Transcript Document

TO GIVE YOU BITESIZE CHUNKS
OF INFORMATION RELATED TO
THE MAIN CONTEXT OF YOUR
YEAR 11 EXAM
YOU WILL NEED TO TAKE NOTES ON EACH
SECTION
WRITE DOWN ANY QUESTIONS YOU HAVE
FOR THE END OF THE SESSION
DON’T PANIC - THE EXAM IS NOT TO TRICK YOU!
ONLY TO FIND OUT WHAT YOU ALREADY KNOW
ABOUT THE WORK YOU HAVE DONE IN KEY STAGE 4.
MATERIALS FOR MAKING
CONTAINERS
MANUFACTURING PROCESSES
INDUSTRIAL PRACTICES
SCALE OF PRODUCTION
HEALTH AND SAFETY
SORTING OF WASTE MATERIAL
ENVIRONMENTAL ISSUES
ERGONOMICS
AESTHETICS
ICT – CAD/CAM – CNC - CIM
COSTS, PARTS & COMPONENTS
MAINTENANCE
SUITABILITY & DESIGN REQUIREMENTS
SOCIAL CONSIDERATIONS
THIS THE CONTEXT OF SOME QUESTIONS FOR SECTION A.
MAKE A STUDY OF WASTE DISPOSAL AND STORAGE USED AROUND
YOUR HOME AND OR SCHOOL.
YOU MUST TAKE COLOURED PENCILS IN TO THE EXAM.
STUDY THE METHODS IN
WHICH WASTE CAN BE
SORTED AND STORED
LONG CHAIN MOLECULES !!
GOOD AVAILABILITY !!
VARIETY OF COLOURS !!
LOOK AT THE EXAMPLES ON
THE BACK OF YOUR PREP
SHEET
QUALITY FINISHES !!
EASY TO WORK WITH !!
HIGH IMPACT STRENGTH !!
HIGHLIGHT THE MATERIALS
EASY TO CLEAN !!
RESISTS CORROSION !!
CHECK THE PROPERTIES
WITH YOUR TEXT BOOK.
LOW IN COSTS !!
GOOD STRENGTH TO
WEIGHT RATIO !!
BROADLEAF OR DECIDUOUS TREES
CONIFEROUS TREES
GROW IN WARM TEMPERATURES
GROW IN COLDER TEMPERATURES
LOSE THEIR LEAVES IN WINTER
KEEP THEIR LEAVES ALL YEAR ROUND
GROW SLOWLY – 100YEARS
GROW QUICKLY - 30 YEARS
MORE EXPENSIVE
LESS EXPENSIVE – READILY AVAILABLE
BETTER GRAIN STRUCTURE FOR
IMPROVED QUALITY FINISH
GOOD CONSTRUCTIONAL TIMBER AND
GENERAL WOODWORKING PROJECTS
CONTAINS NO IRON
CONTAINS IRON
LESS VULNERABLE TO CORROSION – RUST
VULNERABLE TO CORROSION – RUST
MAINLY PURE METALS
MIXED WITH CARBON TO OBTAIN
ALLOY STEELS OF VARYING
STRENGTHS
CAN BE MIXED WITH ONE ANOTHER TO
OBTAIN REQUIRED CHARACTERISTICS.
ALL ARE GENERALLY EASY TO WORK WITH
ONLY MILD STEEL IS EASY TO WORK
WITH
COMMON TO BOTH
ELASTICITY
PLASTICITY
MALLEABILITY
DUCTILITY
HARDNESS
TOUGHNESS
DUCTILITY – THE
ABILITY TO
UNDERGO COLD
PLASTIC
DEFORMATION
ELASTICITY – THE
ABILITY TO FLEX
AND BEND WHEN
FORCED.
