Unit 1: The Engineering World Help Booklet

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1 Name. BTEC NQF Level 2 Engineering Unit 1: The Engineering World Help Booklet This Booklet MUST be used with the Engineering Book to gain a Merit and Distinction. 1

Engineering Sectors and Products Types of Products The Engineering Sector (The types of Engineering) Description (What it is) Typical Products (Things that are made in that

Things that have wheels and go on the road. Things that have a lot of electrical bits in them. Machines and things that don t have many electrical bits.

Planes used by the air force, jet planes you go on holiday in, helicopters, rockets, space ship.

2 Engineering Sectors and Products Types of Products The Engineering Sector (The types of Engineering) Description (What it is) Typical Products (Things that are made in that type of engineering) Aerospace Automotive Electrical/ Electronic Mechanical Biomedical Communications Chemical Things that are made that fly. Things that have wheels and go on the road. Things that have a lot of electrical bits in them. Machines and things that don t have many electrical bits. Things that are used in hospitals. Things that you use that allow you to talk to people. Things that are used that are chemicals, or have chemicals in them. Planes used by the air force, jet planes you go on holiday in, helicopters, rockets, space ship. Car, motorbike, vans, lorries TV, ipad, calculator, microwave Engines, machine vice, lathe. Artificial arms / legs, pace maker, X ray machine. Mobile phone, satellite, computers. Petrol, medicines, things you use for cleaning, foods. Aerospace Automotive Electrical Mechanical Biomedical Communications Chemical 2

Drilling: Cutting a hole in the work using a drill. Parallel Turning: Cutting the work but keeping it straight.

3 Machining Processes (Using machines to make things) Turning Using a lathe to make round things from metal. The chuck holds the item you are changing shape, the chuck turns and a cutting tool cuts off material. Facing off: Cutting the front or back of the work to make it flat. Drilling: Cutting a hole in the work using a drill. Parallel Turning: Cutting the work but keeping it straight. Milling Using a machine (like the one in the workshop) to cut material, usually metal, with a cutter. The thing you are cutting can be held in a vice or clamped to the bed of the machine. Two main types = Horizontal / Vertical, some can do both. Drilling Making a circular hole using a drill bit. The shank of the drill bit is held by the chuck of the drill and turns, the front of the drill bit cuts the material. Shank Flute Cutting Edge Safety Thinks that are not safe when using the machines and stuff you could do to stop getting hurt. Loose clothes can get caught in them (wear an apron). Bits of metal flying off into your eye (wear goggles). Burns form the tools or metal (let them cool down or use gloves). Touching bits of the machine that move (guard on the machine). These are called PPE or: Personal Protective Equipment 3

Forming Processes (Using metal as a liquid or hitting it to get it to a shape) Casting Done by pouring or

can be made Hollow shapes can be made Not a lot of waste made The shape has a good outside face (shiny and

engineering book, page 8 for the explanation of these.

You usually do this by squeezing it in a machine (hitting it with a big hammer or rolling it between rollers).

4 Forming Processes (Using metal as a liquid or hitting it to get it to a shape) Casting Done by pouring or injecting a liquid metal into a mould (like plastic injection moulding but with metal) Advantages: Hard shapes can be made Hollow shapes can be made Not a lot of waste made The shape has a good outside face (shiny and smooth) Types of casting: Sand casting Semi Permanent and Permanent Investment Casting Die Casting Look at the engineering book, page 8 for the explanation of these. Forging This is when you heat up a metal until it is soft, then make it into a shape. You usually do this by squeezing it in a machine (hitting it with a big hammer or rolling it between rollers). KEY WORD : PLASTIC DEFORMARTION (Changing the Shape of the Metal) Different Types of Forging: Drop Forging Press Forging Upset Forging Look at the engineering book, page 9 for the explanation of these. 4

Fabrication Processes (Means joining metal together ) Welding Joining metal together

You use lots of heat to fuse (attach) the metal together.

Advantages = Make lots of joins fast (large scale production) Good finish (looks good

metal. Advantages = Cheep, does not make fumes when doing.

