Industrial and Commercial Processes Flashcards
(159 cards)
1
Q
What is one-off production?
A
The design and manufacture of a single item or product
2
Q
Name 3 advantages of one-off production
A
- Unique product each time
- High quality product as high level of skill is needed
- Products can be made to measure
3
Q
Name 2 disadvantages of one-off production
A
- Labour-intensive = takes a long time to produce, so you may have to wait a long time for the product to be produced
- Very expensive
4
Q
What is batch production?
A
System of manufacturing used to produce a fixed quantity of ‘batch’ of identical products
5
Q
Name 3 examples of one-off products
A
- Wedding dress
- Stadiums
- Ships
6
Q
Name 3 characteristics of one-off production
A
- Highly skilled workers
- Constant discussion with client
- Specialist area of work (e.g. jewellery)
7
Q
Name 3 characteristics of batch production
A
- Production-line set-up
- Workers semi-skilled and flexible
- Parts often bought from other companies and assembled
8
Q
Name 2 advantages of batch production
A
- Quick response to customers’ demands
- Production line can be changed quickly
9
Q
Name a disdvantage of batch production
A
Tools need to be reset for new production run
10
Q
What is mass production?
A
Making the same product continuously
11
Q
Name 2 characteristics of mass production
A
- Semi-automated with much computer control
- High level of investment in machinery
12
Q
Name 2 advantages of mass production
A
- Low unit costs
- Can operate 24/7
13
Q
Name a disadvantage of mass production
A
Initial machinery and tooling costs are very high
14
Q
Give 3 examples of products that are produced by batch production
A
- Clothes
- Watches
- Baked goods
15
Q
Give 3 examples of products that are produced by mass production
A
- Cars
- Televisions
- iPhones
16
Q
When is sand casting used?
A
When producing complex shapes
17
Q
Give 3 examples of products that are sand casted
A
- Car engine parts
- Kitchen and bathroom taps
- Screws
18
Q
Describe how sand casting works
A
- Encase a mould pattern (usually made from wood) in moulding sand = relief pattern
- Consists of 2 parts: cope and drag
- Cope contains 2 taper tubes (act as delivery tubes for the metal): runer and riser
- Remove pattern to leave an empty cavity
- Drag and cope placed together
- Sand tightly packed around them (to prevent air being trapped inside/metal getting out)
- Pour molten metal into riser to fill the tubes
- When metal solidified and cooled, sand removed and taper tubes cut
19
Q
Name 3 advantages of sand casting
A
- Any waste can be reused
- Complex shapes and forms can be achieved
- Hollow products can be achieved with the use of cores
20
Q
Name 3 disadvantages of sand casting
A
- Consumes great deal of energy in order to melt metal
- New sand cast has to be packed each time the product has to be made
- Time-consuming to pack sand each time
21
Q
Name the tool
A
Pillar drill
22
Q
Name the tool
A
Hand drill
23
Q
Name the tool
A
Cordless drill
24
Q
Name 3 advantages of a pillar drill
A
- Can be used continuously
- Chuck can be removed to accept larger drill bits
- Speed can be varied
25
Name 2 disadvantages of a pillar drill
* Fixed in one position
* Can be dangerous
26
Name an advantage of a hand drill
Portable
27
Name 2 disadvantages of a hand drill
* You need to provide the power
* Will only hold bits up to 10 mm
28
Name 3 advantages of a cordless drill
* Portable
* Generally has a variable speed control
* Can be made to reverse direction
29
Name 3 disadvantages of a cordless drill
* Power limited by battery type and size
* Charging batteries can take some time
* Will only hold bits up to 10 mm
30
What does wood turning allow?
Allows circular wooden products to be made
31
Name 2 products that can be made using wood turning
* Fruit bowls
* Stair spindles
32
What are lathes used for?
