Engineering Diploma Resource Guide ST350 ETP Materials & Processes (Engineering) Introduction Understanding properties of engineering materials is imperative to achieve successful design, production and maintenance techniques. In design, without understanding which materials are suitable for the required application, we cannot confidently satisfy customer requirements. More importantly we cannot select the most effective and efficient forming processes. This resource allows students to practically investigate material properties, focussing on thermoplastics to design products and form them using injection moulding techniques. Delivery This resource consists of 10 assignments each comprising a variety of separate activities. These assignments typically begin with a PowerPoint presentation that enables the teacher to introduce the background information required to complete the other activities within the assignment. Each assignment contains between one and two hours of study. Demonstration activities are carried out by the teacher using a physical injection moulder rig. Students carry out hands-on activities using a software simulation of the hardware, allowing all students to carry out practical activities at the same time. The students also then have an opportunity to verify their solutions using the hardware rig, ensuring they relate the virtual element to a real system and its components. The assignments can be carried out in a sequence to deliver specific elements of the diploma specification where relevant. Alternatively assignments or even activities * could be used to support the focus of the centre devised learning activity. For example students could complete the Smart Materials research activity as part of their study in Level 2 Unit 8: Innovation, Enterprise and Technological Advance. The following grid highlights where in the diploma the resource might be used to support specific elements or the focus of the centre devised learning activities. Assignment Title Level 1 Units Level 2 Units Level 3 Units 1 Plastics 5 2,4 2 Design 5 2,4,8 7 3 Materials 5,7 2,4,8 4 Materials Properties 5 2,4 5 Testing Properties of Materials 5 2,4 6 Injection Moulding 2,4,5 2,4,8 7 Tools and Fabrication 2,5 2,4 8 Suitable Product Material 2,5 2,4 9 Waste, Recycling and Cost 5 2,4 10 Problem Solving: Door Knob 5 2,4 Hardware and Software Applications 2,4,5 2,4,8 3 * Note where assignment activities are selected in isolation, marking moderation will be required to account for non-completed activities. Diploma Resource Guide (Materials & Processes) P7299 1
Assessment Assessment is designed to test the students through both formative and summative methods. The curriculum includes continuous assessment, assessment tests and a workbook journal to create a portfolio of work during the lessons. The tutor PowerPoint presentations are setup to be used in conjunction with the ClassAct Student Response System. This enables students to be assessed on tutor led activities. Differentiation Each tutor will require different outcomes and levels of understanding from the resource, depending not only on the level of the diploma and the unit they are delivering, but also the context within which it is being utilised. Tutors will need to review the activity within the resource they intend to use and identify whether any differentiation or adaptation will be required. This may be achieved in a number of ways. Editing Tutor Presentation Where PowerPoint presentations have been included they are designed to cover the required knowledge for the learners to successfully complete the rest of the assignment. If the tutor is using only the PowerPoint element or coupled with just one practical activity, they may wish to edit the content of the PowerPoint to deliver only the required content for that practical or alter the content to fit with another centre devised activity. Example: In the delivery of the Level 3 Unit 3, Tutor A edits the Mechanical Properties PowerPoint to include information on atomic structures of materials. Selecting Specific Activity Tutors might want to utilise one activity from an assignment to demonstrate a specific principle or topic without some of the more detailed knowledge. Example: Tutor B wishes for the students to investigate Manufacturing Processes and Waste from assignment 9 as an introductory lesson within Level 2 Unit 4: Producing Engineering Solutions. Tutor Devised Activity The tutor may wish to develop their own learning activity focused around the provided hardware or one of the software applications. This practice is highly recommended wherever possible in order to not only maximise use of the resource but also personalise the learning from both the tutors and learners perspective. Example: Using the set of material samples included in the resource, Tutor C sets a task for each student to name 3 applications of each of the 10 samples as an assessment in Level 1 Unit 5. The first task is to identify and classify the material and then consider its applications and possible forming processes. Note where assignment activities are selected in isolation, marking moderation will be required to account for non-completed activities. Diploma Resource Guide (Materials & Processes) P7299 2
