust and are all magnetic
METALS
What is the difference between ferrous and Non-ferrous metals
Ferrous contains iron and non-ferrous does not contain any iron
METALS
Give three examples of non-ferrous metals
Aluminium tin and copper
METALS
Are non-ferrous metals magnetic and do they rust?
They are not magnetic and do not rust
METALS
Alloys. What are they?
Alloys are metals that have been formed by mixing two or more metals
METALS
Alloys. Why are metals sometimes alloyed?
To enhance their properties
METALS
Give 2 examples of metals that are alloys? And why it is an alloy?
Stainless steel is an alloy of steel and chromium
Adding chromium makes steel less prone to rusting
Duralumin is an alloy of aluminium copper and manganese
Makes the aluminium strong as well as lightweight
METALS
Where do all metals originate from?
Some kind of ore or mineral extracted from the earth
METALS
What does the production of all metals include?
Some kind of heating or smelting process
FERROUS METALS
Give three examples of ferrous metals
Cast iron
Mild steel
Carbon steel
FERROUS METALS
cast iron, what are the two types?
White cast iron and grey cast iron
FERROUS METALS
Why is white cast iron not easy to work with?
It is hard and brittle
FERROUS METALS
Why is grey cast iron useful?
It can be cast unto intricate shapes
FERROUS METALS
When is grey cast iron used often?
It is often used for components on machines such as tailstocks on lathes
FERROUS METALS
Give a disadvantage of cast iron?
It is brittle and it will shatter
FERROUS METALS
What are some uses of cast iron?
Cookware and braking systems in cars
FERROUS METALS
Mild steel, what is it an alloy of?
Iron and carbon
FERROUS METALS
The more carbon that is added to the iron, what is the outcome?
The harder the steel becomes
FERROUS METALS
Can mild steel be heat treated?
No
FERROUS METALS
What is the biggest problem with steel?
It rusts
FERROUS METALS
To stop steel from rusting/oxidation what can be done?
What are the two methods?
A barrier needs to be put between the steel and the atmosphere, this can be done by painting the steel
The other method could be galvanisation, a layer of zinc is put over the steel or plastic coating where a thermoplastic is melted over the steel
FERROUS METALS
Carbon steel, what can medium carbon steel be used for ?
Objects such as garden tools
FERROUS METALS
What can high Carbon steels be used for?
Products that need to be harder, such as hammers cutting tools and drills
FERROUS METALS
What is the main disadvantage of carbon steel?
It is a ferrous metal so it is prone to rusting
FERROUS METALS
What is the carbon content of white cast iron?
1.7-2.9%
FERROUS METALS
What are the properties of white cast iron?
Brittle and very hard
Cannot be machined
FERROUS METALS
What are some uses of white cast iron?
Heavy machinery
FERROUS METALS
What so the carbon content of grey cast iron?
2.5-4.0%
FERROUS METALS
What are some properties of grey cast iron?
Can be machined
Easily cast
Corrosion resistant
FERROUS METALS
What are some uses of grey cast iron?
Cast iron cookware
Disk brakes
Components for machines
FERROUS METALS
What is the carbon content of mild steel?
0.15-0.30%
FERROUS METALS
What are some properties of mild steel?
Ductile, tough, malleable
Has high tensile strength
FERROUS METALS
What are some uses of mild steel?
General engineering
Nuts and bolts
FERROUS METALS
What is the carbon content of medium carbon steel?
0.30-0.70%
FERROUS METALS
What are the properties of mild carbon steel?
Harder than mild steel but less ductile and less malleable
FERROUS METALS
What are some uses of medium carbon steel?
Garden tools
Springs
FERROUS METALS
What is the carbon content of high carbon steel?
0.70-1.40%
FERROUS METALS
What are some uses of high carbon steel?
Hammer heads
Drills
Cutting tools
NON-FERROUS METALS
Give three examples of non-ferrous metals
Aluminium
Copper
Zinc
NON-FERROUS METALS
Aluminium, give some properties
It is soft and malleable. It conducts heat and electricity well
NON-FERROUS METALS
Why is aluminium always alloyed?
To enhance and improve its properties
NON-FERROUS METALS
Why is aluminium used a lot in the aircraft industry?
Bc abuse it is very light weight
NON-FERROUS METALS
Give one disadvantage of aluminium
It is very difficult to weld due to its low melting point
NON-FERROUS METALS
Copper, give 4 properties
Malleable
Ductile
Excellent heat conductor
Excellent electricity conductor
NON-FERROUS METALS
Where is copper often used and found?
Household central heating systems and water systems
NON-FERROUS METALS
What is copper often used in
Decorative items such as jugs and kettles
NON-FERROUS METALS
Zinc, what does it have to protect it from oxidation?
An oxide layer
NON-FERROUS METALS
When is zinc often used?
Water tanks and car bodies are dipped in it to prevent oxidation
Used for buckets
NON-FERROUS METALS
What kind of casting is zinc used in?
