Create your own revision guide - PowerPoint Presentation

1. Create your own revision guideNameTeacherSubject..Engineering manufacture

2. Engineering MaterialsFerrousNon FerrousThermosetThermoplasticCast IronAluminiumEpoxy resinABSMild SteelBronzeMelaminePETHigh Speed SteelBrassUrea formaldehydeHDPEStainless SteelCopperPVCLow Carbon SteelZincHIPSDuraluminiumNylonTin PolypropyleneFerrous – a metal containing iron.Non Ferrous – a metal that has no iron.Thermoset – strengthen when heated and cannot be reformed.Thermoplastic – soften when heated and harden when cooled, this can be repeated.

3. Research a suitable useFor the following materials FerrousNon FerrousThermosetThermoplasticCast IronAluminiumEpoxy resinABSMild SteelBronzeMelaminePETHigh Speed SteelBrassUrea formaldehydeHDPEStainless SteelCopperPVCLow Carbon SteelZincHIPSDuraluminiumNylonTin PolypropyleneAfter you have found a suitable use , state the reason why the material is suitable as this will be asked in the exam. Typically a 6 mark question.

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5. Smart MaterialsQuantum Tunnelling CompositesThermo chromicShape Memory Alloyhttps://youtu.be/SBXQ-6uI8GY

6. SMART Materials: Top Trump CardsYOUR TASK is to produce a set of 5 cards, one for each SMART material.Each card should show the followingPropertiesExamples of useReasons for useImprovements on traditional materialsSMART Materials:Shape Memory alloyProperties:Bendable, it will return to its original shape if heated above a certain temperature Examples of use: Sprinklers in fire alarm systems, spectacle frames, coffee machines. Reasons for Use: It’s easily shapen and keeps its shapeImprovements on traditional materials:Glasses had to be re-bended by hand but now you can use heat INSERT PICTURE(S) HERESMART Materials:Shape Memory polymerProperties: Will return to its original shape if heated above a certain temperature. A good insulator.Examples of use: Window sealing foam, sensors and robots Reasons for use: Strong, low cost, can be triggered by temperature and light Improvements on traditional materials: Can be tailored to a broad range of materials and temperatures. INSERT PICTURE(S) HERESMART Materials:Piezoelectric actuatorsProperties: When electricity is applied to a Piezo Actuator it changes shape by an small but amount. They can be “stacked”Examples of use: Controlling hydraulic valves, adjusting machining tools and some motors Reasons for Use: Very small and precise movements, no motors or gears to go wrong.Improvements on traditional materials: Easy to control pumps and valves. Very small & controlled movement unlike motorsINSERT PICTURE(S) HERESMART Materials:Piezoelectric transducersProperties: When under impact they create a small electrical current. When electricity is applied they move a small amount.Examples of use: Guitar hero drum sensors. Touch sensitive surfaces, engine sensors Reasons for Use: Reliable and sensitive way of creating an electrical signal from movement or vice versa.Improvements on traditional materials: Small movement needed unlike switches. Simpler than a motor for small movementsINSERT PICTURE(S) HERESMART Materials:Electrochromic materialsProperties:Change colour when electricity is appliedExamples of use: Smart windows, electrochromic mirrors and electrochromic display devices Reasons for Use: Privacy in office windows, automatic tiniting of windows depending on sunImprovements on traditional materials: Usually you have to choose the colour of a material and it can’t be changed easilyINSERT PICTURE(S) HERELinks to help:http://www.bbc.co.uk/schools/gcsebitesize/design/electronics/materialsrev5.shtml http://www.azom.com/article.aspx?ArticleID=6038 http://www.mindsetsonline.co.uk/Catalogue/ProductDetail/shape-memory-polymer?productID=6ef6577e-aee2-4060-8136-8fe2b3876274&catalogueLevelItemID=4e3da675-119e-4854-b42e-a7c46e133508 http://www.explainthatstuff.com/electrochromic-windows.html https://www.americanpiezo.com/piezo-theory/actuators.html https://www.nde-ed.org/EducationResources/CommunityCollege/Ultrasonics/EquipmentTrans/piezotransducers.htm And Wikipedia of course but keep it simple.Youtube if you must but DO THE WORK not just waste time gazing at videos!Good Luck

