Summer 2022 Flashcards
Explain the process of compression moulding
The exact required amount of plastic is placed in the mould. The mould then heats the plastic causing it to soften. The hydraulic press then applies pressure, forcing the plastic into the shape of the mould
What is calendaring?
Calendaring is a process where a material is passed through a series of rollers to create a consistent, flat sheet. The extruded material is then often collected on a large roll
What is an example of when calendaring would be used?
Making aluminium foil roll
What is rotational moulding?
Rotational moulding is used to manufacture large hollow products
Explain the process of rotational moulding:
Plastic granules are placed in the mould and the mould is heated. The mould is then rotated on 2 axis so the molten plastic covers the surface of the mould
What are the advantages of rotational moulding?
Moulds are much cheaper than other moulding methods as pressure is not required for the process
What surface finishes would be suitable for a piece of chipboard?
- Laminating
* Veneering
Why is it important to recycle aluminium?
Recycling aluminium uses significantly less energy than extracting from ores
What is a smart material?
A material that can be changed or controlled by an external stimuli
What is an example of what compression moulding would be used to make?
Plug socket
What type of polymer does compression moulding usually involve?
Thermosetting polymer
What is a prototype?
A representation of a product before it is produced in any quantity
What does a prototype do?
It helps evaluate and test a design, and to confirm design methods and costs
Why should a product already be modelled and tested before building a prototype?
Prototyping is expensive
What are prototypes made of?
Prototypes are often made of the same material as the real product and often have fully functioning parts
What 6 things are required for a prototype to be successful?
The prototype must:
- Satisfy the requirements of the brief
- Be potentially marketable
- Consider Aesthetics
- Demonstrate innovation
- respond to client wants and needs
- Are funtional
What is this measuring / marking out tool and how / when is it used?
Tape Measure
Used when measuring longer pieces of material or measuring distances
What is this measuring / marking out tool and how / when is it used?
Steel rule
used for accurate measurements on smaller material. Steel provides consistency and a flat end allows you to measure from the edge of a piece of material easily
What is this measuring / marking out tool and how / when is it used?
protractor
used for measuring angles to be drawn on any materials
What is this measuring / marking out tool and how / when is it used?
French curves
used to draw curves - different shapes and sizes are available to be selected as required
What is this measuring / marking out tool and how / when is it used?
Compass
used to draw circles on paper, card, and timber. A similar tool called a divider has 2 spikes and is used to mark out metal
What is this measuring / marking out tool and how / when is it used?
outside calliper
used to measure the outside diameter or thickness of a material. Often used when turning material on a lathe so a quick and accurate measurement check can be made
What is this measuring / marking out tool and how / when is it used?
scriber
used to scratch the surface of metal to indicate where the material should be cut (as a pencil would with wood)
What is this measuring / marking out tool and how / when is it used?
try square
used to draw lines at 90* to an edge. Similar products are used for metal and is called an engineers square
What is this measuring / marking out tool and how / when is it used?
marking gauge
the adjustable block is placed against the side of a piece of wood and the spike is dragged along the edge of the material to create a mark
Name and explain the wastage process shown in the photo:
Perforation
Perforation is a manufacturing process that involves scoring a sheet of material with many holes. This creates a sheet of material with a pattern of holes within it.
Name and explain the wastage process shown in the photo:
Turning
A piece of timber or metal is placed on a lathe. The lathe then spins at a high speed. A turning tool is then pushed into the timber or metal whilst it is spinning in order to change its shape. The material may be held in place by compressing it at each end, this would allow a spindle or a cylinder to be shaped. However, the material may also be screwed into a lathe faceplate, which would allow a curved base (bowl shape) to be created.
Name and explain the wastage process shown in the photo:
Sawing
Sawing is a process which allows a narrow slit to be cut into the material by a saw blade. A saw blade consists of a series of narrowly spaced teeth. Sawing can be used to separate the material into separate pieces, or to cut off unwanted sections.
Name and explain the wastage process shown in the photo:
Milling
Rotary cutters are used to remove material from a piece of material by advancing a rotary cutter into the surface of the material. The rotary cutter may be fed in at an angle to cut the desired shape
Name and explain the wastage process shown in the photo:
Drilling
Drilling is a process that uses a drill bit to cut a circular hole into a material. The drill bit is rotated at high speed by a rotary cutting tool. The drill bit is then pressed into the material by the drill and causes a circular hole to be cut into the material. A twist drill bit is used to drill a hole of a fixed diameter into a piece of material. A countersink bit is used to profile an existing hole so that a screw can sit flush with the surface
Name and explain the wastage process shown in the photo:
Die Cutting
Name and explain the addition process shown in the photo:
Brazing
Brazing involves joining 2 metals together with a filler material. The filler material melts an is added to the joint to form a join between 2 components. This is similar to welding and soldering, however unlike welding the base components are heated but to below their melting point, and unlike soldering, both the base component and filler material is heated
Name and explain the addition process shown in the photo:
Welding
Welding uses electricity or gas torches to generate high levels of heat. This heat is used to fuse different metal components together. The process involves melting the joint between the metal components to be joined and then a “filler material” is added to the joining point between the 2 components. The “filler material” melts and forms a pool of molten material called the weld pool, this cools to form a joint between the 2 base materials
Name and explain the addition process shown in the photo:
Soldering
Soldering involves joining 2 metals together with a filler material. The filler material is melted and is added to the joint to form a join between 2 components. This is similar to welding and brazing, however the base components are not melted or even heated whatsoever, only the filler material.
Name and explain the addition process shown in the photo:
3D printing
3d printing is a computer aided manufacturing process that follows CAD designs to place layers of plastic on top of each other to create a 3d object. A filament of plastic is fed into the machine on a spool and heated so that it becomes soft and sticks to the layer below itself. The CAD design must be put into a slicing software before printing to determine how the inside of the model will be filled
Name and explain the reforming/deforming process shown in the photo:
Casting
Casting involves the use of a molten material. The molten material is poured into the mould cavity in the mould. The molten material then cools within the mould until it solidifies, taking the desired shape of the mould cavity.