Die casting
NON-FERROUS METALS
What is melting point of aluminium?
650 degrees Celsius
NON-FERROUS METALS
What are some properties of aluminium?
Lightweight, corrosion resistant, good conductor
NON-FERROUS METALS
What are some disadvantages of aluminium?
It can crack under stress and it requires constant annealing when worked
Does not withstand great loads
NON-FERROUS METALS
Give three uses of aluminium
Aircraft industry
Engine components
Castings
NON-FERROUS METALS
What is the melting point of copper?
1100 degrees Celsius
NON-FERROUS METALS
What are some properties of copper?
Good conductor of heat and electricity
Corrosion resistant
NON-FERROUS METALS
Give two disadvantages of copper
Danger of electrolysis if joined to iron pipes in water systems
When it is worked it requires constant annealing
NON-FERROUS METALS
Give three uses of copper
Electric cables
Central heating
Printed circuits
NON-FERROUS METALS
What is the melting point of zinc?
420 degrees Celsius
NON-FERROUS METALS
What is a property is zinc
Corrosion resistant
NON-FERROUS METALS
What is a disadvantage of zinc
When worked it will become brittle
NON-FERROUS METALS
Give three uses of zinc
Castings
Batteries
Galvanising
ALLOYS
Give three examples of alloys
Stainless steel
Duralumin
Brass
ALLOYS
Why might you alloy a metal?
To make it harder, to make it more resistant to corrosion or to improve machining characteristics
ALLOYS
Stainless steel why is it hard to cut?
Because chromium and nickel is added so it becomes hard
ALLOYS
What composition is stainless steel?
Chromium
Steel
Nickel
ALLOYS
Give one advantage of stainless steel
Corrosion resistant
ALLOYS
Give two disadvantages of stainless steel
Expensive
Hard to cut
ALLOYS
Give three applications of stainless steel
Kitchen utensils, pipes
Medical tools
Chemical and nuclear industries
ALLOYS
What composition is duralumin?
Aluminium
Copper
Manganese
ALLOYS
What are two advantages of duralumin
Lightweight
Strong
ALLOYS
Give one disadvantage of duralumin
Work hardens
ALLOYS
What are two applications of duralumin
Aviation industry
Automobile industry
ALLOYS
What is the composition of brass?
Copper and zinc
ALLOYS
Give three advantages to brass
Casts well
Easy to machine
Good conductor of heat and electricity
ALLOYS
Give two disadvantages of brass
Susceptible to cracking when cold worked
It has to be constantly annealed
ALLOYS
Give four applications of brass
Central heating valves
Electrical components
Ships propellers
Plumbing fittings
PLASTICS
what are the two types of plastic?
thermosetting and thermoplastic
PLASTICS
what is the difference between thermosetting plastics and thermoplastics?
thermosetting plastics can only be heat and shaped once, they are harder to recycle they are made by mixing a resin and a catalyst
thermoplastics can be reheated and softened many times, they can be recycled easily
PLASTICS
thermoplastics, what kind of molecules are they made up from?
thermoplastics are made from long chains of molecules, they are held together buy small cross links
PLASTICS
thermoplastics, how are polymer chains held together?
they are held together by mutual attractions, these are called Van Der Waals
PLASTICS
thermoplastics, what happens to the molecules when heated?
bonds between the molecules weaken and become pliable, once allowed to cool the chains reposition and the plastic becomes hard
THERMOPLASTICS
what are the properties of acrylic?