7. Heat TreatmentHardening involves heating of steel up to annealing temperature, and then quenching it rapidly in water or oil. This improves the hardness and tensile strength of the steel.Tempering involves heating the steel and cooling in air. It slightly reduces the hardness and strength of the steel, but improves the ductility and toughness.Annealing involves treating steel up to a high temperature, and then cooling it very slowly to room temperature, so that it has a high ductility and toughness, but low hardness.

8. Material PropertiesPropertyDefinitionToughnessAbility to resist impactHardnessAbility to resist scratchingDuctileAbility to be stretched into a wireMalleableAbility to be hammered into a shapeConductivityAbility to allow electrons to flow through the material.StiffnessAbility to resist bendingTensile StrengthAbility of an object to withstand great force or pressure.Corrosion ResistanceAbility to withstand breaking down when in contact with other substances

9. Machining Techniques TurningMillingDrillingForming TechniquesDie CastingSand CastingInvestment CastingDrop ForgingPress ForgingFor each Technique you need to know:WHAT it isHOW it worksWHY you would do itEXAMPLES of products made in this way

10. Machining Techniques: TurningLathes are used to make round parts like cylinders, bolts, knobs etcThe machine is a Centre LatheIt is used for TURNING (reducing diameter) and FACING (making shorted and neater)DRILLING on a LatheBORING a hole to make it biggerCutting a THREADKNURLINGPARTING OFF (where a finished object is chopped off)

11. Machining Techniques: TurningSome examples of objects that have been turned on a lathe…BEARINGSCLAMPING KNOBBRAKE DISCSPULLEYSMACHINE PARTS (CHUCK)PIPE FLANGESPLUMBING FITTINGS

12. http://www.technologystudent.com/equip1/mlathe1.htm http://www.technologystudent.com/pdf2/lathey1.pdf http://www.youtube.com/watch?v=qZtS7xW45XoCentre LatheMachining Techniques: Turning

13. Machining Techniques: MillingMilling Machines are used to make accurate parts with holes, slots and flat sectionsThe machine is a MILLING MACHINEIt is used for SHAPING metal objects using a rotating bit that con both drill down and cut sidewaysDRILLING holesCUTTING SLOTSCUTTING SHOULDERS(like steps)

14. Machining Techniques: MillingSome examples of objects that have been cut on a milling machine…Golf ClubsBrackets & MountingsEngines and engine partsAlloy Wheels

15. http://www.youtube.com/watch?v=CVnSq2fDfGU&list=PL1688EC2A1583EED2 Milling MachineMachining Techniques: Milling

16. Forming Techniques: CastingCasting is a way of melting metal and pouring it into a mould to make a complex shape.https://www.youtube.com/watch?v=WptzR_-o9aY Die Casting is where a metal Die (mould) is used and the molten (liquid) metal in injected in under pressureThe machine is large and expensive but once set up the cost is low for each productDie Casting

17. Forming Techniques: CastingExamples of products that are CAST using…Die CastingMetal toy carsIron pansHigh end CamerasEngine partsHandles

18. Forming Techniques: CastingCasting is a way of melting metal and pouring it into a mould to make a complex shape.Sand CastingSand Casting is where there is no Die but a mould made of sand that can only be used a few timesThe equipment and mould is cheaper to buy and make but it takes a LONG time so is no good for making lots of productshttp://youtu.be/7BI4v0Gqc7khttp://youtu.be/rgL2Jn5mk1A

19. Forming Techniques: CastingExamples of products that are CAST using…Sand CastingOrnamental railing endsEngine parts (pipes)One-off Sculptures / ornamentsPLUS anything else that could be die cast but could also be sand cast if you only wanted a small number.

