Materials and Components Flashcards
What is Reverse Engineering?
Reverse Engineering is the process of taking something (a product, a device, an electrical component etc) apart and looking its workings in detail, usually with the intention to construct a new device that does the same thing or better without copying anything from the original.
Benefits:
- allows to look at the interrelationships between parts/components
Can identify…
- possible methods of manufacture
- possible range of materials used
- assembly sequence
- construction details
- Can identify potential faults
- Can give a potential insight of costs
Save time and money as product is not being developed from scratch.
What is Injection Moulding
Injection Moulding is the process of injecting molten material under high pressure into a mould or die to achieve a certain form
+ Fast Production
+ High Repeatability
+ Precise
+ little to no plastic waste
- High Initial Cost
- Part design and size restrictions
- Plastic resin is poured into a desired shape
- The holding pressure is applied to increase density of the plastic.
- The plastic is then cooled and solidified
- The plastic is carefully released
Silver
white lustre precious metal, tarnishes quite quickly
Properties - sonorous, ductile and very malleable so can be shaped into intricate shapes
Uses - Jewellery, dental fillings, plasters, mirror back
Aluminium
- commonly used an alloy its increase its potential applications
Properties - low density, resistant to corrosion and 100% recyclable
Uses - aerospace industry (plane hulls, wings), packaging (drink cans), transport (cars, electronics)
Brass
- alloy of copper and zinc
- commonly used as decoration as its thought to look nice due to its gold colouring from the mixture of copper and zinc
Uses: Coins, insruments, ornaments, plumbing and electrical applications
Bronze
- alloy of copper and tin
- not used as much anymore due to brass having more functional properties
Uses: ornaments, sculptures,
Low and Medium Carbon Steels
- varying levels of carbon - higher carbon content the higher the strength but too much can make the steel brittle
Uses - Metal works,tools
Smart Materials
SM are materials that can change their properties if exposed to an external stimulus (e.g. light, heat etc)
Microbead Technology
- smart technology linked to graphic products
- an example being scratch and sniff, where the desired smell is surrounded by micro capsules (through the process of micro encapsulation) that break easily upon impact
Photochromic
Materials that change colour when subjected to changes in light. E.g. light reactive lenses in glasses allows them to function as sunglasses. The advantage of this being they don’t need to purchase an additional prescription of glasses
Thermochromic
Thermochromic materials changes when subjected to different temperatures. Example products being colour changing art work, clothes and graphic products.
Shape Memory Alloy (SMA)
SMA is an alloy that when deformed returns to its original shape when heated
(e.g. nitinol)
Polymorph
Polymorph is a low melt polymer. At 60’ it becomes soft and putty so it can be moulded in different shapes. It can be used to make products like handheld aids for people who have difficulty gripping items. It can also be used to make prototype parts for products as it can bed used quicky and easily without heavy machinery.
Piezoelectric
Piezoelectric materials are materials that can produce a voltage and change shape when voltage is supplied to them. Its used in everyday objects like lighters and ignition switches.
What is CNC?
CNC machining is a type of automated machining process that uses computer numerical control technology to shape an object by removing material from a workpiece until desired shape is achieved
+ accuracy of shapes and interlocking fittings
+less human error
+ hard materials
+ repetition of shapes
+ difficult or complex shapes can be produced
What’s the advantages of prototyping
- Allows designer to identify possible faults in the design prior to the full-scale production (saves potential wastage of resources and applications)
- Allows the manufacturer to identify suitable production processes and possible standard parts that could be used allowing for efficient and economic production of the product
What is a composite material?
A combination of two or more materials that have different properties that when mixed together have improved properties. Individual materials remain distinct within the new material.
What is Carbon Fibre
A very strong polymer that has been reinforced with carbon fibres (composite materials)
+ Strong
+ Lightweight
+ Excellent strength to weight ratio
+ Resistant to corrosion
Generally manufactured using compression moulding
Uses: Sport Equipment, Car/cycle bodies, tent poles
What is GRP?
GRP is glass reinforced plastic (commonly called fibreglass) (composite materials).
+ Strong (not as strong as carbon fibre)
+ Flexible
+ Less expensive
Uses: Boat Hulls,roofs,baths
Properties Of Materials
Tensile Strength: The ability of a material to stretch under tension, material with high tensile strenghts will shear
Elasticity: The ability of a material to absorb force and flex in different directions, returning to its original position
Plasticity: The ability of a material to be change in shape permanently.
Ductility: The ability of a material to change shape (deform) usually by stretching along its length
Malleability: The ability of a material to be reshaped in all directions without cracking
Toughness: The ability of a material to absorb sudden shock without breaking or shattering.
Jig
A device used to guide a tool to a specific position on a workpiece. Provides high accuracy, precision and repeatability
Bought in-components +/-
Bought in components are pre-manufctaured parts which are bought in to aid the production of a product
+ + dont require expensive machinery or specilaists to make the components which is cost effective
+ Improved quality control and ensures consitency for the manufacturer which saves time
- more storage space required for parts
- ordering takes time, and delays occur
Temporary/Permanent Fixings
Nails (Permanent) - Wood
- Round wire - very cheap, poor quality
- Oval Wire - reasonably priced, better quality
- Panel pin - extra support or for thin sheets of wood
Screws (Temporary) - Wood/Plastic
Nuts + Bolts (Temporary) - All materials (Nuts usually made of low/medium carbon steel, alloy steel)
Rivets (Semi - Permanent) - Metal
When talking about consider their application for the product, how easy are they to manufactuerer, can they be removed for replacement of parts, will they requrie skilled workers to apply/machinery to make?
Knockdown fittings
Temporary however many are used to permanently join together items such as cabinets and other furniture.
Fixit Block
Rigid joint
