more production stuff

Question 1

what are production aids

Answer 1

tools and techniques used to aid production, often speeding up or simplifying a process

Question 2

what is a reference point

Answer 2

a point where measurements are made from
- helps control accuracy

Question 3

what is a datum point

Answer 3

the point where x, y and z meet at (0,0,0)

Question 4

why are reference points important

Answer 4

• they align CAM machines with the materials they are operating on
• they reduce measurement errors

Question 5

what do CAM machines use reference points for

Answer 5

to guide the tool being used

Question 6

how to use a reference point for scaling the size of something like a drawing

Answer 6

1. choose a reference point
2. figure out how far away each point on the drawing is from the point
3. multiply these coordinates by a scale factor
4. plot your new coordinates

Question 7

what is a template

Answer 7

a shaped piece of rigid material used as a pattern for processes such as cutting out or drawing around

Question 8

advantages of templates

Answer 8

• quicker and easier than measuring out the dimensions of the shape eac time
• useful in quality control, as you can check your components against the template
• using a template makes the procure consistent

Question 9

features of templates

Answer 9

• need to be strong
• need to be hard wearing
• so that they can be used repetitively without getting damaged or worn

Question 10

what are patterns

Answer 10

templates that are used to cut out pieces of fabric - these pieces are then sewn together to make a textiles pridgcb

Question 11

what are patterns normally made from

Answer 11

tissue paper which are then pinned to a fabric so that you can cut around them

• can be made from materials such as resin wood and metal

Question 12

how are patterns made using CAM

Answer 12

• CAM cutting machines are used to cut the fabric
• The patterns are drawn out using CAD. the coordinates of the patterns outline are then used to tell the machine how to cut the pieces of fabric

Question 13

what does casting involve

Answer 13

forming a material into a particular shape - determined by a pattern

Question 14

what can patterns be used to make

Answer 14

moulds that are used in the casting process and make products that are a consistent shape

Question 15

what is a jig

Answer 15

a device that guides the tools that are working on a component, or makes sure that the workpiece is positioned in the right place for machining

Question 16

what does a drilling jig do

Answer 16

• guides the drill, which helps cut down errors and makes sure that components are consistent
• using this means you don’t have to mark out exactly where you want to drill, saving time and effort

Question 17

what does a dovetail jig do

Answer 17

allows complex, dovetail joints to be cut easily and quickly, with minimal measuring and marking out

Question 18

potential disadvantage of using jigs

Answer 18

although they can be really useful, they can take a long time to make, so not worthwhile using one if you’re only gonna make a few products

Question 19

what are paper and board made from

Answer 19

cellulose fibres

Question 20

how is board/paper made

Answer 20

1. trees are cut down and taken by lorry to a paper mill
2. the bark is stripped off. The wood is then cut into small pieces by a chipper
3. these small bits of wood undergo chemical or mechanical pulping to turn them into a mushy brown pulp
4. The pulp is then washed and bleached to make it white, hen it’s pressed clay between rollers, dried and cut to size

Question 21

why is pulping an important stage in paper and board making

Answer 21

it converts the wood into individual cellulose fibres (pulp)

Question 22

what does mechanical pulping involve

Answer 22

grinding down the wood to separate out fibres

Question 23

what does chemical pulping involve

Answer 23

heating the wood with chemicals - this dissolves other parts of the wood, leaving just the fibre behind

Question 24

where else can cellulose fibres come from

Answer 24

other plants like grasses - the process is similar to wood but theres no debarking or chippung

Question 25

examples of types of board that may have an extra stage in production

Answer 25

corrugated cardboard needs its fluted middle layer sticking to the outer layers to form a laminate

Question 26

How is wood made

Answer 26

1. Trees are felled (cut down)
2. the bark is removed and the trunk is sawn up
3. the wood is the seasoned by drying it

Question 27

what does the way a trunk is sawn affect

Answer 27

how the plank looks and how much its likely to bend or warp (twist)

Question 28

ways wood can be seasoned

Answer 28

air drying or kiln drying

Question 29

summarise air drying

Answer 29

involves stacking up wood outside or in sheds and allowing air to circulate around it

Question 30

summarise kiln drying

Answer 30

similar to air drying but its done in a heated chamber with fans to circulate the air

Question 31

pros and cons of kiln drying

Answer 31

• quicker
• ## but conditions have to be carefully controlled to avoid the wood drying too fast (which can damage it)

Question 32

how is MDF made

Answer 32

using wood that has been processed into cellulose fibres

Question 33

how is chipboard made

Answer 33

using a mixture of dried wood chips, shavings and saw dust

Question 34

whats the long name for glue

Answer 34

urea formaldehyde

Question 35

what is added to mixtures such as chipboard and mdf

Answer 35

glue

Question 36

how is plywood made

Answer 36

using wood that has been softened, either through soaking it in hot water or steaming it
- a thin sheet is peeled from the softened wood, cut to a suitable size and dried
- the cut wood can then be arranged into stacks of three or more layers (each with a grain direction of 90 degrees)
- glue is then added between each layer and the sheets are heated and pressed

Question 37

where do metals come from

Answer 37

the ground as a metal ore

Question 38

what is a metal ore

Answer 38

a rock with enough metal locked up in it to make it profitable for the metal to be extracted from the rest of the ore

Question 39

how are metals made

Answer 39

1. metal is mined from the ground as a metal ore
2. metal is then extracted using displacement or electrolysis
3. impurities are removed from the metal in a process called refining
4. the refined molten metal is usually cast

Question 40

describe the two ways of extracting metals

Answer 40

• some metal ores can be crushed then heated in a furnace with other materials such as charcoal. the metal separates out and will often sink to the bottom where it can be tapped off
• electrolysis uses electricity to extract a metal from its ore

Question 41

why are metals refined

Answer 41

because when they’ve been extracted from their ores, they will contain impurities

Question 42

what are impurities

Answer 42

small amounts of other substances

Question 43

what is casting

Answer 43

a process which involves pouring metal into a mould and allowing it to cool and solidify into the required shape

Question 44

Examples of metal ores that have to be prepared before extraction takes place

Answer 44

bauxite is heated under pressure with chemicals to separate aluminium oxide

Question 45

what are most plastics made from

Answer 45

crude oil

Question 46

how are plastics made

Answer 46

1. crude oil is extracted from the ground and taken into a refinery
2. here, its heated using a process called fractional distillation, which separates it into different chemicals called fractions
3. some of these fractions can be linked together to make polymers and some need cracking
4. these plastics can then be used

Question 47

what is cracking

Answer 47

a process where you heat fractions and break them down into smaller molecules