stiff, hard, durable, easily scratched and a good electrical insulator
THERMOPLASTICS
what are the properties of high density polyethylene
good electrical insulator
chemical resistant
impact resistant
flexible
THERMOPLASTICS
what does HDPE stand for
high density polythylene
THERMOPLASTICS
what are the properties of low density polyethylene
good electrical insulator
chemical resistant
flexible
THERMOPLASTICS
what are the properties of polyethylene therephthalate
good alcohol and oil barrier
chemical resistant
high impact resistant
high tensile strength
THERMOPLASTICS
what are the properties of Polyvinyl chloride
good chemical resistance
weather resistant
stiff tough hard and lightweight
THERMOPLASTICS
what are the properties of polypropylene
light, hard, impact resistant and chemical resistant
THERMOPLASTICS
what are the properties of polystyrene compressed
light hard stiff, brittle, low impact strength
THERMOPLASTICS
what are the properties of polystyrene expanded
buoyant, lightweight, good insulator
THERMOPLASTICS
what are the properties of acrylonitrile butadiene styrene
chemical resistant
hard and tough
THERMOPLASTICS
give 3 disadvantages of acrylic
brittle, can break
scratches easily
splinters easily
THERMOPLASTICS
give 2 disadvantages of HDPE (high density polyethylene)
colour tends to fade over time
can break under stress
THERMOPLASTICS
give 2 disadvantages of low density polyethylene
colour tends to face over time
can break under stress
THERMOPLASTICS
give 2 disadvantages of polyethylene terephthalate
can discolour
when used in containers for foodstuffs, it has to be treated to prevent taste issues
THERMOPLASTICS
give 2 disadvantages of polypropylene
UV light causes degradation
oxidation can be a problem during manufacturing processes
THERMOPLASTICS
give 2 disadvantages of polystyrene compressed
weak and ignites easily
THERMOPLASTICS
give 1 disadvantage of acrylonitrile butadiene styrene
UV light causes degradation
THERMOPLASTICS
give 4 applications of acrylic
lighting
cd cases
car lights
baths
THERMOPLASTICS
give 4 applications of high density polyethylene
water tanks
water pipes
buckets
bowls
THERMOPLASTICS
give 4 applications of low density polyethylene
washing up liquid bottles
dustbin sacks
cable insulation
packaging film
THERMOPLASTICS
give 1 applications of polyethylene terephthalate
fizzy drinks bottles
THERMOPLASTICS
give 3 applications of polyvinyl chloride
electrical wiring insulation
pipes and guttering
floor covering
THERMOPLASTICS
give 3 applications of polypropylene
medical syringes
carpets
kitchenware
THERMOPLASTICS
give 3 applications of polystyrene compressed
CD cases
refrigerator linings
water tanks
THERMOPLASTICS
give 2 disadvantages of polystyrene expanded
crumbles and breaks
easily ignites
THERMOPLASTICS
give 3 applications of polystyrene expanded
packaging
insulation
displays
THERMOPLASTICS
give 2 applications of acrylonitrile butadiene styrene
mobile phones
safety helmets
THERMOPLASTICS
give 2 disadvantages of polyvinyl chloride
can become brittle over time
UV light causes brittleness
THERMOSETTING PLASTICS
what are the 3 properties of epoxy resins
corrosion resistant
electrical resistant
good bond qualities
THERMOSETTING PLASTICS
what are the 2 properties of urea formaldehyde
strong, hard brittle
heat resistant
THERMOSETTING PLASTICS
what are the 2 properties of polyester resin
good electrical insulator
heat resistant
THERMOSETTING PLASTICS
give 2 disadvantages of epoxy resins
can cause allergic reactions
suspected if health problems
THERMOSETTING PLASTICS
give 1 disadvantage of urea formaldehyde
can emit toxic vapours during manufacturing
THERMOSETTING PLASTICS
give 2 disadvantages of polyester resin
brittle
can crack
THERMOSETTING PLASTICS
give 3 applications of epoxy resins
adhesives
paints and coatings
electronics
THERMOSETTING PLASTICS
give 2 applications of urea formaldehyde
electrical fittings
domestic appliance components
THERMOSETTING PLASTICS
give 2 applications of polyester resin
glass reinforced boats and cards
garden furniture
THERMOSETTING PLASTICS
how are the molecules linked?
they are linked side-to-side and end-to-end
THERMOSETTING PLASTICS
what are the links called in thermosetting plastics?
they are called covalent bonds because the bonding is very rigid
HARDWOODS
what kind of trees do hardwoods come from?
they come from broad-leafed trees, the seeds are enclosed
HARDWOODS
what kind of climates to hardwood trees usually grow in?
they usually grow in warmer climates
HARDWOODS
how long do hardwood trees take to reach maturity?
80 - 100 years
SOFTWOODS
What kind of trees do softwoods come from?
they come from cone-bearing conifer trees, they have needles not leaves
SOFTWOODS
how long does a softwood tree take to mature?
around 30 years
SOFTWOODS
give 3 examples of softwoods
scots pine
parana pine
whitewood
HARDWOODS
give 3 advantages of oak
strong hard tough
works well
durable
HARDWOODS
give 3 advantages of mahogany
easy to work
durable
finishes well
HARDWOODS
give 3 advantages of beech
physically hard
tough
polishes well
HARDWOODS
give 4 disadvantages of oak
expensive
heavy
prone to splitting
can be physically hard
HARDWOODS
give 3 disadvantages of mahogany
grain can be variable
prone to warping
physical hardness varies
HARDWOODS
give 3 disadvantages of beech
can be prone to warping
not suitable for outside applications
can be difficult to work
HARDWOODS
give 3 applications of oak
garden furniture
construction
high quality furniture
HARDWOODS
give 3 applications of mahogany
furniture
veneers
floorboards
HARDWOODS
give 3 applications of beech
workshop benches
school desks
furniture
COMPOSITES
what are these?
composites are when 2 or more materials are combined together by a bond
COMPOSITES
what is the result of a composite?
mechanical, functional and aesthetic properties are improved
SOFTWOODS
pine, give 2 advantages of pine
straight grain and easy to work
SOFTWOODS
give 1 disadvantage of pine
knots can make working difficult
SOFTWOODS
give 4 applications of pine
construction
roof joists
floorboards
furniture
COMPOSITES
MDF, why would it be laminated?
