Product Design Theory Flashcards
(145 cards)
1
Q
What is the definition of anthropometrics?
A
The measurement of the size and proportions of the human body
2
Q
What is the definition of ergonomics?
A
-The scientific study of people
3
Q
What are some examples of ergonomics?
A
-sounds eg. Fire alarm
-smell eg. Smell of gas
-sight eg. Visual distortion of road writing
4
Q
What is bespoke/ one-off production?
A
-one-off products that are tailor-made specific to users needs.
5
Q
-give an example of a product made in bespoke/ one off manufacture?
A
-suits
-ceramics
-jewellery
6
Q
What is batch production?
A
-Batch production is used when a greater numbers of products are required, but doesn’t need continuous production
7
Q
What is an example of a product made in batch production
A
-seasonal goods eg. Christmas decorations/ Easter eggs
8
Q
What is mass/line production?
A
-continuous production, when a high number of products is needed to be made quickly and consistently
9
Q
-What products are made in line/mass production?
A
-pens
10
Q
What is quick response manufacture?
A
-when production is triggered by consumer demand and not through traditional methods.
11
Q
-What is the BSI?
A
-British standards institution, has a bunch of standards that any product sold in England must adhere to.
-Has the kite mark as the logo
12
Q
What is iso?
A
-International organisation for standards
- SO has worldwide standards, which the member countries can test for, allowing companies to extend markets and trade in other countries.
13
Q
What is the CE?
A
-confirmative European
-This is not a tested standard. However, the letter CE appear on electronic devices show how they’ve been tested and are safe.
14
Q
What is the UKCA?
A
-shows that a product meets the UK standards for safety
15
Q
What is the WEEE directive?
A
-waste from electrical and electronic equipment
16
Q
What is the FSC?
A
-Forest stewardship Council
-The label is given to ethnically produced wood
17
Q
What dose COSHH stand for?
A
-Control of substances, hazardous to health
18
Q
What is a hardwood?
A
-hard woods come from delicious trees, which lose their leaves in winter
19
Q
-give an example of three hardwoods?
A
-Oak
-Teak
-Beech
20
Q
-What is a softwood?
A
-softwoods come from coniferous trees
21
Q
-Give an example of three softwoods
A
-pine
-Spruce
-Cedar
22
Q
What is tracked Farming?
A
-using a feller brancher to harvest of strip of trees in a set area.
23
Q
-What is a polymer?
A
-a long chain of monomers that make up a Thermoplastic or a Thermo setting plastic
24
Q
What is vacuum forming?
A
-vacuum forming is when is sheets of plastic (usually HIPS) is heated up, then vacuumed over a mold with a tapered edge, so that it forms the shape of a mold.
25
-What is thermoforming?
-when a sheet of plastic is heated up and then mould is pressed onto the surface of the polymer whilst the plastic is vacuumed into shape at the same time
26
-what is line bending
-A strip of heat used to bend sheet polymers
27
-What is extrusion?
-extrusion is when plastic is pushed through a die to form tubes, piping, etc. the flow of plastic is continuous and comes through a hopper into a screw like contraction, after it then goes through a cooling tube to set it.
28
-What is injection moulding?
-injection moulding is when a polymer is melted, and then is injected into mould at high speeds so that it forms the shape of the mould.
29
-what is blowmolding?
-When an extruded piece of plastic runs into a mould, air is then blown into this, the pressure from the air causes the extruded plastic to form the shape of the mould
30
What is compression moulding?
-plastic is placed into a heated mould, a hydraulic press, then compresses the plastic so that it melts and forms the shape of the mould
31
-what products are made through vacuum forming?
-yoghurt, pots
-Packaging
32
-What products are made for thermoforming?
-plastic containers
33
-what products are made through extrusion?
-hollow tubes,
-pipes
-T sections
34
-what products are made through injection moulding?
-Lego
-computer mouses
35
-what products are made from blowmolding?
-drinks bottles
-laundry detergent containers
-cleaning product bottles
36
-what is made through compression moulding?