COMMON TO BOTH
PLASTICITY – ABILITY
TO BE CHANGED
PERMANENTLY
THROUGH EXTERNAL
BLOWS
ELASTICITY
PLASTICITY
MALLEABILITY
HARDNESS – THE
ABILITY TO RESIST
WEAR AND ABRASION –
USUALLY BRITTLE
DUCTILITY
HARDNESS
MALLEABILITY – THE
EXTENT TO WHICH A
MATERIAL CAN
PERMANENTLY
DEFORM IN ALL
DIRECTIONS
WITHOUT CRACKING
TOUGHNESS
TOUGHNESS – THE
ABILITY TO WITHSTAND
SUDDEN SHOCKS OR
IMPACT. RESISTS
CRACKING WHEN
BENDING
LONG CHAIN MOLECULES THAT ARE
CHEMICALLY BONDED TOGETHER
LONG CHAIN MOLECULES THAT
ARE ENTANGLED BUT FLEXIBLE
RIGID AND NON FLEXIBLE
CAN BE RE-SHAPED WITH LITTLE
HEAT
HIGH RESISTANCE TO HEAT
VARIETY OF COLOURS
GOOD ELECTRICAL INSULATORS
PLASTIC MEMORY THAT ALLOWS
THEM TO RETURN TO ORIGINAL
SHAPE
TENSOL CEMENT
FRAME JOINTS
BOX JOINTS
EDGE JOINING
NAILS & SCREWS
KNOCK DOWN
SOLDERING
INJECTION MOULDING
WELDING
VACUUM FORMING
RIVETTING
STRIP / LINE HEATING
NUTS & BOLTS
ULTRA-SONIC WELDING
MORTISE AND TENON –
DOWELLED JOINT –
REQUIRES A TENON SAW AND
ACCURATE MARKING OUT
BUTT JOINTS REINFORCED WITH
DOWELS FOR STRENGTH
TENON
FRAME JOINTS
DOWEL
BOX JOINTS
EDGE JOINING
NAILS & SCREWS
MORTISE
KNOCK DOWN
COMB JOINT –
ATTRACTIVE JOINT WITH
STRENGTH FROM LARGE
GLUEING AREA
FINGER
NAILS & SCREWS –
USED TO HOLD ITEMS
TOGETHER WHILST GLUE
SETS
HOUSING JOINT – USED FOR
SHELVES AND PARTITIONS.
POSITIVE SUPPORT
TEMPORARY FIXING
HOUSING
POSITIVE
SUPPORT
SOLDERING – INCLUDES :RIVETTING – NUTS & BOLTS :-
SOFT SOLDERING
SILVER SOLDERING
SOLDERING
BRAZING
WELDING
RIVETTING
SOFT SOLDERING – QUICK
AND EASY METHOD OF
JOINING COPPER, BRASS
AND TIN PLATE
SILVER SOLDERING –
JOINTS ARE BUILT UP IN
DECREASING
TEMPERATURES
BRAZING – ALLOY OF
COPPER AND ZINC. VERY
HIGH TEMPERATURE
ALL REQUIRE FLUX TO HELP
KEEP JOINT CLEAN AND
STRONG.
NUTS & BOLTS
WELDING
INCLUDES FOLLOWING
OXYGEN – ACETYLENE – VERY HOT
FLAME USING BURNING GASES TO
MELT BOTH PARENT METAL AND
FILLER ROD – MAINLY THIN PLATE
WORK.
ELECTRIC ARC – USES ELECTRICAL
CURRENT (ARC) TO CREATE HEAT
ENOUGH TO FUSE TOGETHER PARENT
METALS – CAN BE USED FOR LIGHT
AND HEAVY PLATE WORK.
ROUND HEAD – REQUIRES AN
ENGINEERS (BALL PEEN
HAMMER) AND RIVET SET
(DOLLY) TO ROUND OVER THE
HEAD OF THE RIVET
POP RIVET – QUICK AND EASY
METHOD OF JOINING THIN
PLATE. WEAKER THAN A SOLID
ROUND HEAD RIVET.
NUTS & BOLTS – A TEMPORARY
FIXING THAT RELIES ON
FRICTION TO HOLD PARTS
TOGETHER. HOLDING THROUGH
MECHANICAL ADVANTAGE OF
SCREW THREADS.