to improve strength and aesthetic qualities
COMPOSITES
MDF, what is an advantage of it over wood? for cutting and machining purposes
it has no grain so it does not split or warp
COMPOSITES
why should great care be taken when drilling, cutting or sanding MDF
dust / fibres are produced and can cause irritation to the skin
COMPOSITES
what is MDF used for?
furniture and kitchen units
worktops
COMPOSITES
chipboard, how is it made?
wood particles are glued together under heat and pressure
COMPOSITES
what forms does chipboard come in?
it comes in normal, medium and high density form
COMPOSITES
why is chipboard only suitable for internal purposes?
if it gets wet it will get waterlogged it will swell and break down
COMPOSITES
laminates, how are they made?
it is made by bonding two or more layers of material together
COMPOSITES
what form do laminates come in?
sheet form
COMPOSITES
what are laminates often used for?
they are often used in flat-pack furniture
COMPOSITES
what kind of fittings are uses for laminates and why?
knockdown fittings, these are used because traditional wood joining methods cannot be used
COMPOSITES
plywood, how is plywood manufactured?
manufactured from layers of veneers that are bonded together using glue
COMPOSITES
how thick are the veneers usually?
1mm thick
COMPOSITES
why is plywood very strong and stable?
they are strong because the grain direction is 90 degrees to the sheet above and below
COMPOSITES
how many layers are there in plywood? even or odd numbers?
odd numbers, 3 5 and 7
COMPOSITES
if plywood becomes wet, what will happen?
the layers will delaminate and come apart
COMPOSITES
what are some applications of plywood?
flooring, flat pack furniture, in school workshops
COMPOSITES
blockboard, how is blockboard manufactured?
made up from strips of wood that are usually 25mm wide then covered in veneer and glued together in high pressure
COMPOSITES
why is blockboard only suitable for indoor use?
the glues used are water-based and if it becomes wet it will come apart
MODERN MATERIALS
thermo-ceramics, what are they?
they are advanced ceramic materials that have very good properties that make them useful for engineering purposes
MODERN MATERIALS
thermo-ceramics, how are they so hard?
they have a complex internal structure
MODERN MATERIALS
thermo-ceramics, when are they useful to be used?
in places where there is need for stability and strength at high temperatures
MODERN MATERIALS
thermo-ceramics, give two examples of where thermo-ceramics have been used
turbine blades in jet engines and turbo chargers of racing cars
MODERN MATERIALS
thermo-ceramics, how are they manufactured?
by combining ceramic and metallic powders by sintering. the powders are heated and placed in a die they are subjected to high pressure until the particles bond with each other
MODERN MATERIALS
thermo-ceramics, give two disadvantages of thermo-ceramics
they can be brittle so if they are dropped they can break. they are also very expensive compared to traditional materials
MODERN MATERIALS
photochromic glass, what is photochromic glass?
it is glass that automatically darkens when exposed to UV light
MODERN MATERIALS
photochromic glass, what is photochromic glass mainly used in?
spectacles
MODERN MATERIALS
photochromic glass, how does photochromic glass work?
when it is exposed to UV light the glass darkens then when there is no UV light, the glass clears
MODERN MATERIALS
tinted glass / photochromic glass, what is in the glass that makes it like that?
minute particles of silver halide
MODERN MATERIALS
solar panels, why are they becoming more popular?
we are now looking for renewable sources of energy to replace fossil fuels
MODERN MATERIALS
solar panels, how are they constructed?
thin layers of silicon that have had various impurities added
MODERN MATERIALS
solar panels, how do they work?
one layer of silicon when exposed to sunlight become electron rich. the other layer becomes electron deficient, creating an electron flow and there is a voltage between the layers
MODERN MATERIALS
solar panels, what is a disadvantage of solar panels?
the voltage produced is small so many solar panels are needed
MODERN MATERIALS
solar panels, where are they used widely?
where mains electricity is not readily available
MODERN MATERIALS
liquid crystal displays, what were they widely used in?
laptops and computers
MODERN MATERIALS
liquid crystal displays, what colours are the pixels subdivided into?
green red and blue
MODERN MATERIALS
liquid crystal displays, give a disadvantage of LCD’s
the images in LCD TV’s are sometimes inferior and do not have the same viewing angle as cathode-ray tube TV’s
MODERN MATERIALS
electroluminescent lighting, how does it work?
an organic phosphor is sandwiched between two conductors as an electric current is applied and it emits radiation in the form of visible light
MODERN MATERIALS
electroluminescent lighting, how are they constructed?
paper-thin wires, strips or panels are put onto whee the light wants to be.
