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A-level DT > Unit 3-A/B > Flashcards

Unit 3-A/B Flashcards

(116 cards)

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1
Q

What is fabrication?

A

Joining components using nuts, bolts, welding or riveting

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2
Q

What is moulding?

A

Shaping melted material into a desired shape using a mould or die

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3
Q

What is sintering?

A

Making objects from powder form by heating below melting point

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4
Q

What is laminating?

A

Bonding different layers of material with a bonding agent

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5
Q

What is stamping?

A

Pressing or stamping shapes into material under high pressure

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6
Q

What is milling?

A

Shaping a product from a solid block of material

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7
Q

What is turning?

A

Rotating materials in a lathe to form cylindrical shapes

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8
Q

What is injection moulding?

A

Injecting molten material under high pressure into a mould or die

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9
Q

What materials can be injection moulded well?

A

Aluminium
plastics

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10
Q

What is extrusion?

A

Pushing or pulling molten material through a die

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11
Q

What is bonding?

A

Glueing or joining different materials together under high pressure to produce sheet materials

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12
Q

What is casting?

A

Material in liquid form poured into a mould

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13
Q

What are cutting/wasting processes?

A

Material being removed to create the desired shape

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14
Q

What are shaping and forming processes?

A

Bending material, laying fiberglass, or laminating wood to form a shape

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15
Q

What is a jig?

A

A tool to make sure parts are made exactly the same

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16
Q

What are the advantages of using jigs?

A

No need to mark out so more efficient
Less chance of errors

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17
Q

What is a former?

A

A tool to make sure parts are shaped or bent to exactly the same shape

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18
Q

What is a template?

A

A tool which can be drawn around to consistently mark and irregular shape

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19
Q

What is a pattern?

A

A replica of finished shape used when casting to make the mould made from cheap, soft material
Also used for vacuum forming

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20
Q

What is a mould?
Hollow shape used to cast metal or plastic

A
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21
Q

What are moulds for metal made from?

A

Special sand
Metal
Plaster

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22
Q

What are moulds for resin made from?

A

Plaster
Rubber

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23
Q

What are examples of cutting systems?

A

Laser cutting
Plasma cutting
Water Jet cutting
Milling cutter

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24
Q

How does a laser cutter work?

