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A-Level Product Design > Technical Principles > Flashcards

Technical Principles Flashcards

1
Q

Compressive Strength

A

The ability to withstand being crushed or shortened by pushing forces (compression)

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2
Q

Tensile Strength

A

The ability to resist stretching or pulling forces

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3
Q

Bending Strength

A

the ability to resist forces that may bend the material

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4
Q

Shear Strength

A

the ability to resist sliding forces on a parallel plane

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5
Q

Torsional Strength

A

the ability to withstand twisting forces from applied torque or torsion

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6
Q

Hardness

A

the ability to resist abrasive wear such as scratching, surface indentation or cutting

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7
Q

Toughness

A

the ability to absorb impact force without fracture

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8
Q

Plasticity

A

the ability to be permanently deformed (shaped) and retain the deformed shape

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9
Q

Ductility

A

the ability to be drawn out under tension, reducing the cross-sectional area without cracking, for example stretching a material into a wire

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10
Q

Malleability

A

the ability to withstand deformation by compression without cracking. Malleability increases with rise in temperature.

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11
Q

Electrical Conductor

A

allows the flow of electrical current through the material. A good conductor gives very little resistance to the flow of charge.

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12
Q

Electrical Insulator

A

does not allow the flow of electricity through the material

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13
Q

Thermal Conductor

A

allows the transfer of heat energy through the material. A material with high thermal conductivity allows the transfer of heat to occur quickly across the material.

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14
Q

Thermal Insulator

A

prevents the transfer of heat energy through the material

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15
Q

Thermal Expansion

A

the increase in material volume in response to a heat input

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16
Q

Opaque

A

Prevents light from travelling through

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17
Q

Translucent

A

allows light through but diffuses the light so that the objects appear blurred. frosted glass is an example of a translucent material

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18
Q

Transparent

A

allows light to pass through easily which means you can see clearly through the material

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19
Q

Density

A

the mass of the material in a standard volume of space

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20
Q

Fusibility

A

the ability of the material to be fused or converted from a solid into a liquid or molten state, usually by heat. Good fusibility is an essential property for a metal being cast

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21
Q

Magnetism

A

the natural force between objects that causes the material to attract iron or steels

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22
Q

Corrosion/degradation

A

the ability of the material to withstand environmental attack and decay.

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23
Q

Ferrous Metal and examples

A

a metal containing mostly iron and carbon. Ferrous metals are magnetic and will rust.
Low carbon steel, medium carbon steel, cast iron

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24
Q

Non-ferrous Metal and examples

A

a metal that does not contain iron. Non-ferrous metals are not magnetic and do not rust.

Aluminium, Copper, Zinc, Silver, Gold, Titanium, Tin

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25
Q

Alloy with ferrous and non-ferrous examples

A

a metal made of two or more metals, or combining two or more elements, one of which must be a metal. Alloys can be sub classified as ferrous or non-ferrous alloys.

Ferrous alloys: Stainless Steel, Die Steel (tool steel)
Non-Ferrous alloys: Bronze, Brass, Duralumin, Pewter

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26
Q

Hardwood with examples

A

a wood from broad-leafed (deciduous) trees. These trees are generally slow growing and lose leaves in autumn.

Oak, Ash, Mahogany, Teak, Birch, Beech

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27
Q

Softwood with examples

A

a wood from coniferous (cone bearing) tree. these trees are generally fast growing and to be evergreen.

Pine, Spruce, Douglas fir, Redwood, Cedar, Larch

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28
Q

Manufactured Board with examples

A

a man-made wood-based composite material. Manufactured boards are available in much larger sizes than solid wood.

Plywood, Marine plywood, Aeroply, Flexible plywood, Chipboard, MDF

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29
Q

Thermoplastic with examples

A

a material which can be repeatedly reheated and reshaped, allowing it to be recycled after its initial use. Thermoplastics have long linear chain molecules held by van Der walls forces.

Low Density+High Density Polyethylene (L/H DPE), Polypropylene (PP), Nylon

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30
Q

Thermosetting Polymer with examples

A

a material which when heated undergoes a chemical change whereby the molecules from rigid cross links. Thermosetting polymers cannot be reheated and reshaped, even at very high temperatures.