Shearing This is when you cut materials in a straight line, the metal is usually soft,

5 Fabrication Processes (Means joining metal together ) Welding Joining metal together so it won t come apart (not like nuts and bolts that you can take to bits). You use lots of heat to fuse (attach) the metal together. Types of welding: MIG Welding = Most common, uses electricity to make the heat Advantages = Make lots of joins fast (large scale production) Good finish (looks good after the join has been welded) Oxy-Acetylene = Mixes oxygen gas and acetylene gas to make the heat. Advantages = Cheep to do Spot Welding = Uses electricity and electrodes to join the metal. Advantages = Cheep, does not make fumes when doing. Look at the engineering book, page 9 for the explanation of these. Shearing This is when you cut materials in a straight line, the metal is usually soft, like aluminium, but you can also cut steels. The shape of the materials cut are usually flat, have an angle on them, or are round. The machine used to cut them uses a blade and a lot of force to cut them (like you cutting a cake with a knife). Examples 5

PCB manufacture (making) is usually done by us, not by big industries.

6 Electrical/Electronic Processes Circuit boards, used in electronic devices to make them do a job, for example in your phone). PCB means Printed Circuit Board, some are very easy to make, some are hard, but they all control electronic devices (stuff with electrics in). PCB manufacture (making) is usually done by us, not by big industries. This is how they are made 1) Design what you want 2) Produce the artwork (draw the design on a computer Look at the engineering book, page 10/11 for the explanation of these. 3) PCB Etching getting it ready to add the bits 4) Drill the board to fit the components (bits ) in. 5) Populating and soldering (add the components into the holes and solder them in) Surface Mount Technology This is when you want lots of Printed Circuit Boards and is the way we make them today in industry because it makes lots of them quickly. Look at the engineering book, page 11 for the explanation of how it works and the advantages of it. 6

usually expensive, like a one off ring,or

Examples are alloy wheels, T shirts with

Continuous Production Making lot and los

7 Scales of Production: how much of a product (thing) is made One - off Production = Making one of something, sometimes called a prototype, these are usually expensive, like a one off ring,or prototype car or smart phone. Prototypes are made to see if something works before you make loads of them. Batch Production = Making a number of parts that are the same, but usually not producing lots and lots, can be from 10 to 10,000. Examples are alloy wheels, T shirts with names on and bread buns / cakes. Mass Production = Making lots of parts and products, uses machines that all they do are make the parts and products. Examples are cars, TVs and I Phones. Continuous Production Making lot and los of the same thing all the time, the products are cheep and usually small. Examples are sweets, paper clips, screws and nails. Look at the engineering book, page 11 / 12 for more detail on scales of production and examples. 7

Modern Production Methods (how things are made now) In the past, lots of thinks were made by peoples hands, this would mean

Now, products are made from machines that can make lots quickly, this makes the price lower.

Robots: Not like the ones in films, these are ones that can help us to make things, assemble (put thing together) products

Robots can help us to explore places we cant get to or are dangerous to be, like out of space.

Robots can pack boxes for us or direct luggage at an air port, remember they usually don t look anything like us.

It means Computer Numerically Controlled and is a machine that we control by programming it to make something, an example is

8 Modern Production Methods (how things are made now) In the past, lots of thinks were made by peoples hands, this would mean they would be quite expensive because they could not make them very quickly, so there were not loads of them. Now, products are made from machines that can make lots quickly, this makes the price lower. Below explains how machines can change things. Robots: Not like the ones in films, these are ones that can help us to make things, assemble (put thing together) products and help us to do things, they do what we tell them, usually by programming them. Examples are shown below. Robots can help us to explore places we cant get to or are dangerous to be, like out of space. Robots can help us to assemble products, like weld bits on cars or paint them. Robots can pack boxes for us or direct luggage at an air port, remember they usually don t look anything like us. What does CNC mean? It means Computer Numerically Controlled and is a machine that we control by programming it to make something, an example is a CNC lathe or Millar. What does CAM mean? It mean Computer Aided Manufacture and means using programmed machines (as shown opposite) to make something. What does CAD mean? It means Computer Aided Design and is when a computer helps us to draw things that can be used to work a CAM machine, examples are 2D design, that works the laser cutter and tinkercad that works the 3D printer. Look at the engineering book, page 13 / 14 for more detail on modern production methods. 8

Materials and their Processes in Engineering This means how different materials can be used for making and for using in different things.