A

High intensity light beam burns through material

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25
How does a plasma cutter work?
Electrical arc to heat and cut through metal Air blows molten metal away
26
How does a water jet cutter work?
Water with abrasive injected through a nozzle at a very high pressure
27
How does a milling cutter work?
Mechanical cutting using rotating bit to remove material
28
How do CNC machines benefit prototyping?
Developments allow creating of high-quality models at much higher speed Quicker development allows them to beat competition to market
29
How does 3D prototyping benefit designers?
They can get feedback from clients Assess functionality Feedback on aesthetics Mechanical tests
30
What is a feasibility study?
Working out if the idea is worth pursuing to a manufacturing and marketing stage
31
What is analysed in a feasibility study?
Cost and investment required Suitable materials Volume needed
32
What benefits can come from a feasibility study?
Reduce development time and cost Confidence and security before major investment
33
What are the costs of blow forming?
Moderate tooling costs Low unit costs
34
What are typical applications of blow forming?
Chemical, consumer and medical packaging
35
What is the quality and finish of blow forming?
High quality parts, High quality surface finish
36
What is the speed of blow forming?
Very rapid cycle times (1-2) mins
37
What sort of production is blow forming suitable for?
High volume production runs
38
What sort of materials can be blow formed?
All thermoplastics
39
What are typical applications of thermoforming?
Bath shower trays Packaging Aerospace and transportation interiors
40
What are the costs of thermoforming?
Low to moderate tooling costs Low to moderate unit costs
41
What is the quality and finish of thermoforming?
Depends on the material, pressure and technique
42
What is the speed of thermoforming?
Roll fed 10s – 60s Sheet fed – one off to batch
43
What sort of production is thermoforming suitable for?
Roll fed – batch to mass Sheet fed – one off to batch
44
What sort of materials can be thermoformed?
All thermoplastics
44
What are typical applications of rotation moulding?
Automotive parts Furniture Toys
45
What are the costs of rotation moulding?
Low tooling costs Low to medium unit costs
46
What is the quality and finish of rotation moulding?
Good surface finish Low pressures during moulding product low stress concentrations
47
What is the speed of rotation moulding?
Long cycle times (30-60mins)
48
What sort of production is rotation moulding suitable for?
Low to medium volumes (>10,000)
49
What sort of materials can be rotation moulded?
Mainly Polyethylene (PE) Other thermoplastics such as PA, PP, PVC or EVA could be used
50
What are typical applications of injection moulding?
Automotive Consumer electronics and appliances Industrial and household products
51
What are the costs of injection moulding?
Very high tooling costs Very low unit costs
52
What is the quality and finish of injection moulding?
Very high surface finish Highly repeatable
53
What is the speed of injection moulding?
Very fast cycle times (30-60s)
54
What sort of production is injection moulding suitable for?
High volume mass production
55
What sort of materials can be injection moulded?
Almost all thermoplastics Some thermosetting plastics Some metal powders in polymer matrix
56
What are typical applications of metal stamping?
Automotive parts Consumer products Furniture
57
What are the costs of metal stamping?
High tooling costs Low to moderate unit costs
58
What is the quality and finish of metal stamping?
High quality and precise bends because of machined tooling
59
What is the speed of metal stamping?
Rapid cycle times (1 – 60 seconds)
60
What sort of production is metal stamping suitable for?
High volume production
61
What sort of materials can be metal stamped?
Most sheet metals including carbon steel and stainless steel
62
What are typical applications of roll forming?
Automotive and transportation Construction Enclosures for white goods
63
What are the costs of roll forming?
High specialised tooling costs Low to moderate unit costs
64
What is the quality and finish of roll forming?
Good pitch accuracy
65
What is the speed of roll forming?
Very rapid Complexity and length of parts can decrease speed Long changeover time
66
What sort of production is roll forming suitable for?
Batch production > 1500m
67
What sort of materials can be roll formed?
Mainly used for steel parts
68
What are typical applications of forging?
Automotive and aerospace industries Hand tools Metal implements Heavy duty machinery
69
What are the costs of forging?
Moderate to high tooling costs Moderate unit costs
70
What is the quality and finish of forging?
Excellent grain structure
71
What is the speed of forging?
Rapid cycle times (<1 min depending on size and shape)
72
What sort of production is forging suitable for?
All types of production
73
What sort of materials can be forged?
All types of metal
74
What are typical applications of sand casting?
Architectural fittings Automotive parts Furniture Lighting
75
What are the costs of sand casting?
Low tooling costs Moderate unit costs
76
What is the quality and finish of sand casting?
Poor surface finish High level of porosity
77
What is the speed of sand casting?
Moderate cycle times (30 mins)
78
What sort of production is sand casting suitable for?
One-off to medium volume production
79
What sort of materials can be sand cast?
ferrous and non-ferrous alloys
80
What are typical applications of die casting?
Automotive parts Kitchenware Furniture
81
What are the costs of die casting?
High tooling costs Low unit costs
82
What is the quality and finish of die casting?
Very high surface finish Variable mechanical properties
83
What is the speed of die casting?
Rapid cycle times Depends on size and complexity
84
What sort of production is die casting suitable for?
High volume production
85
What sort of materials can be die cast?
Non-ferrous metals only
86
What are typical applications of investment casting?
Aerospace Construction Consumer electronics Consumer appliances
87
What are the costs of investment casting?
Low to moderate tooling Moderate to high unit costs
88
What is the quality and finish of investment casting?
Very high quality for complex shapes High structural integrity
89
What is the speed of investment casting?
Long cycle times (24hrs)
90
What sort of production is investment casting suitable for?
Low to high volume production
91
What sort of materials can be investment cast?
Almost all ferrous and non-ferrous metals
92
What are typical applications of punching and blanking?
Automotive and transportation parts Consumer electronics Appliances Kitchenware
93
What are the costs of punching and blanking?
Low to moderate tooling costs Low to moderate unit costs
94
What is the quality and finish of punching and blanking?
High quality and precise Edges do need deburring
95
What is the speed of punching and blanking?
Rapid cycle times (1-100 per min) but tooling changeover is slow
96
What sort of production is punching and blanking suitable for?
One off to mass production
97
What sort of materials can be punched and blanked?
Almost all metals
98
What are typical applications of water jet cutting?
Aerospace parts Automotive parts Scientific apparatus
99
What are the costs of water jet cutting?
No tooling costs Moderate unit costs
100
What is the quality and finish of water jet cutting?
Good quality
101
What is the speed of water jet cutting?
Moderate cycle times depending on material thickness
102
What sort of production is water jet cutting suitable for?
One off to medium volume
103
What sort of materials can be water jet cut?
Very few materials which cannot be water jet cut
104
What are typical applications of sintering?
Automotive parts Electrical components Cutting tools
105
What are the costs of sintering?
High tooling costs
106
What is the quality and finish of sintering?
Good quality Material is as strong as machined equivalents
107
What is the speed of sintering?
Rapid cycle times (seconds to complete) for small objects
108
What sort of production is sintering suitable for?
Medium to mass production
109
What sort of materials can be sintered?
Metals Ceramics Polymers
110
What are typical applications of milling?
Medical and consumer goods
111
What are the costs of milling?
Low cost
112
What is the quality and finish of milling?
Very high quality
113
What is the speed of milling?
Varied based on the side and material
114
What sort of production is milling suitable for?
One off to medium volume production
115
What sort of materials can be milled?
Most solid materials can be milled

A-level DT (35 decks)

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