Used to 'turn' materials = to make round objects
33
Describe how you use a lathe (include safety things)
1. Piece of material is held and rotated by the lathe, while a tool or bit is pressed onto the material to cut it
2. Before using it, check all guards are in place & aren't cracked
3. Keep your hands away from moving pieces
4. Make sure lathe is set to rotate at the correct speed for the material being cut + tool used
5. Make sure material is held tightly and straight
1. Long pieces of material needed to be held securely at both ends (stops it from wobbling)
34
Describe how you prepare wood for a lathe and explain why you do this
Make saw cuts and remove corners by planing = allows wood to fix onto lathe without slipping
35
Name part A
Drive centre
36
Name part B
Tailstock
37
Name the turning process
Facing
38
Name the turning process
Parallel turning
39
Name the turning process
Taper turning
40
Name the turning process
Parting
41
Name the turning process
Drilling
42
Name the turning process
Knurling
43
Describe the turning process facing
Tool moved at right angles to axis, facing end surface
44
Describe the turning process parallel turning
Tool moved parallel to axis to form a cylinder, reducing the diameter
45
Describe the turning process taper turning
Tool moved at angle to axis to produce a taper
46
Describe the turning process parting
Narrow tool fed into work to trim, to length or part work from stock bar
47
Describe the turning process drilling
* Tail stock used to hold chuck into which a dril can be placed
* As work rotates, drill is fed into the work
48
Describe the turning process knurling
Hardened steel wheel pressed into the rotating work to produce straight or diamond pattern
49
Name 3 advantages of metal turning
* Chuck can hold a variety of sizes and lengths
* Very accurate sizing can be achieved with fine adjustments of the cross slide
* Drilling and tapping can be carried out
50
Name 3 disadvantages of metal turning
* Very difficult to set up non-cylindrical items
* Long objects can flex if not correctly supported along their length
* Once an object has been removed, it is difficult to reset it to centre
51
Name 3 products made by blow moulding
* Shampoo bottles
* Water butts
* Milk containers
52
Describe how blow moulding works
1. Tube (parison) of softened plastic is inserted into a solid mould
2. Air is then injected which forces the plastic to expand to the shape of the mould
3. Product dropped out of machine as two halves open
53
Name 3 advantages of blow moulding
* Very cheap unit costs
* Produces high volume - can run 24/7
* Not very labour-intensive
54
Name 3 disadvantages of blow moulding
* Initial costs of machine and tooling very high
* Sometimes a seam if left around product where mould closes
* Products sometimes need to have flashing removed
55
Describe vacuum forming
1. Sheet of thermoplastic (e.g. HIPS) is heated until it goes soft
2. A mould is put onto the vacuum bed & bed is then lifted close to the heated plastic
3. Air is sucked out from under the plastic = creating a vacuum
4. Air pressure from outside the mould then forces the plastic onto the mould
56
Name 3 examples of product made from vacuum forming
* Yoghurt pots
* Trays
* Masks
57
Name 3 products made by injection moulding
* Buckets
* Bottle caps
* Wheelie bins
58
Describe injection moulding
1. Hopper filled with plastic pellets
2. Which are then fed along the machine by a large screw & are heated as move through it
3. Once the plastic is fully melted, the molten plastic is injected into a mould
1. Mould made out of 2 separating halves which come together to from whole shape of product
4. Cools in the mould until solid and then is released
59
Name 3 advantages of injection moulding
* High level of accuracy
* Little or no secondary surface finishing required
* Identical components formed each time
60
Name 3 disadvantages of injection moulding
* Initial machine and mould costs high
* Some flashing may have to be removed
* Sprue pins need to be cut off
61
Name 3 things you need to do before vacuum forming
* All vertical surfaces need to be slightly tapered = so product can easily removed from mould
* Round off sharp corners = don't puncture or rip the plastic
* Incorporate vent holes to avoid pockets of aire becoming trapped
62
Name 3 advantages of vacuum forming
* Lightweight, hollow products can be made
* Relatively cheap moulds can be made from MDF in school workshop for a one-off item
* Surface textures can be moulded into products
63
Name 3 disadvantages of vacuum forming
* Thermoplastic material sometimes thins too much and may burst/pop
* Webs sometimes form between items = product formed cannot be used
* Products need to be trimmed and cut out
64
What is wood laminating used for?
To produce the desired shape or curve
65
Describe wood laminating
Thin strips of wood (2-6 mm) are glued together and held in a jig, which keeps them in the right shape till the glue has dried = strips of wood stay bent
66
Name 3 products made from wood laminating
* Rocking chair runners
* Table legs
* Roof beams
67
Name 3 examples of products made by extrusion
* Plastic-covered wire
* Rain water guttering
* Copper pipes
68
What is type of products is extrusion used to make?