!!!!!! There are different types of materials that come under different names, these are: Modern Composite Materials, these are materials that are made of more than

Kevlar is another example that can be used for body armour because it is strong and light. High Performance Materials, materials that are very good at doing things. E.

Another Material to Remember Metallic Foam: A foam that has metal bits in it, it is mainly used because it is strong and light, it can be used in the doors of cars so

9 Materials and their Processes in Engineering This means how different materials can be used for making and for using in different things. For example, you wouldn't use jelly for building a house!!!!!!! There are different types of materials that come under different names, these are: Modern Composite Materials, these are materials that are made of more than one thing, for example Glass Reinforced Plastic, made from glass and plastic and carbon fibre, carbon and fibre. Kevlar is another example that can be used for body armour because it is strong and light. High Performance Materials, materials that are very good at doing things. E.g. titanium for drill bits because it is hard. Smart Materials, these are materials that change when you do something to them, like warm them up. E.g. material that changes colour when you add heat. Another Material to Remember Metallic Foam: A foam that has metal bits in it, it is mainly used because it is strong and light, it can be used in the doors of cars so that if there is a crash it can stop the people in the car getting hurt. Powder Metallurgy When powder is put into a mould, pushed together, is heated up and it sticks together to make something. An examples is a gear. Look at the engineering book, page 16 / 17 for more detail on materials and their processes in Engineering. 9

New Technologies in Engineering (Things that are quite new that we can

hydrogen gas. An example is to help power a car.

materials to make them work better in a way.

looks better and wont rust, for example railings.

people or communicate with them, like e-mail and phones) and ICT

help people get to places quicker, like Tesco deliver service.

full wing, the planes that you use to go on holiday have two wings that

fuel. Lighter, so again uses less fuel fly.

10 New Technologies in Engineering (Things that are quite new that we can use to do and make things) Optical Fibres = Uses glass wires to help move information fast, like broadband. Hydrogen Fuel Cells = A device that helps to make energy (power) from hydrogen gas. An example is to help power a car. Surface Nanotechnologies = materials that can be added to other materials to make them work better in a way. Adding chrome to a bike so it wont rust, adding plastic to metal so it looks better and wont rust, for example railings. Telematics: using telecommunications (things that help us to talk to people or communicate with them, like and phones) and ICT (computers) to make company's better, an example is GPS (Sat Nav) to help people get to places quicker, like Tesco deliver service. Blended Wing Bodies: These are wings on aeroplanes that are only one full wing, the planes that you use to go on holiday have two wings that are connected to the plane at either side, blended body wings are one long wing. Advantages: Flies better through the air so is faster and uses less fuel. Lighter, so again uses less fuel fly. Bionics: This means using computers in the medical industry (hospitals) to work things that are used to help people, for example a pace maker to help the heart work, or to help to move artificial limbs. Look at the engineering book, page 18 / 19 for more detail on new technologies in engineering. 10

Sustainable Engineering Products (things that we can use over and over again, or power that we get from things that will never run out).

Then people can change things to make it better for the environment. This means looking at everything about the product like: 1.

4. Assembling the product (e.g. putting all the bits of the torch together). 5.

any). 6. Getting rid of the product after it is no use (e.g. re-cycling the plastic of the torch or sending it to land fill).

better for the environment, similar to being able to take your torch to bits easily to re-cycle them, not being made of many bits and it

Minimising Waste Production in Engineering (stopping things not being used again) The four Rs = These are 4 things that designers (people

the product so that it doesn't need to use many mate- much energy to work, this could mean making a phone smaller so it doesn't use as many

Examples are giving clothes away to use again, or stripping a bike down to use in another bike.