-electrical sockets
37
-What is sandcasting?
-when the mould is made from sand,
Sand takes the shape of an existing product and is then filled with molten metal.
38
-what products are made from Sand casting?
-carriage wheels, woodworking, clamps, drain covers
39
-what is high-pressure die casting?
-When molten metal is stored in a chamber, a pneumatic hydraulic plunger, then forces a shot of molten metal into a mould at a high pressure
40
-what products are made from high-pressure die-casting?
-locks, gears
-toy cars
41
-what is gravity diecasting?
-When molten metal is poured into mould and gravity is relied on to fill the mould properly
42
-What products are made from gravity diecasting?
-machinery
43
-What is press forming?
-when sheet metal is pressed into 3-D shapes using metal presses (hydraulic press) and moulds.
44
-what products are made from press Forming?
-car body panels
-metal seats
45
-What is drop forging?
-when you shape hot metal into the shape, the metal isn’t molten however can still be worked with easily
46
-what products are made from drop forging
-spanner, pliers, screwdriver
47
-What is spinning?
-spinning a metal at high speeds and pushed over a former to form the shape of the metal
48
-What products are made from spinning?
-kettles, saucepans
49
-what is wrought iron forging?
-when metal is shaped using hammers
-The metal is hit and bent in to shape
50
-what products are made through wrought iron forging?
-horse shoes
-fences
51
-what is Bending?
-when sheet metal is bent into shape using a hydraulic press
52
-what is rolling?
-when stock metal is passed through rollers to reduce the thickness
53
-What is MiG welding?
-when inert gas is used to heat up a filler rod to join two metal metals.
54
-what is TIG welding?
-tungstead inert gas is used to heat a localised area to join metals. This is through the use of a non combustable electrode
55
-what is brazing?
-when a brazing torch is used to heat two dissimilar metals in order to join them.
56
What are the characteristics of low carbon steel?
- iron with 0.3 percent carbon
- stiff and strong
- uses: nuts, bolts, washes
57
What are the characteristics of medium carbon steel?
-iron with an addition of 0.6% carbon
-strong and extremely hard
-uses: Guardening tools, drain covers
58
-what are the characteristics of cast iron?
-iron with an add of 2 percent carbon
-hard and rigid
-uses: machine parts, brake disks
59
-what are the characteristics of aluminium?
-light and strong
-extracted from bauxile
-uses: kitchen wear
60
What are the characteristics of copper?
-high melting point, corrosion resistant
-uses: electrical contacts, pipe work
61
What are the characteristics of zinc
-low tensile strength, low melting point
-uses: buckets, coatings
62
What are the characteristics of silver
-good electricity conducting, antibacterial properties
-uses: cutlery, decorative items, jewellery
63
What are the characteristics of gold
-high melting point, good electrical conductor
-uses: jewellery
64
What are the characteristics of titanium?
-high melting point, good strength,
-uses: surgical applicants, jewellery
65
What are the characteristics of tin
-low melting point, soft and malleable
-uses: tin foil and coatings
66
What are the characteristics of stainless steel?
-alloyed with chromium, Nickel and magnesium
-corrosion resistant, doesn’t stain, tough and wear resistant
-uses: cutlery
67
What are the characteristics of die steel?
-alloyed with chromium and magnesium
-hard, tough, water resistant, hard
-used for tool bits, machinery, cutting bits
68
What are the characteristics High speed steel?
-alloyed with tungsten, chromium, vanadium
-uses: cutting tools, milling bits, lathe tools
69
What are the characteristics of bronze?
-is 10% tin with a base metal of copper
-is hard, had high strength, is corrosion resistant
-uses: statues, coins
70
What are the characteristics of brass?
-base material is copper with 35% zinc
-corrosion resistance, wear resistant, good electrical and thermal conductor
-uses: cast valves, tops, ornaments
71
What is a trade mark?
-colours, logos, songs etc that identifies a company
72
What is copy right
-copy right is an automated protection for work eg work such as art, photography, music etc. already coke with copy right
73
What is quality assurance?