TENSOL CMENT 70
TENSOL CEMENT 12
A SOLVENT BASED
ADHESIVE. NOT VERY
STRONG. WORKS BY
ATTACKING THE
SURFACE OF THE
ACRYLIC TO BOND
THEM TOGETHER.
SUPPLIED READY TO
USE AND SETS QUICKLY
TENSOL CEMENT
DRILLED AND JOINED WITH
MACHINE SCREWS
MAKE SURE YOU
SUPPORT THE
UNDERNEATH OF THE
PLASTIC BEFORE
DRILLING
DO NOT OVER TIGHTEN
TO AVOID CRACKING
THE MATERIAL.
A POLYMERISING ADHESIVE
LIKE ‘LIQUID’ ACRYLIC THAT
LINKS WITH THE MATERIAL
RESULTING IN A JOINT THAT
IS NEARLY AS STRONG AS THE
ACRYLIC ITSELF. NEEDS
CAREFUL MIXING AND A
LONGER SETTING TIME.
PENCIL, RULER, TRY SQUARE,
MARKING GAUGE, MARKING
KNIFE.
SCRIBER, ENGINEERS SQUARE,
STEEL RULER, CALIPERS,
DOT PUNCH, DIVIDERS.
HACKSAW, TIN SNIPS, COLD
CHISELS, ABRAFILE
TENON SAW, COPING SAW,
FRET SAW, BENCH HOOK,
MITRE BLOCK
COMMON TO ALL
SANDING MACHINE,
JACK PLANE, CHISEL,
MALLET, SPOKESHAVE,
TURNING, DRILLING.
GLASS PAPER, VARNISH,
PAINTS, POLISH, WAX.
MARKING OUT
FORGING, PRESSING,
BENDING, TURNING,
MILLING, DRILLING
CUTTING TO SIZE
SHAPING/FORMING
JOINING
FINISHING
EMERY CLOTH, WIRE WOOL,
PAINT, POLISH, DIP COATING.
MUST HAVE PAPER BACKING
LEFT ON. - PENCIL,
CHINAGRAPH OR SPIRIT PEN,
SCRIBER, RULER, TRY OR SET
SQUARE, MOST METAL WORK
MARKING OUT TOOLS.
HACKSAW, COPING SAW,
BAND SAW, HAND FILES,
STRIP BENDER/HEATER, VACUUM FORMER,
INJECTION MOULDING, CASTING.
GO TO TECHNOLOGYSTUDENT.COM TO SEE
VIDEOS OF THESE PROCESSES.
DRAW FILING, EMERY CLOTH,
WET AND DRY, POLISH,
COMMON TO ALL MATERIALS
JIGS AND FORMERS
MARKING OUT
CUTTING TO SIZE
SHAPING/FORMING
JOINING
FINISHING
USED TO MAINTAIN ACCURACY FOR MARKING
OUT, CUTTING AND SHAPING.
ESSENTIAL TO REPEAT ACCURACY OF PARTS
THAT GO TOGETHER TO MAKE COMPLETE UNIT.
ITEMS THAT ARE PRODUCED (MADE) SINGLY. POSSIBLY DUE
TO THE NATURE OF THE PRODUCT, E.G. BRIDGES, SATELLITES,
JEWELLERY, WEDDING DRESSES, MACMILLAN COLLEGE AND
OF COURSE YOU - SAFETY AND RELIABILITY ARE OFTEN OF
HIGH PRIORITY THAN COSTS, ALSO HIGH AESTHETIC
CONSIDERATIONS.
A SYSTEM OF PRODUCING IDENTICAL ITEMS IN FIXED NUMBERS
FOR A SPECIFIC CLIENT. E.G. SCHOOL TIES, FURNITURE,
DESIGNER CLOTHING, ITEMS WITH CLIENT LOGO RATHER THAN
MAKERS LOGO. WHEN THE BATCH IS COMPLETE, THE TOOLS
USED CAN BE USED TO PRODUCE A BATCH OF DIFFERENT
PRODUCTS.
