Specialist Techniques And Processes + Material Management Flashcards
What is a tape measure used for.
Measure longer pieces of material or measuring distances e.g. length of a room
How are steel rulers used?
Accurate measurements on smaller material. Steel provides consistency and a flat end allows you to measure from the edge of a piece of material easily.
How are protractors used?
Measuring angles to be drawn on any materials
How are french curves used?
Used to draw curves - different shapes and sizes are available to be selected as required.
How are compasses used?
Used to draw circles on paper, card and timber. A similar tool with two spikes is used to mark out metal (called a divider)
How are outside calipers used?
Used to measure the outside diameter or thickness of metal. Often used when turning material on a lathe so a quick and accurate measurement check can be made.
How are scribers used?
Used to scratch the surface of metal to indicate where the material should be cut (as you would a lencil in wood)
How are try squares used?
Used to draw lines at 90° to an edge. Similar products are used for metal and called an engineer’s square.
How are marking gauge used?
The adjustable block is placed against a piece of wood and the spike (on the left) is dragged along the edge of the material to create a mark.
Scenario: drill two holes in pieces of wood for an accurate dowel joint. This needs to be done over 100 times to make a batch of products
What manufacturing aid do I use?
The pieces of wood would be placed into a jih that has been set up to drill each hole in exactly the right place.
The jig may have a metal hole locator to prevent it from getting worn hpgiven the number being made.
Scenario: Flower design to be cut out of thin plywood using a fret saw. Each flower should be the same and 20 are needed?
What manufacturing aid would you use and why?
Cut out one of the flower designs using card and then draw around it carefully using pencil on the sheet of the plywood.
Use the lines to carefuuly cut them out using the fret saw.
Scenario: Star featured on a birthday card produced in a batch of 1000. The star is cut out to reveal a picture inside. The star must be cut accurately and be in the exact position.
Use a die cutter to stamp out the star design.
A jig could be used in conjunction to ensure the star is cut out in the exact place.
Die cutter may need to be manufactured specifically or there may be an off-the-shelf option available.
Scenario: Fairy design to be laser cut in acrylic as part of a gift set. 30 products are required and they should be cut to minimise material wastage
What manufacturing aid would you use?
Design should be prepared on CAD and copied and pasted to ensure an exact replica.
Design should be tessellated to fit as many fairies on one piece of material to minimise waste.
What is wastage?
Wastage is the process of cutting away material with tools and equipment.
Name 3 examples of wastage?
- Die cutting
- Sawing
- Milling
- Drilling
- Turning
What is addition?
Additin is the process of adding on material
Uses of addition?
Name 3
- Brazing
- Welding
- Lamination
- Soldering
- 3D printing
Deforming and reforming
Materials are shaled and formed using specialist machines and equipment to create new products
Deforming and reforming uses
Materials are shaped and formed using specialist machines and equipment to create new products
Uses of deforming and reforming
- Vacuum forming
- Bending
- Blow moulding
- Casting
- Injection moulding
- Extrusion
Why is material management vital?
- Manufacturers will lose money if too much scrap raw material is produced during cutting
- Profits could be increased if they are able to find ways to lower the cost per product by saving material.
What are the different methods of marking out effectively?
Tesselating Nesting Marking out Datum references Marking out
Tesselating
A method to used arrange items to be cur so that, when fitted together, as many as possible can be cut out a sheet of material
Marking out
This improves the accuracy of a finished product
Datum references
When marking out an object, datum references are used as a point for all measure,ents to be taken from and can be chosen by the manufacturer.
Marking-out tools (jigs)
Jigs are toold made specifically to help place a material in the same llace repeatedly.