-procedures and and policies put in place to ensure products are manufactured correctly to the correct tolerances
74
What is quality control?
-the maintaining, checking and testing of products and products through out products to ensure they meet correct tolerances
75
-what are go no go gauges
-used to check parts are in tolerance, if the product fits into the Gage perfectly then it should be in the correct tolerance
76
Why are X rays and ultra sounds used in production?
—check manufactured objects for defects such as cracks, other flaws
Eg, looks for cracks in a pipe
77
What is inclusive design?
-the design of mainstream products so they are accessible to as may people as possible.
78
-what is empathetic design?
-where designers take pert in tasks simulating restrictions faces by a user group, so they have a better understanding of what they are designing for
79
What is a case study of inclusive design?
-ford developed third aged suits to simulate difficulty’s which old people may face when driving so that they can develop there cars with an understanding
80
-why would a lubricant be added to a polymer?
-reduces viscosity and lovers manufacturer temperature
81
Why may a placitiser be added to a polymer?
-makes a plastics less hard and brittle and more flexible
82
Why are antioxidants added to polymers?
-reduces environmental degradation, which leads to damage/ degradation of the plastic
83
Why are UV light stabilisers added to polymers?
-to prevent polymers being broken down by uv lights
84
What is a composite?
A composite is a material which is produced from two or more constituent materials. These materials are dissimilar and merged to create strengths.
85
What is an example of a composite material
Concrete-
-cement powder, sand aggregate particles are mixed with water
-this creates a high compression strength
86
What is pressure treatment?
-timber is compressed in a vacuum, and then antifungal treatments are inserted through the pressure
87
What is tensile testing?
-tensile testing measures the material strength, and the behaviour of the material under detention by gradually increased in the forces until it breaks
-tensile strength is the maximum stress and material can with stand before it breaks
88
What is toughness testing?
-toughness testing is a method used to evaluate materials ability to absorb energy, without cracking or breaking.
-Toughness testing the first amount of energy and material, and absorbed before a fracture or failure occurs.
89
What is harness testing?
-hardness testing is a technique used to determine a materials resistance to scratching or indenting.
-hardness value is an numerical measurement obtained from hardness testing, indicating the materials resistance to deformation
90
What is x-ray/radiographic testing?
-this is a nondestructive testing method that employs x-rays to examine the internal structure of an object x-rays show any defects that may occur.
91
-what is ultrasonic testing?
-is a testing method that utilises high frequency soundwaves to inspect the internal structure of materials
92
-What is metal enhancement?
-each metal has a range of properties, metal enhancement aim to change or enhance some of these properties without reducing others
93
What is metal hardening?
-hardening involves heating up mild and carbon steel, to 1275 degrees Celsius or above and the quenching it in cold water
-this place is stress on the platelets which then improves the hardness
94
-What is flame hardening?
-gas flames raised the temperature of the outer surface water jets are then used to quench the material
95
-What is induction hardening
-The metal has a hard outside and softcore and induction coil is used to heat a localised area of the workplace as it moves up and rotates jets of water cool the work rapidly
96
-What is tempering?
-after hardening steals are often too harder than required, meaning that they are often too brittle
-to reduce the brittleness tempering is used. This is where the metal is heated between 175 to 400° and is then left to air cool
97
-what is work hardening?
-this is where a metal is bent upbeat with a hammer which leads to the crystals, becoming distorted, making the metal harder.
98
-what is annealing?
-annealing is a process that removes the effects of work hardening, it heats the metal up to above its re-crystallisation temperature, and then allows the metal to be slowly cold, meaning the crystals move back to place
99
-what is case hardening?
-hardening is a process used to form a hard skin around the component
-this involves the metal being heated to a cherry red colour and then being dipped into carbon powder and allowed to cool
-this process needs to be repeated two or three times before being heated again, and then quenched in water
100
-What are oxides on metal?
