Manufacturing 2. Measurement of woods, metals and plastics can be carried out using various tools. Three are listed below.

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1 Manufacturing Measurement Measurement of woods, metals and plastics can be carried out using various tools. Three are listed below. Metric Ruler Outside Callipers Micrometer The most accurate is the micrometer which is used in metalwork and the least accurate of the three is the ruler. Outside Callipers are often used in wood turning to check the diameter of the blank. Shaping Metals The steel ladder hook below has been shaped using a variety of tools shown below. Rounded corner formed by cutting slant with hacksaw and rounding off with a file Bends formed by placing steel in engineer s vice and beating with hammer Hacksaw File Engineer s Vice Hammer

2 Manufacturing Finishing The steel ladder hook was painted black to prevent rusting. Before painting it was rubbed with emery cloth to remove rust and provide a rougher surface for the paint to grip. It was then cleaned with a rag and turpentine (using protective gloves). Emery Cloth Turpentine Paint Wood Turning Woodwork Lathe Wood turning is used to make rounded products such as table legs, bowls and rails. Before turning on the machine it is necessary to follow four stages to prepare the wooden blank. These are shown below. Step Draw diagonals on both ends using pencil / ruler Step Punch one end using a centre punch and hammer Step 3 Saw a diagonal on the other end using a tenon saw Step 4 Plane off the corners using a jack plane

3 Manufacturing Various tools can be used to shape the wooden block on the woodwork lathe. The picture opposite shows a selection. Adhesives Gouges Chisels Adhesives are basically glues. The table below shows three different types and what they are used for. Epoxy Resin PVA Tensol Cement Contains a tube of resin and a tube of hardener. Mix the two together then apply to the surfaces for a really strong fix. Excellent for joining different materials e.g. wood to metal or metal to plastic A white glue used to join pieces of wood together Used to glue to pieces of acrylic (Perspex) together. Laser cut plywood Quality Assurance The bird box opposite had been made mainly by laser cutting pieces of plywood (strong man-made board). It is designed to be sold in a cardboard box as a flat pack and constructed at home by the person who bought it. Computer controlled operations like laser cutting ensure a high level of accuracy so that it is easy for members of the public to build the bird box at home. If accuracy was not there the quality of the product would be poor and it would be hard to fit the pieces together.

4 Manufacturing Questions. The pictures below show two measuring devices. (a) (i) State the name of each measuring device. (b) Which of the two devices is the most accurate?. A steel bracket is shown below. (a) (i) Describe how to create the bend using workshop tools Bend

5 Manufacturing (ii) It was decide to round off the corners for safety. Describe how this could be done using standard workshop tools. (b) The bracket was painted with black hammerite paint. Describe two stages required to prepare the bracket before finishing 3. The picture below shows a wooden blank mounted on a woodwork lathe. (a) Describe four stages required to prepare the blank before placing it on the lathe 3 4

6 Manufacturing (b) During turning two tools were used to shape the piece of wood. State the names of these tools. 4. The pictures below show three different methods of joining materials together. Joining two pieces of acrylic. Metal to wood 3. Wood to wood (a) State the name of a suitable adhesive for each product The picture opposite shows a laser cut storage system made from plywood. (a) State why plywood is a suitable material (b) State a quality assurance issue in the manufacture of the storage system