Personal Learning and Thinking Skills (PLTS) The grid below highlights where opportunities exist using the resource s assessment methods to indicate achievement of the required PLTS statements. Other opportunities could be formulated with further input from tutor or student. Assignment IE CT RL TW SM EP 1 6 1 1,2,3 2 6 1 1,2,3 3 6 1 1,2,3 4 6 1 1,2,3 5 6 1 1,2,3 6 6 1 1,2,3 7 6 1 1,2,3 8 6 1 1,2,3 9 6 1 1,2,3 10 1,2,4,6 1,2,5,6 5,6 1 1,2,3 Module Review 5,6 1,2,3 Key: IE Independent Enquirers CT Creative Thinkers RL Reflective Learners TW Team Workers SM Self Managers EP Effective Participators Functional Skills This resource has embedded within it many opportunities for contextualised functional skills teaching, both through the structure of the delivery and also specifically in the nature of the activity content/task. Presentations and Demonstrations These activities offer scope to engage students in speaking and listening tasks within an engineering context. Students can show understanding of tutor led tasks through integrated assessment questions or in direct dialogue with tutor and other students. Alternatively students could investigate a topic independently or as a small group and then perform the presentation/demonstration to the whole class. Research These activities will allow students to show competence in a variety of functional skills, such as reading and extracting information and using ICT based sources to obtain and record information. Practical Investigation Students will have opportunities to apply core functional skills during practical investigations. They will have to access software applications, operate equipment, read text and follow written instructions. They will also have to write text and record data to document their understanding and observations. Assignment Review In each assignment students are invited to complete a review of their study noting any salient points and highlighting the main outcomes of their learning. These reviews allow students to practice their writing and communicative skills whilst reinforcing there technical understanding of engineering. Tutor Devised Activities Functional skills should also be considered when tutors devise their own activities. Students will have additional opportunities to further research, discuss and present information relating to the topics they have been studying within the curriculum resource. Diploma Resource Guide (Materials & Processes) P7299 3
Applied Functional Skills Examples In addition to the opportunities integrated within the structure of the curriculum resource, some specific examples of applied functional skills have been identified as follows. Assignment 4 Material Properties: Students use a simulator to test materials to measure their melting points and to determine if they are heat conductors. They work with the measure of temperature and complete a table to record material type, melting point and heat conduction properties. Assignment 6 Injection Moulding: Students investigate how mould temperature and volume of a plastics injection moulder affects the plastic part produced. They work with measures of temperature and volume. Students collect, record and interpret data in a table. Assignment 8 Suitable Product Material: Students use a simulator to test materials to determine their density and tensile strength. They work with measures of weight, area, volume and force. Students calculate strength to weight ratio. They record and interpret results in a table to determine the appropriate material for an aircraft frame. Assignment 9 Waste, Recycling and Cost: Students work to three decimal places to calculate the cost to make a plastic component using the raw material cost per unit volume and the volume required. Assignment 10 Problem Solving Door Knob: Students interpret a design brief to develop a cabinet door knob with fixtures, taking into consideration costs and performance of the various options. They calculate total cost from the materials costs to three decimal places. Curriculum Content This section lists the detailed content of each assignment and its distinct learning activities. The list can be used to select the work appropriate to the centre devised schemes of work The grid highlights the nature of the material its intended outcomes and nominal times for activity completion. Diploma Resource Guide (Materials & Processes) P7299 4
Assignment Assignment Title Activity Activity Description Learning Objectives Minimum Time (mins) 1 Plastics 1 Plastic Materials (Presentation) General Characteristics / Main Types of Plastics / Modifying Plastics / Types of Plastics / Plastic Reference Chart / Line Bending / Vacuum Forming Turning / Hot Wire Cutting / Injection / Moulding / Laminating / Comparing Plastics Explores different types of plastic, their properties and the processes used to make things from plastic. 1 Plastics 2 Plastic Spoon (Research) Students use an interactive application to research the secondary materials and manufacturing processes used in making a plastic spoon. Researches the secondary materials and manufacturing processes used in making a plastic spoon. 1 Plastics 3 Model Car (Demonstration) The Thermoject moulder is used to make a solid plastic object with moving parts. Sees an injection moulder used to make a solid plastic object with moving parts. 2 Design 1 The Design Loop (Presentation) The Scenario / Customer Feedback / The Design Loop Explores a systematic approach to designing a product - The Design Loop. 30 2 Design 2 2 Design 3 Corn Cob Holder (Demonstration) The Injection moulder Simulator is used to show how small plastic corn cob holders can be made. Design Choices (Research) (Practical) Students use the Injection moulder Simulator to make and evaluate two designs of doorknobs. Makes a plastic corn cob holder using an inject moulder simulator and a mould. Makes plastic doorknobs for fixing with a nut or a bolt using an injection moulder simulator and a mould. 3 Materials 1 Metal Materials (Presentation) General Properties / Appearance / Origin of Metals / Alloys / Composition of Metals / Common Metals - Uses / Melting Point / Conductivity / Rate of Tarnish and Corrosion / Workability / Density Explores the properties, origins, composition, and uses of metals and alloy. Diploma Resource Guide (Materials & Processes) P7299 5
