P83-86, 104-106

Question 1

Describe the process of sawing and cutting using hand tools

Answer 1

1) mark out cutting lines, measure from datum point
2) material should be clamped or held in a vice to prevent movement
3) drag saw backwards to create niche which marks starting point clearly. use full length of cutting blade + avoid pressing too hard- saw could bend = inaccurate bending
4) support the end piece at the end of the cut to ensure clean cut
5) remove rough edges by sanding machine, filing or sandpaper

Question 2

What is wasting/wastage?

Answer 2

• “subtractive” processes
• material is removed to cut/shape it
• eg sawing, filing, routing, drilling, turning, laser cutting etc.

Question 3

What are addition/additive processes?

Answer 3

• process where material is added
• eg lamination, printing, soldering, welding, 3D printing, lay-up method for CFRP, etc

Question 4

What are forming/ deforming processes?

Answer 4

• where material are shaped/ deformed
• eg laminating with a mould to bend wood, vacuum forming HIPS, steam bending timber etc.

Question 5

What are reforming/ redistrubition processes?

Answer 5

• materials are melted to liquid, made into totally different shape
• eg. injection moulding, blow moulding, extrusion

Question 6

What is a rip/ cross-cut saw used for?

Answer 6

• straight cuts
• cutting wood across/ along the grain
• less accurate (no “back” to keep it rigid)
• rough cuts

Question 7

What is a tenon saw used for?

Answer 7

• straight cuts
• cutting shallow lines into small pieces of wood
• “back” of saw stops blade from bending
• more accurate
• has depth restriction

Question 8

What is a coping saw used for?

Answer 8

• cutting curved lines through thin material
• thin blade + large frame for curves
• for timber, plastic and thin metal

Question 9

What is a hacksaw/ junior hacksaw used for?

Answer 9

• straight cuts
• fine toothed for cutting hard materials such as metal/ plastic

Question 10

What is the kerf?

Answer 10

• gap due to waste created when cutting
• account for kerf when cutting

Question 11

draw a diagram of 3D printing

Question 12

draw a diagram of laser cutting

Question 13

Describe 3D printing

Answer 13

• builds three-dimensional object formed from reels of thermoplastic
• use CAD files that are converted to series of co-ordinates (G-code)
• printer follows to build up object in layers
• additive manufacturing

Question 14

What is batch production?

Answer 14

• making 2- thousands of consistent products
• uses jigs, templates and moulds to ensure consistency
• large batches reduce overall cost of item
• each batch tested for quality and uniformity
• machines may need to be recalibrated or stopped between batches -> down time

used for seasonal products, baked goods, newspapers etc

Question 15

What is a prototype?

Answer 15

• representation of a product
• eg physical model/ CAD model
• helps evaluate and test a design, confirm design methods and costs
• test aspects like size, aesthetics, ergonomics, or function

Question 16

What is one-off production?

Answer 16

• manufacture of a single item
• fully functioning, complete
• eg custom made jewellery, bespoke furniture
• skilled craftsmanship will be high
• costs go up as well

Question 17

What is mass production?

Answer 17

• producing thousands to millions of standardised products
• automation used to efficiently produce high volume porducts
• fewer workers
• set up costs are high
• costs spread over large number of goods, reduces the cost per unit
• used for things that will stay for a few years before getting replaced

used for mobile phones, cars

Question 18

What is continuous production?

Answer 18

• process that takes place 24 hours a day, 7 days a week
• expensive
• highly automated with small work force
• machinery is set up to produce large volume of one item
• used for products that will never go out of fashion

eg components such as screws, nuts, bolts

Question 19

What is a jig used for?

Answer 19

• holds the material and guides the tool
• secures work piece quickly and without causing any damage to material
• always located against reference point or datum edge
• imporves accuracy and efficiancy

Question 20

What is a template?

Answer 20

• a shape to draw aorund
• ensures item is accurately made
• can be replicated for consistant quality
• should be made of durable material

Question 21

What is a paper pattern?

Answer 21

• a shape to attach to materials to be cut
• usually used for textiles

Question 22

What is a fixture?

Answer 22

• holds the material, does not guide tool
• eg. clamp

Question 23

What is a former?

Answer 23

• shape that plastic is formed around in vacuum forming

Question 24

What is a mould?

Answer 24

• what the molten plastic is injected into in injection moulding

Question 25

What is a datum reference point?

Answer 25

- point from which all reasurements are taken - accuracy is increased by ensuring measurements are taken from only these points

Question 26

What is a scale drawing?

Answer 26

- allows designer to accurately represent an object or building in one practical size | proportions are the same, can be scaled larger or smaller

Question 27

Describe turning

Answer 27

- lathe used for turning timbers or metals at speed - while material spins tool is held against it to cut, sand and deform evenly around object - commercial wood turning operated by CNC machinery - rotation speed adjusted, depends on diameter of material

Question 28

Draw a diagram of turning

Question 29

What is steam bending?

Answer 29

1) timber placed in steam box 2) steam increases moisture content = timber is more flexible, 1hr per 25mm of thickness 3) timber bent around former and clamped in place 4) moisture dried from timber, shape is kept

Question 30

What is laser cutting?

Answer 30

- directs laser beam at precise focal length to cut, etch or engrave on material - accurate- laser beam does not blunt or wear out - speed, power and dimension settings according to material - consumes lots of power