20. Forming Techniques: CastingCasting is a way of melting metal and pouring it into a mould to make a complex shape.Investment CastingInvestment casting used to be called “Lost-wax Casting” because:You make a shape out of waxYou dip it in ceramic to make a hard shellYou MELT to wax so it dribbles outYou can the use the ceramic shell as a mould to cast steel or aluminiumYou the SMASH (or remove) the ceramic shell to get the metal out

21. Forming Techniques: CastingExamples of products that are CAST using…Investment CastingBasically anything that needs to be CAST but is a very complicated shape that could never be removed from a normal Die (mould)

22. Forming Techniques: ForgingForging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it.Drop ForgingIn Drop Forging there is a metal Die (similar to Die Casting). A Billet (lump) of steel is placed in between the 2 halves.The top half is lifted and dropped repeatedly onto the bottom half until the steel is the right shapeForging is much stronger than casting because the crystal structure in the steel or aluminium is compressedhttp://www.youtube.com/watch?v=UJ2-jm9CjiM

23. Forming Techniques: ForgingForging is a way of heating metal to soften (but not melt) it and then dropping a shaped Die on top to shape it.Press ForgingPress Forging is VERY SIMILAR to Drop Forging.HOWEVER… instead of dropping the upped Die it is PRESSED slowly down from abovePress Forging tends to be used for BIGGER Forged products

24. Forming Techniques: ForgingExamples of products that are FORGED using…Drop Forging / Press ForgingToolsfixingsBracketsWeaponsBasically anything steel that needs to be STRONG and withstand IMPACTAlloy Wheels

25. Applications and advantages/ disadvantages of the following modern production methods for production/ assembly lines:RobotsComputer Numerically Controlled (CNC) machinery.What we have to focus on:Modern Production Methods

26. In Industry it is not efficient or profitable to make everyday products by hand. On a CNC machine it is possible to make hundreds or even thousands of the same item in a day. First a design is drawn using design software, then it is processed by the computer and manufactured using the CNC machine. The machine featured below is the BOXFORD DUET. This is a small CNC machine and can be used to machine woods, plastics and aluminium. In industry, CNC machines can be extremely large. The Duet is one of the smaller CNCs and is ideal for use in schools. Computer Numerically Controlled machinesWhat are CNC machines?CNC: https://www.youtube.com/watch?v=ZOIWy6MsXOs

27. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same.3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc.. which need skilled engineers.4. CNC machines can be updated by improving the software used to drive the machines5. Training in the use of CNCs is available through the use of ‘virtual software’. This is software that allows the operator to practice using the CNC machine on the screen of a computer. The software is similar to a computer game.Advantages

28. 6. CNC machines can be programmed by advanced design software such as Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers / engineers.7. Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money.8. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally.9. A skilled engineer can make the same component many times. However, if each component is carefully studied, each one will vary slightly. A CNC machine will manufacture each component as an exact match. Advantages

29. 6. CNC machines can be programmed by advanced design software such as Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers / engineers.7. Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money.8. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally.9. A skilled engineer can make the same component many times. However, if each component is carefully studied, each one will vary slightly. A CNC machine will manufacture each component as an exact match. Advantages

30. CNC machines are more expensive than manually operated machines, although costs are slowly coming down.2. The CNC machine operator only needs basic training and skills, enough to supervise several machines. In years gone by, engineers needed years of training to operate centre lathes, milling machines and other manually operated machines. This means many of the old skills are been lost. 3. Less workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment.4. Many countries no longer teach pupils / students how to use manually operated lathes / milling machines etc... Pupils / students no longer develop the detailed skills required by engineers of the past. These include mathematical and engineering skills.Disadvantages

31. Consider the Advantages and Disadvantages involved with using robots in productionRemotely Operated Vehicles (ROV)(Titanic opening sequence)Manufacturing & Weldinghttps://www.youtube.com/watch?v=KEQdn57Kz1QPaintinghttps://www.youtube.com/watch?v=jB_3awvUTyo Quality Control: https://www.youtube.com/watch?v=MmjAFsKdVcE Packaginghttps://www.youtube.com/watch?v=BAF-ALWwlLw

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