11 Sustainable Engineering Products (things that we can use over and over again, or power that we get from things that will never run out). Life Cycle Assessment This means looking at a thing that has been made and seeing what it has done to the environment. Then people can change things to make it better for the environment. This means looking at everything about the product like: 1. Getting the materials it is made from. 2. Making the materials (e.g. making plastic from oil). 3. Making the bits for the product (e.g. the parts for the torch). 4. Assembling the product (e.g. putting all the bits of the torch together). 5. Using the product (if the torch had batteries you would keep needing hem, our torch is better for the environment because it doesn't need any). 6. Getting rid of the product after it is no use (e.g. re-cycling the plastic of the torch or sending it to land fill). You would look at these and then see if you could use less materials, less energy in making a product, be able to re-cycle bits to make it better for the environment, similar to being able to take your torch to bits easily to re-cycle them, not being made of many bits and it being able to be wound up so you don t need batteries to make to work it. Minimising Waste Production in Engineering (stopping things not being used again) The four Rs = These are 4 things that designers (people that think of products to make) look at so they can make the products better for the environment, they are: Reduce: This means designing the product so that it doesn't need to use many mate- much energy to work, this could mean making a phone smaller so it doesn't use as many materials. rials or Reuse: This means being able to re-use the materials a product is made from. Examples are giving clothes away to use again, or stripping a bike down to use in another bike. Recycle : This means using materials from a product to make something else. For example using the torches plastic bits again by melting them down and making something else. Recover: This means using the stuff we throw away to make energy, an example is burning rubbish to produce energy. Look at the engineering book, page 20 / 21 for more detail on new technologies in engineering. 11

Lean Manufacturing (this means making something the quickest and best way ) Just In-Time Manufacture This means when you make a product, you only get

This is good because: you don t have loads of materials and bits taking up space in the factory.

Kaizen This means making little changes to how you make something to make it quicker and better.

Because you are not making big changes you don t need to spend loads of money.

12 Lean Manufacturing (this means making something the quickest and best way ) Just In-Time Manufacture This means when you make a product, you only get the materials and bits to make it when you are ready to make it. This is good because: you don t have loads of materials and bits taking up space in the factory. Products can be made quicker with not as many people needed to make them. Kaizen This means making little changes to how you make something to make it quicker and better. This is good because: You don t need to make loads of big changes to make things better. Because you are not making big changes you don t need to spend loads of money. Poka Yoke This means looking at a person that makes something over and over again and tying to see how they can make sure they don t make mistakes by changing how they do their job. This is good because: Products can be made quicker. Less mistakes are made, so less waste and more money is made. The example is if a worker had to put a plug in a socket, they could sometimes use the wrong type of bits, Poka- Yoke would mean looking at how the person could get it right every time. Look at the engineering book, page 22 / 23 for more detail on Lean Manufacturing. 12

Renewable Sources of Energy in Engineering This in when the

have, for example wind turbines, as we will always have

Wind Energy Using the wind to produce , this can be done

things like oil, gas and coal and doesn t make pollution.

Solar Energy Using the suns power to produce by using

This is good because it does not use A bad thing is that

Hydro Energy This is when you use running water to make

river or the weight of water pushing against a dam, they

to produce steam that makes electricity by running a

13 Renewable Sources of Energy in Engineering This in when the energy that is use to make something (e.g. electricity) is made by things that we will always have, for example wind turbines, as we will always have wind, however oil and coal will run out at some point. Wind Energy Using the wind to produce energy, this can be done using wind turbines, this is good because it does not use things like oil, gas and coal and doesn t make pollution. A bad thing is that the wind turbines don t look very good. Solar Energy Using the suns power to produce energy by using cells (the panels you see on roofs). This is good because it does not use things like oil, gas and coal and doesn t make pollution. A bad thing is that the panels are expensive and don t look good. Hydro Energy This is when you use running water to make power, this could be using the seas waves, the flow of a river or the weight of water pushing against a dam, they use a turbine to produce the power. This is good because it does not use things like oil, gas and coal and doesn t make pollution. A bad thing is that in is expensive to set up. Geothermal Energy This means using heat from in the earth to produce steam that makes electricity by running a turbine. Look at the engineering book, page 24 / 25 for more detail on Renewable Energy. 13

14 Explanation of Engineering words/ terms Alloy: A mix of metals to make a different metal. Blind Hole: A hole that is not drilled all the way through. CAD: Computer Aided Design. CAM: Computer Aided Manufacture. CNC: Computer Numerically controlled. Composite: A material that is made of more than one thing to make it stronger. Conductor: Something that lets electricity run through it. Insulator: Something that does not let electricity run through it. 14

Unit :1 MECHANICAL AND ELECTRICAL/ ELECTRONIC ENGINEERING PROCESSES

Unit :1 MECHANICAL AND ELECTRICAL/ ELECTRONIC ENGINEERING PROCESSES Machining processes: The manufacturing of engineered products or parts by the removal of waste materials or shaping of the work piece.