Products that have a regular, fixed cross-sectional profile
69
Describe extrusion
1. Process similar to injection moulding - used for some metals and thermoplastics
2. Material is melted and forced under pressure through a die
3. Produces long, continous strips of moulding exactly the same shape as the the exit hole
70
What's the difference between plastic and metal extrusion?
Plastic extrusion uses plastic pellets & metal extrusion starts with a billet (large lump of metal) that's heated up before placed into the extrusion machine
71
Name 3 advantages of extrusion
* Continuous lengths can be produced
* Complex profiles can be achieved
* Seamless tibes can be produced
72
Name 3 disadvantages of extrusion
* Initial set-up costs of machinery and upkeep are high
* Die costs can be very high
* Hot extrusion of metals e.g. steel can leave oxidised surface finish
73
Name 4 temporary joining methods
* Tapping and threading
* Nuts, bolts and washers
* Screws
* Knock-down fittings
74
Name 4 permanet joining methods
* Nails
* Dowel joints
* Welding
* Rivets - snap and pop
75
Tapping and threading can be carried out on both ___ and \_\_\_
metals and plastics
76
What is tapping?
The process of cutting and internal (female) screw thread
77
What is threading?
Cutting of an external (male) screw thread
78
Describe how tapping and threading is done
* Hole is drilled and 'tap' is used to cut a female thread in the hole
* Screw is inserted into it and tightened until it stops
* You can make round rod fit a threaded hole by cutting a male thread onto the ouside it, using a 'split die' ot on a lathe
79
Name the tool
Tap
80
Name the tool
Split die
81
Name?
'Drunken' Thread
82
Name 3 advantages of tapping/threading
* Can be carried out in plastic and metal
* Size of thread can be varied slightly by adjusting the pressure on the split die
* Nuts and bolts widely available for use with tapped or threaded components
83
Name 3 disadvantages of tapping/threading
* Boths taps and die made from high-speed steel = easy to break if dropped/too much pressure applied
* Taps are easily broken when threading blind holes
* Difficult to start threading and to make the thread parallel to axis of rod or hole being threaded
84
Name?
Nut
85
Name?
Washer
86
Name?
Bolt
87
Name 3 advantages of nuts, washers and bolts
* Can be undone so items can be taken apart
* Come in various lengths and sizes
* Lock nuts can be used for a firm fixing
88
Name 2 disadvantages of nuts, washers and bolts
* Can work loose with vibration
* If correct size is not used you can wear the head down
89
Name part 1)
Countersunk hole
90
Name part 2)
Clearance hole
91
Name part 3)
Pilot hole
92
Name?
Round head
93
Name?
Countersunk head
94
Name 3 tips to follow to avoid splitting the wood or damaging the screw head
* Screw through the thinner piece into the thicker one
* The screw should be three times as long as the piece being fixed
* Drill a clearance hole slightly bigger than the shank of the screw
95
Name 3 advantages of using screws
* Can be easily removed
* Some new types of screws don't need clearance and pilot hole drilling
* Can be used to join dissimlar materials
96
Name 3 disadvantages of using screws
* Steel screws will rust if used outside
* Some screws can be quite hard to remove
* It is difficult to get screws of it they shear off
97
What do knock-down fittings allow?
Allow joints to be made & taken apart easily and quickly
98
What are knock-down fittings used in?
Construction of furniture and kitchens
99
Name?
Round wire (nail)
100
Name?
Oval wire (nail)
101
Name?
Panel pin (nail)
102
What are round wire nails used for?
General-purpose joinery
103
Name 2 advantages of round wire nails
* Big, flat head makes it easy to hit
* Sometimes serrated which helps them to grip
104
Name a disadvantage of round wire nails
Longer nails can bend when hammering them in
105
What are oval wire nails used for?
Fixing floorboards to joists and general joinery
106
Name an advantage of oval wire
Head can be punched below surface and hole filled
107
Name a disadvantage of oval wire
Very difficult to get out as head goes below the surface
108
What are panel pins used for?