PRODUCING ITEMS IN VERY HIGH QUANTITIES THAY CAN
RECOVER THE COSTS OF TOOLING UP. COST OF
MANUFACTURE IS AS LOW AS POSSIBLE. E.G. CARS, BIRO’S,
CHOCOLATE BARS, SCHOOL SHIRTS, CD’S. NO FIXED
NUMBER AND NO SPECIFIC CLIENT.
DISABLED ACCESS
REQUIRED
THE EXAM WILL BE LOOKING FOR MORE THAN JUST THE BASIC UNDERSTANDING
OF – WEAR GOGGLES, TIE YOUR HAIR BACK, WEAR AN APRON.
IT WILL BE CONCERNED WITH RESPONSIBILITY FOR HEALTH AND SAFETY
I.E.
AWARNESS OF SAFETY SIGNS AND THEIR MEANINGS
LEGISLATION REGARDING ROOM LAYOUT
POSITIONING OF SAFETY EQUIPMENT
SAFETY GUARDS AND USAGE
SPEEDS OF MACHINERY
TRAINING PROGRAMMES
MAKING USE OF TRAINING TO
ENABLE SAFE USE OF
MACHINERY AND EQUIPMENT –
GET SUPERVISION.
ADEQUATE SPACE FOR
WALKWAYS BETWEEN
TABLES
WHERE THE EMERGENCY
STOP BUTTONS AND FIRE
EXTINGUISHERS ARE
LOCATED.
THAT THEY ARE IN TACT AND
MOVE FREELY. SIGNS IN PLACE
INFORMING THEIR USAGE
THAT REVOLVING CUTTERS CAN
BE ADJUSTED MANUALLY
ACCORDING TO THE SIZE OF
MATERIAL OR HOLE TO BE CUT
COLOUR CHOICES
10
9
8
7
6
5
4
3
2
USING COMPUTERS IN DESIGNING
INTERNET RESEARCH VISITING THE CLIENT .
LETTERS TO CLIENTS –
FINDING OUT THEIR NEEDS .
QUESTIONNAIRES TO CUSTOMERS.
FINDING OUT WHAT THEY WANT –
COSTS, MATERIALS, SIZES,
APPEARANCE, COLOUR ETC.
WORKING DRAWINGS.
INFORMATION TO HELP
MAKE YOUR IDEAS.
1
0
RED
BLUE
GREEN
BLACK
YELLOW
Series 1
GRAPHICAL RESULTS OF YOUR
QUESTIONNAIRE –
INFORMATION FOR YOUR
SPECIFICATION LIST.
FEEDBACK TO LET YOU KNOW
THAT YOUR IDEAS ARE
ACCEPTABLE BY THE
CLIENT/CUSTOMER
VALUABLE INFORMATION BEFORE
YOU GO TO MANUFACTURING
STAGE.
THE PRODUCT IN RELATION TO ITS
ENVIRONMENT (E & E) AND ITS
USER.
1.
HUMAN PHYSIQUE – HEIGHT,
WEIGHT, RANGE OF REACH AND
MOVEMENT.
2.
HUMAN ABILITIES – STRENGTH,
POSTURE, RANGE OF MOTION.
3.
HOW THE PRODUCT FITS IN WITH
ITS SURROUNDINGS – LOOKS,
SIZE, FEEL, COMFORT ETC.
THE SCIENCE CONCERNED WITH
MEASURING PEOPLE AND HOW
THEY WILL FIT THE PRODUCT.
1.
STATIC DIMENSIONS – TAKEN
WHEN A PERSONS BODY IS IN A
FIXED POSITION. STANDING,
HOLDING TOOLS ETC.
2.
DYNAMIC DIMENSIONS – TAKEN
DURING MOVEMENT. CONCERNED
WITH THE AREA OF REACH FOR
ARMS AND LEGS.
ERGONOMICS USES ANTHROPOMENTRICS
YOU CANNOT DESIGN A PRODUCT WITHOUT FIRST MEASURING THE USER
THIS WILL BE IMPORTANT WHEN THINKING ABOUT THE HAND ACCESS TO
ALLOW RETRIEVAL OF THE CD BOXES
IT IS NOT JUST HOW THE PRODUCT LOOKS.
