Higher Homework MATERIALS & MANUFACTURE

Size: px

Start display at page:

Download "Higher Homework MATERIALS & MANUFACTURE"

Stephany Perkins
5 years ago
Views:

1 Higher Homework MATERIALS & MANUFACTURE

1. The Ant and Beluga chairs shown were designed for a similar

mounting brackets Available in many colours and finishes Stackable

2 1. The Ant and Beluga chairs shown were designed for a similar market. Chair 1 Ant Chair Designed by Arne Jacobsen Price 45 Laminated plywood seat Chrome plated tubular steel legs Polypropelene mounting brackets Available in many colours and finishes Stackable Polypropelene mounting brackets Chair Beluga Chair Price 5 Stackable chair One piece Injection moulded Polypropylene Available in many colours

3 1. (continued) (a) Outline a product specification for these types of chair. (b) Justify the use of the materials used in the production of both chairs. (c) Give four reasons why these chairs are suitable for mass production. (d) Explain the ergonomic issues that would affect the design of these chairs. 4 ()

. A plastic bottle and lid for use on a bicycle is shown below.

were manufactured by the process of injection moulding.

(b) State and justify a plastic that could be used for the bottle or cap.

4 . A plastic bottle and lid for use on a bicycle is shown below. Pop up The bottle was manufactured by the process of blow moulding and the lid components were manufactured by the process of injection moulding. (a) Justify why each of these two processes was used to manufacture these components. (b) State and justify a plastic that could be used for the bottle or cap. 4 The bottle is held onto a bicycle frame in the bottle cage shown below. (c) Describe the issues that the designer would have to consider when designing the bottle cage. (8)

3. A table is shown below. MDF with plastic laminate top and shelf Solid timber legs and cross rails (a) Describe the benefits of using MDF with plastic laminate for the table top.

5 3. A table is shown below. MDF with plastic laminate top and shelf Solid timber legs and cross rails (a) Describe the benefits of using MDF with plastic laminate for the table top. (b) Explain why a solid timber has been used for the legs and cross rails. 3 Parts of the table such as the edge profile on the top and shelf are manufactured using a CNC router. (c) Describe the benefits of using this process when mass producing 3 (8)

4. The body and side panels on the car shown below were manufactured using the process of press-forming. (a) Explain why press-forming is a suitable process for the manufacture of these panels.

6 4. The body and side panels on the car shown below were manufactured using the process of press-forming. (a) Explain why press-forming is a suitable process for the manufacture of these panels. 3 Corrosion of car parts can be a problem. (b) Describe how manufacturers attempt to reduce or eliminate this problem. 4 Just in Time production is used by car manufacturers to reduce costs. (c) With reference to car manufacture, describe Just in Time production. 3 (10)

5. Shelter A Cycle Shelter A Shelters are made from 0 mm 0 mm 3 mm galvanised mild steel tube. Steel cycle racks and stands are manufactured from 50 mm 3.

Windows and canopies are made with 5 mm clear polycarbonate. All fixing straps are aluminium and all bolts and fixings are either aluminium or stainless steel.

Available in heavy duty log roll or tongue and groove finishes with felt tiled roof. All timber products have an expected lifespan of 5 30 years when maintained appropriately.

7 5. Shelter A Cycle Shelter A Shelters are made from 0 mm 0 mm 3 mm galvanised mild steel tube. Steel cycle racks and stands are manufactured from 50 mm 3. mm wall thickness galvanised mild steel tube. Bolts are internally fixed using captive nuts to eliminate unsightly and potentially hazardous external nuts and threads. Windows and canopies are made with 5 mm clear polycarbonate. All fixing straps are aluminium and all bolts and fixings are either aluminium or stainless steel. All ground fixing anchors have tamper-proof security heads. Shelter B Cycle Shelter B Made from top grade Finnish redwood from sustainable forests. Available in heavy duty log roll or tongue and groove finishes with felt tiled roof. All timber products have an expected lifespan of 5 30 years when maintained appropriately. Bolts are internally fixed using captive nuts to eliminate unsightly and potentially hazardous external nuts and threads. Fig 1a An alternative wood/metal option is shown as a detail in Fig 1a. Prices for each shelter depend upon design and size.