Finer work e.g. mitre joints
109
Name an advantage of a panel pin
Small heads can be punched below the surface with a nail punch
110
Name a disadvantage of a panel pin
They bend more easily due to their thinness
111
Name the wood joint
Halving joint
112
Name the wood joint
Butt joint
113
Name the wood joint
Rebate joint
114
Name the wood joint
Housing joints
115
Name the wood joint
Mortise and tenon joint
116
Name the wood joint
Dowel joint
117
Describe a halving joint
Made by cutting away half thickness of material on each half of the joint
118
What are halving joints used for?
Corners
119
Halving joint - pro
Fairly strong
120
Butt joint - pro
Very easy
121
Butt joint - con
Very weak
122
Butt joint - use
Cheap furniture
123
Describe a rebate joint
One part is left plain and other has rebate cut into it
124
Rebate joint - pro
Easy
125
Rebate joint - con
Average strength
126
Housing joint use?
Shelves
127
Mortise and tenon joints use?
Construction of furniture frames
128
Name 4 metal joints
* Soft soldering
* Brazing
* Welding
* Rivets
129
Describe soft soldering
1. Thin layer of solder applied to each piece
2. Both pieces then brought together
3. Gentle flame applied so 2 pieces become 1
130
Name 2 advantages of soft soldering
* Can be used on various metals
* Relatively low temperatures involved
131
Name a disadvantage of soft soldering
Can take a long time to set up
132
Describe brazing
Bonding materials (usually metals) by melting a filler metal or alloy between the components you want to join
133
Name an advantage of brazing
Creates a strong joint
134
Name a disadvantage of brazing
Fumes given off due to flux buring
135
Describe welding
Uses very high temperatures to melt edges of joint = flow together, fuse together as it cools
136
Name 2 advantages of welding
* Creates strong, fused joint
* Some devices are portable and can be easily transported
137
Name 2 disadvantages of welding
* Need to wear very dark goggles
* Can only be used to join similar materials
138
When are rivets used?
In sheet metals
139
When is a pop rivet used?
When there's only access to one side of material
140
Describe how pop rivets work
1. Metal pin inserted through hole in centre of pop rivet
2. Both rivet and pin = placed in hole in material
3. Pin is pulled tight with a riveter (or pop gun) till it snaps off
4. Pulling pin tight = makes end of rivet expand = forming head on 'blind' side
141
Name 3 advantages of rivets
1. Fast and easy method of joining thin sheet metal (pop riveting)
2. Joint can be created as hinges
3. Little specialist equipment required
142
Name a disadvantage of rivets
Can be time-consuming when snap riveting
143
What is PVA glue used for?
Gluing wood
144
Describe how you use PVA glue
Put on joint and must be held together while glue dries
145
Name 3 advantages of PVA glue
* Strong joint
* Does not stain
* Long shelf life
146
Name a disadvantage of PVA glue
Most types are not waterproof
147
What is contact adhesive used for?
Glueing large sheet materials - e.g. Sticking down floor tiles
148
Describe how you use contact adhesive
* You apply it to both surfaces and keep surfaces apart until glue goes tacky
* When surfaces brought into contacts sticking is pretty instant
149
Name 3 advantages of contact adhesive
* Sets in 20-30 minutes
* Gives very strong bond
* Can be used to join dissimilar materials
150
Name 2 disdvantages of contact adhesive
* Does not allow repositioning
* Gives off harmful fumes
151
Describe how you use epoxy resin
Two separate substances are mixed together in equal parts = starts to harden due a chemical reaction
152
What will epoxy resin stick to?
Almost anything
153
Name 3 advantages of epoxy resin
* Very strong
* Waterproof
* Takes about 15 minutes to harden
154
Name a disadvantage of epoxy resin
Expensive (to use on large-scale work)
155
What is acrylic cement used for?
Used to join plastics together
156
Describe how you use acrylic cement
Two plastic surfaces need to be clamped together for 24 hours so permeant bond can form
(dissolves surfaces - "fusing" surfaces together)
157
Name an advantage of acrylic cement
* Waterproof
158
Name 2 disadvantages of acrylic cement
* Gives off harmful fumes
* Very smooth surfaces need to be roughened a bit
* (Takes 3-24 hours)
159