Polyester resin, epoxy resin

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31
Q

Elastomer with examples

A

a material which at room temperature can be deformed under pressure and then upon release of the pressure, will return to its original shape.
Elastomers have weak bonds which allow them to stretch easily. They can be stretched repeatedly and upon immediate release of the stretch, will return with force to the original shape.

Natural Rubber, Polybutadiene, Neoprene

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32
Q

Papers and Boards with examples

A

papers and boards can be described as compliant materials, meaning that they can be scored, folded and cut with basic tooling

Layout Paper, Cartridge Paper, Tracing Paper, Corrugated Card: for take-aways due to being food safe

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33
Q

Composite with examples

A

a material comprised of two or more different materials, resulting in a material with enhanced properties.

Composites can be:
Fibre Based (Carbon Fibre Reinforced Plastic, Glass fibre Reinforced Plastic, fibre concrete)
Particle Based (tungsten carbide, concrete)
sheet based (aluminium composite board, engineered wood)
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34
Q

Smart Materials

A

a material whose physical properties change in response to an input or change in the environment, such as electricity, pressure, temperature or light.

Thermochromatic film (changes colour in response to heat: thermometers), phosphorescent pigment (changes colour in response to light: fire exit sign), Shape Memory Alloys

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35
Q

Modern Materials with examples

A

a material developed through the invention of new or improved processes, e.g as a result of man-made materials or human intervention. They are not ‘smart materials’ as they do not react to external change.

Kevlar, Precious Metal Clay, polymorph

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36
Q

Practical Tensile testing

A

Clamping material samples of the same length and thickness into a vice, applying a load such as weights to the unclamped end. This will test how much the material deflects under load (how tensile it is)

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37
Q

Practical Toughness Testing

A

Material samples are clamped into a vice, each sample is then hit with the same force with a hammer. Tough materials will absorb the impact.

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38
Q

Practical Hardness Testing

A

Abrasive wear can be easily tested bu running a file over the surface of the material, using the same force for all material samples, the material with the fewest scratches is the hardest.

Resistance to surface indentation: can be tested using a dot punch and a hammer. Material sample is supported under the dot punch, dot punch is hit once with a hammer using the same force. the smaller the indent the harder the material is.

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39
Q

Practical Malleability and Ductility testing

A

Both ductility and malleability testing using one test piece. Secure the test piece in a vice, try to bend the material 90 degrees. Cracks or surface damage on the outside of the bend indicates lack of ductility. Cracks or surface damage on the inside of the bend indicates lack of malleability.

40
Q

Practical Corrosion Testing

A

Same size material sample is left outside in an area that is exposed to weather effects and left for a certain amount of time. Visually inspected.

41
Q

Practical Conductivity Testing

A

Electrical conductivity can be tested using a multimeter. collect material samples of the same dimensions and, on the top surface, mark a set distance between the two ends of the material, the distance is the spacing for each probe of the multimeter.

Thermal conductivity can be tested using a thermometer. collect material samples of the same dimensions. measure a set distance from one end to put the thermometer. A Bunsen burner is lit under the end of the material. Record the time it takes for the temperature to reach the set point at the other end of the material.

42
Q

Manufactured Board

A

a man-made, wood based composite material.

43
Q

Industrial Tensile Testing

A
  1. A test piece is placed into a tensometer machine and held in clamps each end.
  2. One Clamp is fixed and the other moves on a worm drive gear mechanism.
  3. As the worm drive travels at a constant rate, tension is applied to the test piece and is stretched.
  4. The load and distance travelled is plotted, giving elastic limit, yield point, maximum load and final breaking point after ‘necking’
44
Q

Industrial Toughness Testing

A
  1. Izod impact test: notched test piece is held vertically in the vice of the test machine
  2. A pendulum is released from a set position and swings to strike the test piece
  3. The energy absorbed by the test piece is calculated from the height the pendulum swings after it hits the test piece
  4. The material that absorbs the most impact is the toughest, shown by how fat the pendulum swings after hitting the test piece. The further it swings after hitting, the more brittle the material.
45
Q