MODERN MATERIALS
electroluminescent lighting, what is an advantage of this?
it has low power consumption
MODERN MATERIALS
electroluminescent lighting, what is a disadvantage of this?
organic phosphor materials that are used have limited life span
CUTTING THREADS ON A ROD
how can a thread on a rod be cut?
threads can be cut either by hand or by a metalworking lathe
CUTTING THREADS ON A ROD
what is the most common way to cut threads on a rod?
by hand, this is the quickest and easiest way
CUTTING THREADS ON A ROD
what tools are required for cutting threads on a rod by hand?
a die and a die stock holder
CUTTING THREADS ON A ROD
what is an important factor to consider when cutting threads on a rod by hand?
the die has to be the same size diameter for the bar, eg 10mm die for a 10mm bar
CUTTING THREADS ON A ROD
what are dies manufactured from and why?
high speed steel as it is harder than mild steel so it will easily cut it
CUTTING THREADS ON A ROD
what do you need to make sure of when putting the die onto the rod?
ensure that the die is on the bar squarely, if it is not a ‘drunken thread’ will be created, this means when a nut or screw is put on, the angles will not fit together properly
CUTTING THREADS ON A ROD
what is a method of ensuring the die is square on the bar?
using a tailstock of a centre lathe, set the work in the chuck in the lathe and place the die between the work and tailstock, by hand turn the work until the die begins to cut
SPACERS AND WASHERS
what materials can washers and spacers come in?
high density polyethylene, nylon and steel
SPACERS AND WASHERS
when are these used?
they are used when components need to be separated on a shaft
SCREWS
what are they often used for?
they are used on bicycle gears, to separate the gears
SCREWS
what are machine screws for and what are woodwork screws used for?
machine screws are used for engineering and woodscrews are used for wood
MACHINE SCREWS
what are these usually manufactured from?
they are manufactured from carbon steel
MACHINE SCREWS
what are the two most common heads/tops for machine screws?
cheese head and countersunk head
MACHINE SCREWS
what are countersunk screws used for?
they are used when the head needs to be flush with the metal into which it is screwed
MACHINE SCREWS
what are cheese head screws used for?
cheese heads sit above the metal into which it has been screwed
MACHINE SCREWS
what kind if production are these usually made in?
they are usually mass produced
SCREWS
what are grub screws used for?
special engineering situations
SCREWS
how can they be tightened?
using a screw driver or a machine
SCREWS
what screw drivers are used to tighten screws?
Phillips or pozi-drive
SCREWS
in milling machines, drilling machines and lathes how can machine screws be tightened?
they can be tightened by hexagonal Allen keys
SCALE OF PRODUCTION
What is one-off production?
a production used for one-off items such as tailor made items made to someones specification
SCALE OF PRODUCTION
What is batch production?
production that produces identical products
SCALE OF PRODUCTION
what is mass production?
mass production are products that are made to follow mass market trends
SCALE OF PRODUCTION
what is continuous production?
it is used to manufacture products that meet everyday mass-market needs
SCALE OF PRODUCTION
why are some products mass produced?
so they can meet everyday mass-market
SCALE OF PRODUCTION
what kind of things are produced in continuous production?
fizzy drinks bottles
water bottles
SCALE OF PRODUCTION
give 2 advantages, 2 disadvantages and 1 application of one-off production
they are made to exact specifications. highly skilled crafts person means high quality products.
it is expensive compared to larger scales of production. it is labour extensive and can be time-consuming.
it is used for bespoke pieces of furniture and products
SCALE OF PRODUCTION
give 2 advantages, 2 disadvantages and 1 application of batch production
it is a fast response to market trends. there are lower unit costs than one-off products.
poor production planning can result in large quantities of products having to be stored. frequent changes in production can cause costly re-tooling.
it is used for seasonal garden furniture
SCALE OF PRODUCTION
give 2 advantages, 2 disadvantages and 1 application of mass production
low unit costs and reduced labour costs,
there is a high initial set-up cost due to expensive machinery. it cannot respond quickly to new market trends.
it is used for electronic products, e.g. phones
SCALE OF PRODUCTION
give 2 advantages, 1 disadvantage and 1 application of continious production
very low unit costs and runs continuously 24/7.
there is little flexibility as production is set up 24/7.
it is used for cans and drink bottles
DIE CASTING
what is die casting used to produce?
it produces metal products
DIE CASTING
what is the differences between gravity die casting and pressure die casting?
pressure die casting is when the molten metal is forced into the die via hydralic pressure. gravity die casting is when the molten metal runs freely into the die
DIE CASTING
what are the 5 steps to die casting?