— most metals have an oxide layer which provides some barriers against the environment, this forms from the metal reacting to the oxygen. for example, copper has a bright red layer which overtime turns green
101
-what is electroplating?
-electroplating is using a metal to coat another base metal.
-The product is placed in a container with another electrolyte solution. Direct current is applied and one metal, then attracts to the product.
102
-what is polymer or dip coating?
-The metal product is treated to approximately 230°, and then is dipped in the fluidisation of plastic powder.
-this is used on outdoor play equipment, coat hangers, et cetera
103
-What is metal dip coating?
-metals are coated with other metals to protect them. This is by dipping/plate in the product into another metal.
-for example, tin plating works by sheets of metal being passed through molten zinc at around 230°
104
-what is powder coating?
-The product which is to be coated is initially statically charged, thermosetting polymer resin is then sprayed through an air gun. The product is then heated in an oven so it melts over the metal.
105
-what is anodising?
-this is where current passes through a sulphuric acid electrode solution
Current flows from the product to the negative cathode.
106
— what is an STL file?
-an STL file is a 3-D format that represents the surface geometry of a 3-D model using a series of triangular faces
107
-what is a G code?
-G code consists of instructions that control movements and actions of a CNC machine, specifying certain toolpaths
108
-what is fused decomposition moulding?
-this is where a thermoplastic filament is heated to its melting point, and extruded fruit and nozzle onto a built platform, the material, then solidifies forming each layer.
109
-what are adhesives?
-an adhesive is a substance that is used to bond or joint to more materials together by creating a molecular or chemical bond
110
-What is cohesion?
-cohesion is when adhesives can exhibit the ability to stick to themselves
cohesion contributes to the adhesives ability to maintain its form and stay in place once its applied
111
-what is viscosity?
-viscosity is how runny a substance is
112
-what is PVA?
-PVA is a water-based adhesive bond, used to bond the majority of timbers
-it is self drying and is not waterproof
113
-What are contacted adhesives?
-contacted adhesives, bond range of materials. The surface is coated in adhesive adhesive them becomes tacky and then when the surface comes into contact with another material, the adhesive will dry holding the material in place
114
-What is epoxy resin?
-epoxy resin is a two part adhesive, including resin, and hardener. They mixed in equal parts and then an exothermic reaction occurs before they set.
115
-what are UV hardening adhesives?
-UV light cure the adhesive, the adhesive will not set, unless it does come into contact with UV light
116
-What is the purpose in labelling products?
-product identification, brand recognition, legal compliance, marketing information, product information
117
-what is the purpose of packaging?
-brand protection, brand identity, customer engagement, to protect the product, to provide information about the product.
118
-what is offset lithography?
-off set photography is use for printing, medium and long print runs
Eg.books
-The process uses oil and water, lymphography works as lithographic plates or chemically treated, so the image absorbs oil and the non-image area is treated to absorb water.
-The area is encoded with ink, the ink sticks to where it isn’t wet on the plate
119
What is screen printing?
-screen, print and transfers ink through a mesh screen onto a material. A stencil of a design goes onto a mesh screen, blocking non-printed areas, ink is in place onto a screen, and a squeegee, pushes the ink through the stencil
-this is used for T-shirts
120
-what is flexographic printing?
-ink is placed onto a roller and then is transferred onto a plate from the roller which then transfers, the image
-this is printing, used in packaging
-uses are plastic bags, cans and wrappers
121
What are preservatives?
-preservatives are treatment which help to protect and prolong the life of wood
-Preservatives are fungal and insect protections
-preservatives may have fire retardant properties
122
-how can wood be hardened?
-Wood can be injected with a natural polysaccharide, to increase the hardness
123
-how can resin and laminates enhance wood?
-manufactured boars such as chipboard are made from compressing wood chips with a resin. This produces a board which is stable and not affected by temperature or humidity.
-structured composite lumber is an enhanced wood, which is made by layer and veneers with resin
124
-what is a smart material?
-Smart materials are “ reactive materials”. For example, their properties can be changed by exposure to external stimuli, including light, electricity, water, etc.