HOW IT LOOKS IN RELATION TO
OTHER ITEMS IN THE ROOM – E.G.
COOKER, FRIDGE, WASHING MACHINE
COMPUTER, STERIO, IPOD ETC.
WHAT DOES IT FEEL LIKE – TEXTURE,
SMOOTH, CLEAN, HYGIENIC ETC.
ARE THE SIZES CORRECT AND IN
RELATION TO ONE ANOTHER –
HEIGHT, WIDTH, THICKNESS.
APPEARANCE – COLOURS,
SHADES, STYLE, CULTURE,
THEME, VALUE FOR MONEY.
DO BOTTLES, CANS, PAPER ETC HAVE
SEPARATE STORAGE
AN OPINION OF THE WHOLE PRODUCT
I.E. IS IT SUITABLE FOR THE PURPOSE???
MATERIALS
RAW MATERIAL COSTS,
TREATING COSTS, HOW
MANY COMPONENT
PARTS CAN BE MADE?
MANUFACTURING
CUTTING TO SIZE,
CLEANING, SHAPING,
ASSEMBLY, FINISHING,
RUNNING COSTS.
SALES
RECOVERING MAKING
COSTS, MAKING A
PROFIT, REPLACING
PARTS ETC.
HOW MANY CONTAINERS CAN BE MADE FROM ONE SHEET OF MATERIAL??
THE LIFE EXPECTANCY OF A PRODUCT OR MATERIAL
THE ABILITY TO WITHSTAND WEAR AND TEAR,
WEATHERING AND DETERIORATION THROUGH CORROSION
PREVENTING CHANGES IN APPEARANCE AND STRENGTH.
CAN THE MATERIALS BE
REPLACED? REUSED, RECYCLED.
WHAT IS THE ‘TURNAROUND’
TIME?????
WHAT EFFECT ON THE
ENVIRONMENT – FEWER TREES,
FEWER NATURAL RESOURCES.
DAMAGE TO OZONE LAYER
THROUGH SPRAY FINISHES ?????
CAN EVERYONE AFFORD THE
LUXURY – IS THERE AN
ALTERNATIVE. ARE STANDARDS
OF LIVING MORE IMPORTANT
THAN LIFE ITSELF?????????
WHICH ONE ??????
A MILD STEEL JIG
WILL HELP KEEP ALL
PARTS IDENTICAL.
SIZE, SHAPE AND
HOLES POSITION
A DEVICE THAT ENSURES REPEAT
ACCURACY OF COMPONENT PARTS.
IT IS AS UNIQUE AS THE PRODUCT
OR PART ITSELF.
ALL SECTIONS
ARE IDENTICAL
IN SHAPE, SIZE
AND HOLE
POSITIONS.
LOCATING TABS
JIG OR FORMER
A more durable material
Increases life expectancy.
Improved accuracy.
Batch producing facility
Quality control check
TUBULAR MILD STEEL
FRAME SHAPED AROUND JIG
TO MAINTAIN REPEAT
ACCURACY
BUT HOW CAN IT BE IMPROVED ???
HOLDING SECURELY!!
GRIPPED
SECURELY
USING
MECHANICAL
SCREW THREAD
ALTHOUGH DESIGNED TO DIFFERENT JOBS, ALL
MECHANISMS HAVE 5 THINGS IN COMMON.
1.
EASY GRIP
2.
MOVING JAWS
1.
THEY MAKE A JOB EASIER TO DO.
3.
TURNING FORCE
2.
THEY INVOLVE SOME KIND OF MOVEMENT.
4.
TWISTING HANDLE
3.
THEY INVOLVE SOME KIND OF FORCE.
5.
ROTARY TO LINEAR
4.
THEY NEED SOME KIND OF INPUT.
5.
THEY PRODUCE SOME KIND OF OUTPUT.