- mould is sprayed with lubricant, helps with removal of cast
- molten metal shot under high pressure into die
- when die is filled, it is still under pressure until it solidifies
- die opens and cast removed by ejector
- gates, runners and rinsers are removed
DIE CASTING
give 2 advantages, 2 disadvantages and 2 applications of die casting
there is a high production rate. there is a good surface finish.
there are high set up costs and there is a long lead time.
die casting produces: taps and model cars
SAND CASTING
give 2 advantages, 2 disadvantages and 2 applications of sand casting
it is inexpensive. complex shapes can be produced.
sand moulds can only be used once. there is a slow production rate.
sand casting produces: engine blocks, garden furniture and caterpillar tracks
MILLING AND ROUTING
what is he process of milling? what is it used to cut?
it is used to cut away metal
MILLING AND ROUTING
what are the differences between milling and routing?
milling cuts metal and routers cut wood, composites and metal
MILLING AND ROUTING
what are the differences between vertical and horizontal milling?
vertical milling, there is a rotating cutter that gets lowered and raised. in horizontal there is a cutter milling the cutter turns right and left, horizontal
MILLING AND ROUTING
what are two important things to consider when milling?
the speed of the cutter and the speed of which the work passes through the cutter
MILLING AND ROUTING
what is a “fence” and what is it used for?
a fence is used to help the router guide into the correct position for when it cuts the work
MILLING AND ROUTING
why do the edges need to be planed before routing?
to ensure that they are square
DRILLING
what are drills made from? and why?
high speed steel, it can be used to cut almost any material as it is harder
DRILLING
what are the two types of twist drills? what are the differences in them?
parallel shank and taper shank drills
parallel shanks are held in the drill chuck and held by the chuck and taper shank are put straight into the drill and held by friction
DRILLING
why do drills have flutes/grooves along them?
these allow for the drill to carry away some of the waste / swarf material
DRILLING
what are the other 6 types of drill? what are all of these used for?
flat bits - drilling deep holes in wood
Forstner bits - used to drill flat-bottomed holes in wood
Auger bits - used to drill deep holes using a carpenters brace
Countersunk bits - allow for a countersunk screw to sit flush into the surface of wood/metal
Hole saws - saws that are circular shaped cutting rings that range from 50-120mm in diameter
Tank cutters - circular cutters that have an adjustable radius for cutting hoes in sheet material
TURNING
what are the 2 basic processes that can be done by lathes? what are these?
facing off and turning down
facing off smooths the end of a material
turning down reduces the diameter of a material
TURNING
what are the differences between woodworking lathes and metalworking lathes?
on woodworking, the cutting tools are held in the hand and rested on the tool rest whereas on metalworking lathes, the cutting tools are securely fixed to the lathe
METALWORKING CENTRE LATHE
what can this be used to do? give four examples
turning down diameters
drilling holes in the centre of round material
producing tapers
producing threads on bars
CENTRE DRILLING AND BORING
what is centre drilling used for?
drilling a hole in the end of a rod or bar along its axis
CENTRE DRILLING AND BORING
why is it important to apply a coolant to the work on a metalworking lathe? what is the coolant?
there will be friction and the bit can become blunt and inefficient
the coolant comes in a soluble oil
METALWORKING CENTRE LATHE TOOLS
what are the 7 metalworking centre lathe tools and what are they used for?
Right-hand knife tool - used to face the left hand edge or cut a shoulder on the left
Left-hand knife tool - used to face the right hand edge of cut a shoulder on the right
Round nose tool - cut in any direction to produce a radii
Parting off tool - moves in right angles into the work to severe it
Form tool - special profiles to cut specific shapes
Knurling tool - produces a pattern or texture
Boring tool - enlarges a hole or produces flat bottomed hole
PRODUCING A SCREW THREAD USING A CENTRE LATHE
what two factors need to be accurate to do this?
the cutting tool must match the thread profile
the rate of rotation of the work must be in relation to the longitudinal cut in order to create the correct thread pitch
KNURLING
What is this used to do?
it is used to produce a pattern onto a surface of material
KNURLING
how does it work?
as the work in the lathe rotates, the pattern on the knurling tool imprints onto the material
PARTING OFF
What is parting off?
parting off is when a tool is used to cut through the work
PARTING OFF
why should care be taken when parting off?
the component being cut may fly off the machine
WOOD LATHE
Why should knots be avoided when turning wood?
they can get caught and fly out
WOOD LATHE
what should be done when turning down long pieces of timber? and what should be done when turning down small pieces of timber?
long pieces should have their corned planed down
small pieces should have their corners cut off
INJECTION MOULDING
what is the process of injection moulding?
when molten plastic is injected into a mould.
plastic granules are forced into a hopper then heat chamber and the plastic is then injected into a two-part mould which is the ‘negative’of the product.the plastic is then cooled rapidly and ejected
INJECTION MOULDING
what are the moulds usually made from?
steel
BLOW MOULDING
What is it used to produce? give an example
hollow products such as bottles
BLOW MOULDING
what is the process of blow moulding?
plastic granules are fed into a hopper then fed through a heat chamber, the plastic starts to melt and is extruded into a hollow tube called a parison. the parison then has air pumped into it and inflates to the shape of the mould, it is cooled and then ejected
BLOW MOULDING
what is the hollow tube called?
a parison
VACUUM FORMING
what plastics are used for vacuum forming?
