AQA GCSE Engineering

What is the function of the drill bit?

To remove material by drilling through. Creates a circular hole.

What material is the drill bit?

High Carbon Steel (HCS) / High Speed Steel (HSS)

What is the function of the chuck?

To hold the drill bit securely. Holds different sized drill bits.

What material is the chuck?

High Carbon Steel (HCS)

What is the function of the handle?

Comfort and grip when using the drill.

What material is the casing of the hand drill?

ABS / HIPS

What material is the over moulding on the handle?

TPE (Rubber)

Name 3 advantages of Injection Moulding.

Complex shapes

Fast process

Mass production

Name 3 disadvantages of Injection Moulding.

Moulds are expensive to buy/make

Initial set up costs are high

Some very complex shapes are impossible

What is a die? (casting)

A mould made of metal

What is pressure die casting?

Forcing molten metal under high pressure into a mould (die).

Give 1 advantage of pressure die casting.

Good surface finish

Give 1 disadvantage of pressure die casting.

Dies (moulds) are expensive to make.

Name 2 advantages of permanent joints.

They don't come loose

They are strong

Name 1 disadvantage of permanent joints.

They can't be taken apart for maintenance

Give an example of a permanent joint.

Welding / Brazing / Soldering / Riveting / Adhesives

Give an example of a temporary joint.

Threaded fastenings

What is electroplating?

Depositing a layer of metal using electrolysis.

What is galvanising

Dipping a steel part in molten zinc.

What is the material of the casing of the hand held vacuum?

LDPE

What is the material used on the cable?

PVC

What is a risk assessment?

Identifying a hazard and its risk. Then controlling the risk.

What are templates?

Standard shapes that are used as patterns

What is a jig?

A work holding or positioning device that is not fixed to the machine bed.

What is a fixture?

A work holding or positioning device that is fixed to the machine bed.

What is quality control?

Finding parts not made to the correct dimensions.

What is quality assurance?

Planning and doing things to make sure that the product is made right the first time.

Give 3 advantages of CAM.

Results are consistent in large-scale production

Accurate surface finish

Speeds up production rate

Give 3 disadvantages of CAM.

Expensive software

Requires training

Can be slower than traditional methods for one-off production.

Give 3 advantages of robots.

Can carry out tasks that would be difficult for a human

Faster work rate than humans

Doesn't need breaks unlike humans

Give 3 disadvantages of robots.

Robots are expensive to buy/build

Takes a long time to write the programs

Errors can cause huge problems

Name three safety hazards related to the pillar drill.

Swarf - safety goggles/guard

Long hair - tie back

Loose clothing - apron

What are the impacts of developments in IT on the product development process?

Before:

Drawing by hand

Paying by cheque

Assembled by humans

After:

Drawn on CAD software

Online banking

Assembled by robots

Explain how environmental issues affect design decisions during manufacture. (6 Marks)

Using less energy

Use less materials

Repairable products

Recyclable materials

Extended lifetime

Reuse product for a different use

What is a design brief?

A short statement of what is required for the product.

What are constraints?

Things that limit what you can make.

What are user needs?

The things that the customers require the product to do. (ACCESS FM)

What is the symbol for diameter?

∅ Circle with diagonal line going uphill.

What is the name of this line: - — - — - — -

Centre line

What is the name of this line: - - - - - - - - -

Hidden line

How must dimensions be drawn?

Coloured in arrows heads with extension lines not touching the edge of the drawing.

What is a transistor?

An electronic switch.

What is a capacitor?

Stores an electrical charge

Name 2 properties of HCS.

Very hard

Recyclable

Name 2 properties of Aluminium alloy.

Corrosion resistant

Very tough

Name 2 properties of PVC.

Insulator

Corrosion resistant

Name 2 properties of LDPE.

Recyclable

Corrosion resistant

What is an alloy?

A mixture of two or more metals to combine properties.

What is a ferrous metal?

A metal that contains iron.

What is a non-ferrous metal?

A metal that does not contain iron.

What is hardness?

Resistance to scratches and wear.

What is toughness?

Resistance to knocks and bumps.

Describe the process of riveting.

The hole is drilled

The rivet is placed in the hole

The support dolly supports the rivet

The rivet is hit with ball-peen hammer

Snap is placed over rivet and hit

Riveted joint is complete

What is anodising?

The electrolysis of aluminium in an acidic solution.

What does a micrometer do?

Measures outside diameters and lengths.

What does a vernier calliper do?

Make a wide range of measurements, including lengths, outside diameters, inside diameters and hole depths.

What does CIE stand for?

Computer Integrated Engineering

What is concurrent engineering?

Carrying out different stages of the design process at the same time.

Describe the process of Injection Moulding.

Plastic granules fed into hopper

Piston is drawn back

Heaters melt plastic

Piston moves forward forcing molten plastic into mould via sprue

Plastic solidifies

Mould opened and part removed

What is the symbol for a transistor?

What is the symbol for a capacitor?