Industrial Rockwell Hardness Testing

A
  1. A preload is applies to the material sample using a diamond indenter which breaks through just the surface of the material.
  2. The preload is the datum or zero reference position
  3. An additional load is then applied to the test material and held for a predetermined time (dwell time)
  4. The load is then released and the distance between the preload and the applied load is measured, the smaller the indentation the harder the material.
46
Q

Industrial Brinell Hardness Testing

A
  1. A hardened standard size steel ball is forced into the materials surface using a pre-set load.
  2. The diameter of the indent in the surface is measured.
  3. The smaller the diameter indent, the harder the material
47
Q

Industrial Vickers Pyramid Hardness Testing

A

Used for very hard materials

  1. Uses a diamond square-based pyramid to indent the surface of the material
  2. Diamond is used as it will not deform under load
  3. A microscope is used to measure the size of the indent
  4. The smaller the indent, the harder the material
48
Q

Industrial Ductility And Malleability Testing

A

A bend test is used to determine how well a material can withstand cracking during one continuous bend.

  1. The test piece is placed into a bending machine and held, supported at the ends.
  2. A mandrel or plunger loads the test piece at the centre and bends it to a predetermined angle, or until the test piece fractures.
  3. The material is inspected for defects.
    Cracks on the outer bend indicate the level of Ductility.
    Cracks on the inside of the bend indicates the level of Malleability.
49
Q

List all Non-destructive testing

A
  1. Ultrasonic testing
  2. X-ray testing
  3. Electrical conductivity
  4. Thermal conductivity
50
Q

Ultrasonic Testing And Examples

A
  1. A transducer generates sound waves which are pulsed into the material.
  2. The intensity of the reflected sound waves signal is recorded on a display unit.
  3. The sound waves travel through the material and if any cracks occur in the sound waves path, the sound will be partially reflected and show up on the display unit.

Used for checking the quality of welds in pipes for offshore oil applications.

51
Q

X-ray testing And Examples

A
  1. An X-ray beam passes through the material and an image is displayed. X-rays and, in particular, micro-focus x-rays allow the observation of tiny details within the materials.
  2. Magnifying images detect flaws such as voids or hairline cracks to be reliably detected.

Used to inspect integrated circuits (ICs) and printed circuit boards (PCBs), and to check for micro-voids in composite materials such as Formula 1 cars or tacks pursuit cycles.

52
Q

Electrical Conductivity test

A
  1. A four-point probe method can be used to determine the electrical conductivity of materials.
  2. Four small-diameter wires are stretched, parallel to each other across a non-conductive polymer block. Held in place and connected to copper terminal blocks.
  3. Two leads are attached to the inner wires and two to the outer wires. The outer leads are connected to a precise current and the two inner leads measure the voltage drop.
  4. Ohm’s law (V=IR) can be used to calculate the resistance of the material sample.
53
Q

Thermal Conductivity Test

A
  1. Using a heat flow meter, a square-shaped material test piece is placed between two temperature controlled plates.
  2. The temperature is increased at a controlled rate and the heat flow through the material is measured by heat flow sensors placed on the surface of the material.
  3. As the material is heated to a specific temperature, the sensors measure and record the rate of the thermal conductivity.
54
Q

Layout Paper + Uses

A

Thin translucent paper with a smooth surface

Sketching, Quick ink, technical drawing, tracing

55
Q

Cartridge paper + uses

A

Off-white paper usually with a slightly textured surface

sketching, rendering in pencil, ink and pastel can be used for printing

56
Q

Tracing Paper + Uses

A

Translucent paper slightly thicker than layout paper

For copying images when sketching

57
Q

Bleed-proof paper + Uses

A

Similar to cartridge paper but has a bleed-proof layer in one side so colours do not run

spirit-based marker renderings

58
Q

Treated Paper + Uses

A

Plain paper with a clear binder or dye layer applied so that the image is able to be held onto the paper surface and brighten the image

Photographic printing

59
Q

Watercolour paper + Uses

A

available in absorbent, smooth, hot-pressed or the more textured cold pressed and heavily textured rough

Water colour painting

60
Q

Corrugated card + Uses

A

Usually with carton board outer layers and a corrugated middle layer, giving the material the ability to withstand and be protected against impact

Protective packaging, model making, prototyping ideas, food packaging

61
Q

Bleached Card + Uses

A

Chemically treated to brighten the surface to make it suitable for high-quality printing.