8 5. (continued) (a) Write a product specification for the design of one of the cycle shelters. (b) Justify the choice of materials used to produce both shelters. (c) Describe and justify the production methods that would be used to manufacture one of the bike shelters. (d) Describe the health, safety and environmental issues associated with the cycle shelters during the manufacture of the component parts. 4 ltotal for Secti on A ()

SECTION B. The model car shown below has been manufactured using the process of die-casting. (a) Explain why die-casting is a suitable process for this type of product.

9 SECTION B. The model car shown below has been manufactured using the process of die-casting. (a) Explain why die-casting is a suitable process for this type of product. (b) There are a number of metals suitable for the manufacture of this product. State the name of one suitable metal and explain why it is appropriate for the manufacture of the model car. (4)

hardware. (a) Explain the advantages of using composite materials.

10 7. The guitar shown above is manufactured as a one piece graphite composite with a high gloss lacquer, phenolic fingerboard and black hardware. (a) Explain the advantages of using composite materials. (b) Explain the benefits of using computerised systems in the design 3 4 (7)

8. Two condiment sets are shown below. Stainless steel Plastic stopper Condiment Set A Price: 4.

Description: The manual twist mechanism for the pepper mill is crafted from solid, cutlery grade stainless steel to withstand the

The pepper mill is constructed with an internal spring tension system which allows it to be adjusted to mill very fine to coarse

00 Material: Stainless steel with brushed finish. Description: Designed for cooks who love gadgets.

11 8. Two condiment sets are shown below. Stainless steel Plastic stopper Condiment Set A Price: Material: Beech, also available in walnut. Description: The manual twist mechanism for the pepper mill is crafted from solid, cutlery grade stainless steel to withstand the rigors of commercial use. The pepper mill is constructed with an internal spring tension system which allows it to be adjusted to mill very fine to coarse pepper. Condiment Set A Rubberised Push Button Acrylic Condiment Set B Condiment Set B Price: Material: Stainless steel with brushed finish. Description: Designed for cooks who love gadgets. With a twist of the wrist, the electric mills lock into pepper and 3 salt grind adjustments. The pepper mill features an original Peugeot case-hardened steel milling mechanism, while the salt mill contains a stainless steel mechanism that will not corrode from the salt. The acrylic section allows easy viewing of contents. A touch of a button activates the mill and its illuminating lamplight. Each use six AAA batteries.

12 8. (continued) (a) Outline a product specification for one of the condiment sets in relation to its intended target market. (b) Justify the choice of materials used to produce both condiment sets. (c) Describe and justify production methods that would be suitable to manufacture the component parts of the condiment sets. (18)

9. The kitchen utensils shown below are manufactured from melamine with hardwood handles. (a) (i) State the name of the manufacturing process used to produce the melamine heads of the utensils.

13 9. The kitchen utensils shown below are manufactured from melamine with hardwood handles. (a) (i) State the name of the manufacturing process used to produce the melamine heads of the utensils. (ii) Explain why this process is suitable for the production of these parts of the product. 1 This range of products comes with a variety of hardwood handles. (b) (i) State two valid reasons for using hardwood for the handles. (ii) Explain the implications, for both the manufacturer and consumer, of using a range of hardwoods. 3 (8)

14 10. The components shown below have been manufactured by the process of compression moulding. Smoke alarm casing Car tailgate Battery housing (a) Explain why compression moulding is suitable for these types of product. (b) State the name of a suitable material and explain why it is appropriate for the manufacture of components. 3 (5)

15 11. The base and frame of the car jack shown below has been manufactured by the processes of piercing and blanking, then press forming. (a) Explain why these processes are suitable for manufacturing the components for this product. 3 Standard components such as nuts, bolts and rivets have been used in the car jack frame. (b) Explain why it is appropriate to assemble the frame using these types of components. (c) Describe the advantages to the manufacturer in using standard components. (7)

1. Chair A Ergolife Stol Made from solid birch and fabric.

Retail price 9 99 Chair A Chair B Messenger Bag Director s Chair

Comes with telescoping legs and folding backrest.