Assignment Assignment Title Activity Activity Description Learning Objectives Minimum Time (mins) 3 Materials 2 Wooden an d Metal Spoons (Research) Students use an interactive application to research secondary materials and manufacturing processes used in making a spoon from wood and metal. Researches secondary materials and manufacturing processes used in making a spoon from wood and metal. 3 Materials 3 Smart Materials (Research) Students use an information sheet to research smart materials. Researches Smart Materials: what they are, what happens to them and how they are used. 4 Material Properties 1 Physical Properties of Materials (Presentation) Types of Properties / What are the Physical Properties? / Density / Thermal / Electrical / Magnetic / Optical / Mechanical Properties / Examples of Physical Properties Discovers the physical properties of materials, and how physical properties make materials suitable for different applications. 4 Material Properties 2 Mechanical Properties of Materials (Presentation) Mechanical Properties / Strength / Plasticity / Elasticity / Ductility / Hardness / Malleability / Static Mechanical Properties / Creep / Fatigue / Resilience / Toughness / Brittleness / Examples of Mechanical Properties Explores the mechanical properties of materials and view examples of static mechanical and dynamic mechanical properties. 4 Material Properties 3 Testing Thermal Properties (Research) (Practical) Students use an interactive application to measure how well materials conduct heat and find their melting points. Uses software to measure how well materials conduct heat and find their melting points. 40 4 Material Properties 4 Moulding Process (Research) (Practical) Students use the Injection moulder Simulator to discover how an injection moulder works. Uses a simulator of an injection moulder to discover how it works. 5 Testing Properties of Materials 1 Testing Materials (Presentation) Material Tests / Test Results / Electrical Conductivity / Tensile Test / Compression Test / Bend Test / Hardness Test / Shear Test Explores the way materials can be tested for electrical conductivity and their strengths. 5 Testing Properties of Materials 2 Hardness, Impact and Tensile Strengths (Research) (Practical) Students use the Virtual Materials Tester software to carry out strength tests on sample materials. Carries out strength tests on sample materials using the Virtual Materials Tester software. 45 Diploma Resource Guide (Materials & Processes) P7299 6
Assignment Assignment Title Activity Activity Description Learning Objectives 5 Testing Properties of Materials 3 Plastic Threads (Demonstration) The Thermoject is used to make plastic doorknobs that are then fixed to a door using a nut or a bolt. Sees an injection moulder used to make plastic doorknobs and see them tested when fixed using a nut or a bolt. Minimum Time (mins) 30 6 Injection Moulding 1 Clamping and Stroke (Demonstration) The Thermoject is used to demonstrate what happens when the clamp and lever of an injection moulder are not used correctly. Sees how clamping and stroke can affect the moulding of a plastic part. 6 Injection Moulding 2 6 Injection Moulding 3 Injection moulding Machine Controls (Practical) Students use the Injection moulder Simulator to investigate the effects on a moulder part of the temperature and flow rate control settings. Mould Flash and Shrinkage (Practical) Students use the Injection moulder Simulator to investigate the shrinkage and flashing of a moulder part. Uses an injection moulder simulator to investigate the effects on a moulded part of the temperature and flow rate control settings. Uses an injection moulder simulator to investigate shrinkage and flashing of a model part. 30 7 Tools and Fabrication 1 Hand Tools (Presentation) Using Hand Tools / Cutting Wood / Cutting Metal / Cutting Plastic / Drilling Wood / Drilling Metal / Drilling Plastic / Trimming Wood / Trimming Metal / Trimming Plastic Discovers a range of hand tools and the materials they are suitable for working with. 7 Tools and Fabrication 2 Machine Tools (Presentation) Machine Tools / Lathe / Milling Machine / Drill Press / Band Saw / Grinder/Buffer / Sander Discovers a range of machine tools, their function and uses. 7 Tools and Fabrication 3 Fabrication Case Studies (Research) Students use the Case Studies software to identify fabrication processes used in industry. Identifies fabrication processes used in industry. Diploma Resource Guide (Materials & Processes) P7299 7
Assignment Assignment Title Activity Activity Description Learning Objectives Minimum Time (mins) 8 Suitable Product Material 1 Electric Cables (Research) (Practical) Students use the Virtual Materials Tester software to test sample materials and choose which material is best for the core in an electrical cable and which is best for the outer cover. Selects appropriate materials for use in electrical cables. 8 Suitable Product Material 2 Strength to Weight Ratio (Research) (Practical) Students use the Virtual Materials Tester software to find the density and tensile strength of different materials and use this to calculate each material's strength to weight ratio. Using their calculations, students select the material most suitable for use in building the frames of airplanes. Selects an appropriate material for use in an airplane frame based on calculating its strength to weight ratio. 30 9 Waste, Recycling and Cost 1 Manufacturing Processes and Waste (Research) Students use an interactive application to identify where waste is produced in manufacturing processes and how waste can be recycled into new, useful products. Identifies where waste is produced in manufacturing processes and how waste can be recycled into new, useful products. 9 Waste, Recycling and Cost 2 Recycling Plastics (Research) Students use an interactive application to see the process that waste thermoplastics go through to be reprocessed into plastic granules suitable for injection moulding. Investigates how thermoplastics can be recycled using a computer simulation. 10 9 Waste, Recycling and Cost 3 Reducing Waste and Cost (Practical) Students use the Injection moulder Simulator to calculate how much plastic is used in the design of parts. Students then calculate the cost of the materials used to make each part and calculate how changing the design of a part can reduce cost. Investigates how thermoplastics can be recycled using a computer simulation. 10 Problem Solving - Door Knob 1 Door Knob (Research) (Practical) Students use the Injection moulder Simulator to design, test and evaluate a door knob to meet the requirements of the client, a bathroom cabinet manufacturer. Applies appropriate problem solving skills to design, prototype, test and evaluate a door knob. Produces a working solution and supporting documentation for the design of a door knob. 60 Diploma Resource Guide (Materials & Processes) P7299 8