Thermoplastics
VACUUM FORMING
What is the former made from
Wood or MDF
VACUUM FORMING
What is the process of vacuum forming
Heat is applied to the plastic to make it soft and pliable. A vacuum is then formed and pressure forces the plastic around the former. Then once the thermoplastic has been formed it cools and it is then removed.
VACUUM FORMING
What are the four stages of vacuum forming?
- A high quality former is produced, it is the exact shape of the product being formed. Small holes put into the former so the pressure can be pulled around the former
- Former placed into machine and thermoplastic placed on top, heat is applied
- Plastic becomes soft and former raised into plastic and forced around former
- Thermoplastic cools and is removed
VACUUM FORMING
Give two advantages, two disadvantages, two applications and 2 polymers used for vacuum forming
Ideal for batch production and it is easy to make mouldy that can be modified.
Mould needs to be accurate to prevent webbing from occurring. Large amounts of waste material is produced.
It is used to make yogurt pots and insides of fridges.
Polymers used are acrylic and PVC
INJECTION MOULDING
Give two advantages, one disadvantage, one application and 2 polymers used for injection moulding
It is ideal for mass production. It is precise and produces good finished surfaces.
High set up cost as mould is expensive to produce. Casings for electronic products.
Polymers used are nylon and HDPE
BLOW MOULDING
Give two advantages, one disadvantage, one application and 2 polymers used for blow moulding
Intricate shapes can be formed and it is ideal for mass production.
There is a high initial set up cost because mould are expensive to produce.
It is used to make plastic bottles and containers
Polymers used are HDPE and PVC
ROTATIONAL MOULDING
what is rotational moulding?
Rotational moulding is the process of producing one-piece hollow components
ROTATIONAL MOULDING
How does it work?
Powdered polymer is loaded into a mould. Heat is applied to the mould and the mould is rotated in a tumbling action until the polymer has melted and stuck to the mould. The mould is cooled and component is removed.
ROTATIONAL MOULDING
Give four advantages. Four disadvantages and four applications of rotational moulding
Easy to produce large products, the end product has no seams, the corners of the product are stress free and the products are very near to the net shape.
Lower volume production, materials available are limited, can be labour intensive and long cycle times usually limit economic batch sizes to between 500 - 10,000
It can be used to made buckets, dustbins, oil drums and traffic cones
HARD SOLDERING
describe the process of hard soldering
Clean the metal with an abrasive material, such as wire wool and then clamp the work to keep it still. Then apply a flux to the join area and apply heat, apply the solder to the join area and heat between 625-800 degrees. The solder will flow around the joint. Creating a joint
THERMOCERAMICS
Thermoceramics can be used in jet engines and in high performance cars. Give three advantages of thermoceramics that make them okay to use for these situations
They are very strong, they can withstand high forces and pressure without breaking.
They are heat resistant so they don’t weaken when heat up.
They are stable and do not expand with heat.
FERROUS METALS
give three characteristics of non-ferrous metals compared to ferrous metals
Non ferrous do not contain iron, they do not rust and they are not magnetic
ALLOYS
What are the metals that are alloyed to make brass
Copper and zinc
SHAPE MEMORY ALLOYS
they are often used in fire alarms and air conditioning. What are the smart properties of SMA that makes them suitable for these?
A change in stimulus (e.g. Temp and electricity) produces a change in movement
MILLING MACHINE
Describe the process of machining a slot into some steel, using a manual milling machine
Clamp the work to the table and choose what cutter to use and fit this into the chuck. Move the work table and choose appropriate feed speed. Feed the block into the cutter on the x, y and z axis using the turning wheel. Take small cuts away at a time
GLASS REINFORCED PLASTIC
a kayak is made from GRP.
Name a polymer used in GRP
Polyester resin
Epoxy resin
GLASS REINFORCED PLASTIC
a kayak is made from GRP
Describe steps involved in making a GRP moulding
The mould needs manufactured first. Apply a release agent to the mouldX and mix the resin, then apply this. Spray a layer of glass fibre then a layer of resin. Then allow to set and remove from mould
GLASS REINFORCED PLASTIC
a kayak is made from GRP.
Why is the production of GRP products suited to batch production.
The mould is reusable therefore saving money and time.
A range of options can be catered for easily, like the colour or size
BLOW MOULDING.
Blow moulding can be used to manufacture plastic bottles
Describe the process of blow moulding
There is a bottle shaped die and there is an extruder in it, this heats the parison and it is then fed in, the die is closed and air is blown in moulding it around the die, it is then cooled and the die is opened, releasing the finished product
BLOW MOULDING
tolerances, the use of tolerances is an essential part of quality control systems within manufacturing.
Give two reasons as to why tolerances are set
Tolerances are set so that the components are made to the correct size, ensuing the products functions properly. Tolerances also set parameters for control checks making sure only correct components will pass
COMPOSITES.