16 1. Chair A Ergolife Stol Made from solid birch and fabric. Rolled up length: 400 mm Diameter: 100 mm Weight approx 1 kg Retail price 9 99 Chair A Chair B Messenger Bag Director s Chair Less than 100 mm thick when folded. Comes with telescoping legs and folding backrest. Made from aluminium, plastic and nylon mesh seat. Integrated cup holder and two pockets in the armrests. Retail price 95 Chair B

17 1. (continued) (a) Outline a product specification for the design of one of the chairs. (b) Justify the choice of materials used to produce each of these chairs. (c) Identify and justify the production methods chosen to manufacture one of the chairs. (18)

13. The teeth in the blade of the cheese grater shown have been manufactured using (a) Explain why piercing and blanking is a suitable process for this type of product.

18 13. The teeth in the blade of the cheese grater shown have been manufactured using (a) Explain why piercing and blanking is a suitable process for this type of product. (b) State the name of the process used to form the product. (c) State the name of a suitable metal for the manufacture of this product and justify why it is appropriate. 1 3 () [X11/301] Page

Rotational moulded Kayak Figure Glass reinforced plastic Kayak Figure 3 (a) Explain why each method of

19 14. Two kayaks are shown below. Figure is produced by a rotational moulded polyethylene. Figure 3 is produced by traditional methods using glass reinforced plastic. Rotational moulded Kayak Figure Glass reinforced plastic Kayak Figure 3 (a) Explain why each method of production is suitable for a product of this type. (b) Identify two manufacturing disadvantages of using rotational moulding for this product. 4 ()

with metal runners (a) Explain and justify the advantages of the composite

20 15. Two sledges are shown below Sledge A BMW Sauber F1 Sled Made from a composite plastic Sledge B Traditional wooden sledge made from solid birch with metal runners (a) Explain and justify the advantages of the composite material used for sledge A over the traditional materials used in sledge B. 4 (4)

Mobile Cloakroom Trolley Laminated MDF Panels Scratch resistant mild steel tubular frame 1 mild steel

21 1. The products shown below have been designed and manufactured for use in pre-school, early years and primary schools. Mobile Cloakroom Trolley Laminated MDF Panels Scratch resistant mild steel tubular frame 1 mild steel double hooks Large base storage area Self-assembly required Retail price 35 Cubby Storage Unit Strengthened tubular PVC plastic frame 4 HDPE plastic bins for shoe and bag storage Wall mounted Retail price 70

22 1. (continued) (a) Outline a product specification for the design of one of the coat racks. (b) Justify the choice of materials used to produce both of these coat racks. (c) Justify the production methods that could be chosen to manufacture both coat racks. (18)

23 17. The garden kneeler shown below allows the user to work in comfort. The product has been manufactured using the process of blow moulding. (a) State the name of a suitable material for the manufacture of the kneeler and justify your choice. (b) State two features that would indicate that the kneeler was manufactured using the process of blow moulding. (c) Justify why blow moulding was used for the manufacture of the kneeler. 1 (5)

24 18. The car wheel shown below is a one-piece aluminium alloy sand casting. (a) Justify the choice of sand casting for the manufacture of this wheel. (b) Explain why additional machining was necessary after sand casting the wheel. A product such as the alloy wheel shown above can also be manufactured by Pressure Die Casting. (c) Explain the benefits gained by manufacturing the wheel using this process. (d) Explain the benefits of using alloys rather than pure metals. 3 (9)

Cable Length 0 Metres Weight 4 kg Cylinder Mower (Manually Operated) Blade HSS (Tool Steel) Handle Foam Rubber

25 19. Each of the lawnmowers shown below have been designed for a well known high street DIY retailer. Electric Hover Mower Blade Mild Steel Handle Plastic coated Mild Steel Body Polypropylene Gears/Fasteners Nylon Cable Length 0 Metres Weight 4 kg Cylinder Mower (Manually Operated) Blade HSS (Tool Steel) Handle Foam Rubber coated Aluminium Body Mild Steel Gears/Fasteners Nylon Wheels Metal Alloy Grass Catcher Nylon with Polypropylene base Weight 7 3 kg