Greeting cards, high-quality packaging

62
Q

Mount Board + uses

A

Made from compressed fine cotton fibres to produce a rigid board

Presenting artwork, picture mounting, modelling

63
Q

Duplex Card + uses

A

Made cup from two layers with the exterior being a water resistant material to give the material a shiny, waxy feel

Food packaging, disposable cups, paper plates

64
Q

Foil backed and laminated card + uses

A

Card with polymer film or foil applied to either one side or both sides to provide a water resistant or heat insulating layer. the foil must be removed before recycling

drinks packaging, milk cartons, take-away box lids

65
Q

Metal Effect card + uses

A

High-quality card with a thin metal effect layer applied to the outer surface for enhanced aesthetics. can be embossed

Gift boxes and packaging, high quality metal effect business cards

66
Q

Moulded paper pulp + uses

A

Recycled paper pulp moulded when wet and dried to a specific shape. usually smooth on the visible inside surface and rough textured on the outer surface.

Moulded packaging products, eco-friendly packaging, egg boxes, fruit packaging

67
Q

Foam Board + uses

A

two outer layers of card with a foam middle core, available in a range of thicknesses

mood board packaging, presentation boards, modelling

68
Q

Fluted PP sheet + uses

A

Extruded sheet with integral ‘flutes’ or corrugations. lightweight and easily bent along the flutes

Signs(construction signs, sale boards for estate agents), storage box construction

69
Q

Translucent PP sheet + uses

A

An extremely tough polymer sheet. Can be scored before bending to produce a plastic hinge, which can be folded many times. Virtually impossible to tear and is water resistant.

Packaging products, folders, boxes

70
Q

Styrofoam + uses

A

Dense, closed cell foam, commonly blue in colour. can be cut, shaped and sanded with standard workshop tools.

product modelling, formers for moulding and laminating

71
Q

Low density polyethylene (LDPE) sheet + uses

A

Tough, available in thin sheet form, transparent, good chemical resistance, flexible.

food wrapping, air pillow packaging, bubble wrap, carrier bags

72
Q

Plastazote foam + uses

A

closed cell polyethylene foam, tough, flexible, good impact resistance, impermeable to liquids (not allow liquids through)

Protective packaging, swimming floats, gym and exercise matts.

73
Q

Cellulose acetate + uses

A

Transparent, tough, naturally biodegrades.

packaging film, membranes, photographic film

74
Q

polylactide + uses

A

Transparent, tough, naturally biodegrades

Biodegradable packaging film

75
Q

Rough Sawn

A

The wood comes from directly from seasoning and has rough surfaces produced from initial conversion. Rough sawn wood will have nominal sizes rather jam accurate finished sizes

76
Q

Planed square edge

A

PSE wood has only one edge that is planed accurately; the rest are rough sawn. Planing removes about 3mm from the original size

77
Q

Planed all round

A

PAR wood has sides and edges that are all planed square, straight and level, leaving a smooth finish and is ready to use. The PAR board is about 3 mm smaller all round then the original size

78
Q

Natural wood

A

Natural wood is only available at the maximum size of the tree. Natural trees need to be connected together for a larger size. Manufactured boards however are used to make a larger sized product.

79
Q

Mouldings

A

some wood is made into mouldings such as skirting boards or wooden trims and are readily available in standard lengths up to approximately 4 metres.

80
Q

Name all stock forms

A 
Sheet
Plate
Bar
Tube
Structural
81
Q

Air seasoning

A

A traditional, inexpensive method which involves stacking the wood under shelter, protected from the rain. Air circulates between the planks to slowly remove the excess moisture.