125
What are shape memory alloys?
-Smart materials
-shape memory alloys are special metal alloys that have the ability to remember their original shape and then return back to it when after being heated or deformed.
-there uses are mainly for medical devices eg. Stents
-a current is passed through and sets the shape of a product
126
-what are thermo-chromic pigments?
-thermo-chromic pigments are specialised colour changing materials that respond to changes in temperature.
-The colour alters based on the temperature they are exposed to
-they contain microcapsules that expand or contract with temperature change
127
What are phosphorescent pigments?
-phosphorescent pigments have the unique ability to admit light after being exposed to a light source. They continue to admit light for a period of time, even after the light source has been taken away.
128
-what are photochromic pigments?
-when photochromic pigments come in contact with UV rays, they have the ability to change their colour
-eg. Sunglasses
129
-what is an illuminescent wire?
-this is a thin flexible wire which emits lights when an altering current voltage is applied
130
-what is a Piezo electric material?
-appears electric material can generate a small electric charge when in response to pressure
-usually used in sensors, lights, speakers
131
-what is a modern material?
-what materials are developed through the use of new and improved processes as a result of man-made materials, they do not change based on external stimuli, and they keep the same properties.
132
-what is carbon Kevlar?
-Modern material
-carbon Kevlar is a synthetic fibre made from long chains of polymers, mixed with carbon, it is known for its high tensile strength
133
-what is high density modelling foam?
-modern materials
-made from polyethylene resin and is designed to have a uniformed cell structure.
-lightweight and enjoyable with an excellent dimensional, stability and resistance and moisture
-mainly used for modelling
134
-what is graphene?
-graphine is a single light of carbon atoms in a 2-D honeycomb lattice
-exceptional strength, flexibility, electrical conductivity, thermal, conductivity, and transparent
135
What is finite element anaylasus?
-predict how a product reacts to real-world forces, vibration, heat, fluid flow and other physical effects, through the use of technology.
-helps to predict weakness in products before manufacture, so you can develop upon them
-allows for the safe simulation of conditions that may be dangerous or difficult to replicate in a physical test environment.
-can get a visual representation of how a product reacts to surroundings
136
Strengths of manufacturing aids eg. Jigs
- used to reduce applied labor time and improve ergonomics and quality.
-faster then drawing out by hand
-makes sure if lots if components are being produced that they are all the same.
-accuracy is improved as human error is reduced
137
Weaknesses of manufacturing aids eg. Jigs
-high initial set up cost for jigs
138
Advantages of using brought components
-time effective, don’t have to manufacture loads of different parts
-cost effective— don’t need all the tools to make the parts as your just buying them
-quality assurance already
139
What is Rapid prototyping and the strengths of this?
-Rapid prototyping is the use of machines to produce realistic 3D models from CAD files.
-The models can be made in a range of materials, which are usually a type of polymer.
• The benefits to designers and manufacturers include:
-it is a fast process, as 3D modelling needs minimal human input -modelling was previously highly skilled, expensive and time consuming
-rapid prototypes can serve as moulds for casting and making production dies
-stereolithographic models of pottery designs can be realistically sprayed and decorated for appraisal by designers and potential customels
140
What is EPOS?
-Electronic point of sale, this is a computer system for processing sales transactions, managing inventory and tracking customer interactions in retail environment.
-this includes components like: barcode scanners, receipt printers, scan barcode items
141
What is ppc
Production planing control system
-this is a process that manages the efficient utilisation of resources, schedules and workflows.
-organises the stocks, the work flows etc
142
What are internal properties?
-things in place such as patternts in order to protect work
143
What is six sigma
-stop manufacturing defects from occurrence by getting processes to the point where they produce stable and predictable results
-it does it through identifying cause of the defect, and then reducing this in the processes.
144
-why may bio batch additives be added to plastics
-reduce the degradation time, meaning, plastic breakdown, faster
145
What is the customer protection act
-protects costumers from unfair trading practices