A table frame is made from solid mahogany and the top is made from a mahogany MDF
Explain three reasons to why the frame is made from solid mahogany rather than veneered MDF
Mahogany is lighter than MDF and so the whole product will be lighter. There is no veneer required so this reduces the time of the manufacture. The product will also be more durable as the edges and corners will not damage as easily
COMPOSITES.
A table frame is made from solid mahogany and the top is made from a mahogany MDF
A handheld router was used to manufacture the table, risk assessments are necessary, PPE is worn to protect the user. Give five more control measures for the safe use of a hand held router
There should be suitable extraction systems. The work should be secure with a clamp. There should be no loose wires. The cutter has to be secure. And the lighting should be good.
COMPOSITES.
A table frame is made from solid mahogany and the top is made from a mahogany MDF
Justify the requirement for risk assessment to be formally recorded and stored
It provides evident that the health and safety legislation is applied. If an accident occurs, it can be used in court. It can be used for training, so all risks and safe procedures are covered
BSI
British standards institute, is here to promote safety throughout product manufacture and usage.
Evaluator the advantages and disadvantages to a business of ensuring their practices and products comply with BSI standards
There will be increased sales as the BSI symbol gives consumers confidence. The employees have improved working conditions and increased productivity.
However there are high setting up costs to comply with standards. Consumers may not recognise the BSI kitemark. It increases the red-tape within the business
SHAPE MEMORY ALLOYS
define a shape memory alloy
A shape memory alloy is a material that can be deformed having been given an outside stimulus. Once it’s been removed it will revert back to its original shape.
SHAPE MEMORY ALLOYS
what is the stimulus that makes smart materials react?
Heat usually provided by electrical input
SHAPE MEMORY ALLOYS
What is the most common and readily available SMA? What is it an alloy of? What does it do?
Nitinol
It is an alloy of titanium and nickel
It is programmed to maintain a particular length or shape at a set temperature, when the temperature is raised, the nitinol will contract or bend. It will remain in this state until the heat source is removed
SHAPE MEMORY ALLOYS
Give some applications of the SMA nitinol
Hot water systems
Heating systems
Air conditioning
Fire alarms
SHAPE MEMORY ALLOYS
Give three disadvantages to shape memory alloys
It is expensive
They are harder to machine compared to steel
They are not as strong as steel
REACTIVE GLASS
what does reactive glass do?
When reactive glass senses light from an arc, it instantly turns from clear to dark
REACTIVE GLASS
Give another application to reactive glass
Reactive glass can replace curtains or blinds. They can turn from clear to dark at the touch of a button
PHOTOCHROMIC PAINT
What can photochromic paints be used in
Security markers and ultraviolet light warning censors
PHOTOCHROMIC PAINT
How are they reversible?
When the light source or UV light is removed, the paint reverts back to its original state
QUANTUM TUNNELLING COMPOSITES
what happens when QTC is relaxed and then stretched compressed or twisted
When relaxed it is a perfect electric insulator but when it is twisted, compressed or stretched it becomes an electric conductor
QUANTUM TUNNELLING COMPOSITES
What happens to QTC the more you stretch, compress or twist it?
The more conductive to electric it becomes
QUANTUM TUNNELLING COMPOSITES
What are two applications of QTC?
Power tools switches and robots
GEARS
give three things that gears can be used for
a change in direction of rotary motion
change spindle speeds
transmit motion through 90 degrees
BEARINGS AND BUSHES
what do bearings do?
bearings reduce the effects of friction and allow shafts to spin more efficiently
BEARINGS AND BUSHES
what is the most common material used for bushes?
bronze
BEARINGS AND BUSHES
give a disadvantage of bushes
bushes wear out over time and have to be removed and replaced
SAND CASTING
give the steps to sand casting
1 - a mould is made in the sand using a pattern. the pattern is a replica of the product, slightly larger though to allow for contraction
2 - then sand is packed around the mould, the mould is removed
3 - the molten metal is then poured in, allowed to solidify, then the sand is broken up and the component is removed
ROTATIONAL MOULDING
give 2 advantages and 2 disadvantages of it
it is easy to produce large products and the end product is seamless
it can be labour intensive compared to injection moulding and the materials available are limited
ADHESIVES
give 2 advantages. 2 disadvantages and an application of PVA
produces a strong bond when joining wood
can be used on card and paper
can take up to 24 hours to dry and requires a clamp to hold work in position whilst hardening
used for wood joints
ADHESIVES
give 2 advantages. 2 disadvantages and an application of epoxy resin
very strong and Waterproof
takes time to cure and harden
requires catalyst and resin
used for: boats
ADHESIVES
give 1 advantages. 1 disadvantages and an application of contact adhesives
instantly sticks, cannot be adjusted during joining process
used for applying veneers
GRINDING
what are the three types of grinding
offhand, disk and surface