82
Q

Kiln Seasoning

A

A more expensive but controlled method which is very quick and can take just a few weeks. Planks are stacked onto trolleys and placed into the kiln where both temperature and humidity are controlled.

83
Q

Additives that make polymers easier and less expensive to process

A

Lubricants: Reduces the viscosity of the molten polymer, making it less sticky

Thermal Antioxidants: These help to prevent the polymer oxidising or discolouring due to excessive heat during processing

84
Q

Additives to enhance aesthetics of polymers

A

Pigments: these are tiny particles that are mixed into the polymer in its molten state to give colour to the final processed product

85
Q

Additives that improve polymer product function

A

Antistatics: The addition of antistatics improves the surface conductivity by attracting moisture from the room surroundings, therefore reducing the static charge.

Flame retardants: bromine, chlorine, phosphorous or metal, when added to polymers such as polyester, reduce the likelihood of combustion or the spread of fire. Important in products exposed to heat such as car engine components.

Plasticisers: these are added to allow plastics such as PVC (for hosepipes) to become less hard and brittle at normal temperature use. Plasticisers also help in processing because they allow polymers to be easily formed at higher temperatures.

Fillers: these have a dual function - to provide bulk to the product, meaning that less polymer is required, and to improve the polymer properties. Mineral fillers can help increase the thermal conductivity of the polymer, meaning they will heat up and cool down more quickly, which gives shorter mould cycle times.

86
Q

Additives to prevent degradation to polymers

A

Antioxidants: help reduce the environmental deterioration of the polymer from exposure to oxygen in the air.

UV light stabilisers: prevents the polymer chains being broken down by sunlight. UV attack can cause the material to lose colour and become more brittle.

87
Q

Additives to encourage degradation

A

Biodegradable plasticisers: Makes the polymer more flexible, softer, and easier to break down, which means faster degradation time.

Bio-batch additives: Oxy-degradable (degrade in the presence of oxygen), photodegradable (degrade when exposed to light), hydro-degradable (degrade in the presence of water)

88
Q

Paper and Board finishes

A

Laminating

Embossing

Debossing

Foil blocking

Varnishing, UV and Spot

89
Q

Lamination Methods

A

Encapsulation: Paper is fed through desktop laminator and heat sealed, leaving polymer sheet cover on both sides including the border of the paper. Laminating polymer used are a mix of PET and Ethylene-vinyl.

Surface Coating: Applied with a roller or spray and is used for applications such as signage to protect it from moisture, dirt and UV rays. Used for business cards and menu cards.

90
Q

Embossing

A

Creates raised design on the surface, uses two dies- a male and female die- made from stainless steel or brass. The dies can be cold or heated. the substrate sheet is placed between the two dies and held under pressure until the embossed area is formed.

91
Q

Debossing

A

Opposite of embossing. Carried out the same way as embossing however produces an imprinted depression which sits below the surface of the card.

92
Q

Foil Blocking

A

Application of heat and pressure to a metallic paper (foil) to create areas of depth and texture. Uses a special machine with heated die, design is stamped onto the material through the foil, which is transferred as it is pressed into the paper. Heat allows the foil to stick to the paper.

93
Q

Varnishing, UV varnishing and spot varnishing

A

varnish is a clear non-pigmented ink used on pre-coated papers and boards to enhance the colour, as well as offer some protection against dirt, fingerprints and water.

UV: Provides vey smooth finish, usually in high gloss or matt. Abrasion and chemical resistant. Varnish is applied through a set of rollers and the sheet is then passed under a UV light to cure.

Spot: Varnish that is applied in specific areas or spots rather than the whole surface area

94
Q

Screen Printing

A

The substrate to be printed sits on the screen print machine base and the upper section secures the screen. The image to be printed is created on a screen (or stencil), which is a mesh held by a frame. The screen has open areas for the ink to pass through. A different screen is required for each colour. This can increase the time taken to produce the print as well as the overall production cost per item. The screen is placed over the substrate on the machine bed.

95
Q

Flexographic Printing

A

Flexographic is the least expensive

A-Level Product Design (14 decks)

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