Engineering Lvl.2 Exam

What are the 7 main sectors of engineering?

Aerospace

Automotive

Biomedical

Chemical

Communication

Electrical/electric

Mechanical

Name some types of engineering processes that come under Machining:

Drilling

Turning

Milling

Name some types of engineering processes that come under Forming:

Casting

Forging

Name some types of engineering processes that come under Fabrication:

Welding

Shearing

Name some types of engineering processes that come under Electronics:

Printed Circuit board (PCB) Manufacturing

Surface Mount Technology

What are the health and safety precautions for drilling?

• Remove loose clothing

• Tie hair back

• Wear PPE (Personal protective equipment)

• Lower the guard

• Use a G clamp

Give 3 advantages and disadvantages of drilling:

Advantages: Adaptable, accurate, reliable

Disadvantages: Minor burns caused by hot materials, Flying pieces of material, Hand or arm could come into contact with revolving parts

Name 7 processes of the lathe, and what they do:

• Turning – To reduce the diameter

• Facing – To reduce the part length

• Forming – To form / shape

• Parting – To cut the part smaller

• Threading – To create a screw thread – Helical form used on nuts and bolts

• Drilling – To create a hole in the center of the part

• Knurling – to create a textured finish on a smooth surface for better grip

Give 4 advantages and disadvantages to the turning process: (lathe)

Advantages

• Perfectly cylindrical parts

• Range of tools - a lot of different processes

• Can use with a lot of different materials

• Accurate

Disadvantages

• Health & Safety

  • Heat created from friction - HOT!

  • Bits of metal can be thrown away form workpiece

• Time consuming due to manual work

What are 4 applications of milling?

Flat surfaces

Grooves and slots

Holes

Finishing off Engine and machine parts

What is sheering and how does it work?

Metal fabrication process for cutting straight lines in sheet or sections of material.

The upper blade and lower blade are forced past each other to cut the metal.

What is drilling?

A process that creates a round hole by removing material

What is a through hole and a blind hole? (drilling)

Through hole - A hole going completely through the component surface.

Blind hole - A hole going into the part but does not go all the way through.

What is turning? (lathe)

A process that rotates the workpiece metal against a cutting tool to create round parts

What is milling and what machine is used?

Process of moving a workpiece in 3 directions around a rotation cutting tool.

Milling machine is used for this process.

What are the steps of sand casting?

1. One half of the component is placed in the mould (DRAG)

2. Sand is packed around the component

3. Component is removed from the mould

4. Step 2 and 3 is repeated for the second half runners, risers and gate sections are added in the mould (COPE)

5. Cores are placed in the void as required

6. The mould halves are fitted together

7. Molten metal is poured into the runner 

8. Once the metal has cooled the sand is removed and the component revealed

What is die casting?

Die casting is a metal casting process forces molten metal under high pressure into a mould cavity.

What are 4 advantages of die casting?

• Die casting provides complex shapes within closer tolerances than many other mass production processes.

• Die castings are produced at high rates of production. 

• Die casting provides parts which are durable, dimensionally stable, and have the feel and appearance of quality.

• Mould can be reused many times

What are 3 disadvantages of Die Casting?

• Very high capital costs to startup the process.

• Not suitable for low volume of components.

• Not as good for casting alloys.

What are the 4 diferent methods of Forging?

1. Impression Die Forging

2. Cold Forging

3. Open Die Forging

4. Seamless Rolled Ring Forging