FOLLOWS THE MOVEMENT
OF THE CAM – CHANGES
ROTARY MOTION TO
LINEAR OR RECIPROCATING
MOTION
THE CAM - TAKES IT
NAME FROM IT’S
SHAPE E.G. PEAR CAM
CRANK ROTATES –
ANY DIRECTION –
TURNED USING A
HANDLE
TABLE MOVES UP AND
DOWN – WITH A
RECIPROCATING
MOTION
PROBLEM = THE
TASK IN HAND
WHAT WOULD YOU
DO DIFFERENTLY –
WHAT ARE THE
NEW PROBLEMS?
ANALYSIS =
INVESTIGATE
WHAT NEEDS TO
BE DONE
PROBLEM
ANALYSIS
EVALUATING
RECORD ANY
CHANGES YOU
MAKE
BRIEF =
WHAT YOU
WILL DO
BRIEF
MODIFYING
PROTOTYPE OF
THE IDEA
MAKING
THE
DESIGN
WHEEL
RESEARCH =
YOUR
FINDINGS
RESEARCH
SPECIFICATION
DEVELOPMENT
ALL THE STEPS
NEEDED TO MAKE
YOUR CHOSEN IDEA
TOOLS AND
EQUIPMENT ETC.
DESIGN IDEAS
CHOSEN IDEA
THE BEST IDEA
TO DEVELOP
FURTHER
SKETCHES OF
POSSIBLE
SOLUTIONS TO
THE PROBLEM
SPECIFICATION =
WHAT THE
PRODUCT MUST
BE AND WHAT IT
MUST DO.
IMPORTANT
REMEMBER THE EXAM IS 2 HOURS LONG
GET PLENTY OF SLEEP THE NIGHT BEFORE
YOU’LL FEEL ON TOP OF
THE WORLD
HAVE SOMETHING TO EAT
KEEP BODY AND SOUL
TOGETHER TO ALLOW THE
MIND TO FUNCTION
CORRECTLY
MAKE SURE YOU GO TO THE
TOILET BEFORE THE EXAM
YOU CAN’T ANSWER CALLS
OF NATURE ONCE THE EXAM
HAS STARTED
Practice drawing using Isometric
grids.
1. Start with a basic regular shape
2. Make the shape softer or rounder
3. Expand the product to include
Consider – Dimensions,
boxes in different positions
4. Label 5 points of Annotation and 5 hidden detail, construction
lines, view points.
points of evaluation.
Sizes, colour, processes, materials,
properties, functions etc.
5. Try producing an Orthographic
drawing of your final solution
1. SCAN READ THE WHOLE PAPER BEFORE YOU ANSWER ANY
QUESTIONS – THIS WILL GIVE YOU THE CONTEXT OF THE PAPER.
2. USE A HIGHLIGHTER PEN TO IDENTIFY KEY POINTS OF THE QUESTION.
3. READ 2 QUESTIONS AHEAD BEFORE ANSWERING – THIS WILL HELP
AVOID REPEATING PREVIOUS ANSWERS AND SAVE TIME.
4. LOOK OUT FOR QUESTIONS WITHIN QUESTIONS – I.E. WHERE MORE
THAN ONE ANSWER IS ASKED FOR
5. NEVER LEAVE BLANK SPACES – MARKS ARE ALWAYS AWARDED
FOR ATTEMPTED QUESTIONS – YOU MIGHT GUESS CORRECTLY!!
6. TAKE TIME BEFORE THE END TO PROOF READ YOUR ANSWERS –
IF IT DOES NOT MAKE SENSE TO YOU – IT WON’T TO THE MARKER
7. ABOVE ALL - DON’T PANIC. IF YOU’RE
STUCK, MOVE ON TO THE NEXT QUESTION –
YOU CAN ALWAYS GO BACK LATER.
REVISION WEBSITES
• http://www.btinternet.com/~hognosesam/elpinan
ds/mainmenu.htm
• Google images of CD, DVD etc holders.
• BBC-GCSE BITESIZE.
• LEARN.CO.UK
• REVISION-NOTES.CO.UK
• TOPMARKS
• SAM LEARNING
• www.the-warren.org