26 19. (continued) (a) Write a product specification for one of the lawnmowers in relation to its target market. (b) Justify the choice of materials used to produce both lawnmowers. (c) Identify and justify the production processes that could be used to manufacture both lawnmowers. (18)

27 0. The body of the adjustable spanner shown below is made by the process of drop forging. (a) Explain why drop forging is a suitable process for producing the body of this adjustable spanner. (b) State two features that would indicate that this product was made by drop forging. (c) State a suitable material that could be used for the body of the spanner and 1 (5)

The door of the kitchen cabinet is manufactured using solid timber.

28 1. The carcass of the kitchen cabinet shown below has been constructed using (a) Explain the benefits to the manufacturer of using knock down fittings instead of traditional joining methods. The door of the kitchen cabinet is manufactured using solid timber. (b) Explain the benefits to the consumer of using solid timber for the cabinet doors. (c) Describe the obsolescence issues associated with modern fitted kitchens. ()

. Two cooling fans are shown below. Both have been designed for use in an office or domestic environment.

operated) Height 1 Metre Weight 3 kg Air Multiplier technology amplifies surrounding air 1 times to generate an uninterrupted flow of smooth air

airflow power and oscillation mode Retail price 99 99 Pedestal Cooling Fan Blades Stainless Steel Sheet Blade Guard Plastic Coated Mild Steel

29 . Two cooling fans are shown below. Both have been designed for use in an office or domestic environment. Bladeless Cooling Fan (remote controlled) Body Material ABS Remote Material ABS Variable speeds and oscillating operation Power 5 Watts (mains operated) Height 1 Metre Weight 3 kg Air Multiplier technology amplifies surrounding air 1 times to generate an uninterrupted flow of smooth air Dimmer-switch airflow control precisely adjusts airflow power, without the limited settings of conventional fans Remote airflow control changes airflow power and oscillation mode Retail price Pedestal Cooling Fan Blades Stainless Steel Sheet Blade Guard Plastic Coated Mild Steel Mesh Body/Stem and Base Chromed Mild Steel Gears/Fasteners Nylon 3 speed settings and oscillating operation. Power 50 Watts (mains operated) Height 0 7 to 1 1 metre Weight 3 5 kg Retail price 0 00

30 . (continued) (a) Write a product specification for one of the fans in relation to its target market. (b) Justify the choice of materials used to produce both fans. (c) Identify and justify the production processes that could be used to manufacture both fans. (d) Explain the health, safety and environmental issues associated with the production and use of these fans. 4 ()

(a) Identify and justify the manufacturing process for

31 3. A rubber composite material has been used in the production of the car park ramp shown below. (a) Identify and justify the manufacturing process for products such as these. (b) Describe three advantages of using composite materials. 3 (5)

4. Many home owners install decking in their gardens. A softwood has been used in the manufacture of the spindles. (a) Describe two issues related to the use of softwoods for this product.

32 4. Many home owners install decking in their gardens. A softwood has been used in the manufacture of the spindles. (a) Describe two issues related to the use of softwoods for this product. The spindles have been produced using a CNC lathe. (b) Explain two benefits of using this process to produce the spindles. The spindles are manufactured in batches. (c) Describe two issues for the manufacturer of using batch production for these components. ()

X211/301 PRODUCT DESIGN HIGHER. 70 marks are allocated to this paper. LI X211/301 6/3/8570 X211/301

X211/301 PRODUCT DESIGN HIGHER. 70 marks are allocated to this paper. LI X211/301 6/3/8570 *X211/301* X11/01 NATIONAL QUALIFICATIONS 007 TUESDAY, MAY 1.00 PM.00 PM PRODUCT DESIGN HIGHER 70 marks are allocated to this paper. LI X11/01 6//8570 *X11/01* Attempt ALL questions. SECTION A 1. The Ant and Beluga