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Design for Manufacture Questions

Design for Manufacture Questions.

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Design for Manufacture Questions

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  1. Design for ManufactureQuestions

  2. Woods 1) Describe the three categories of timber. 2) What do the terms hardwood and softwood refer to?3) Explain what the term hygroscopic means?4) What can be done to prevent warping?5) Describe some of the ecological issues relating to the use of timber, especially hardwoods.Softwoods1) Describe the aesthetic properties of softwoods.2) Describe the structural properties of softwoods.3) Where are softwoods found?4) Which softwood would you choose for a) interior joinery/skirting boards b) good quality furniture c) exterior work?Hardwoods1)What are the general characteristics of hardwood trees?2) Where do you generally find hardwoods?3) Describe some of the ecological arguments against using hardwoods.4) Describe why a designer would prefer to use hardwoods in terms of a) aesthetics b) strength5) Which hardwood could be used for woodworking tools?6) Which hardwood could be used for building houses etc?7) Why would might walnut be chosen for prestige car dashboards? Man Made Boards1) Describe what is meant by a Man Made Board (MMB)?2) Explain three reasons for using MMBs rather than natural timbers.3) Explain the disadvantages of using MMBs4) Give an example of a mass produced product that utilises MMBs.5 )Give an example of a product that utilises MMBs.Design for Manufacture1) Describe what is meant by the term Standard Component. Give two examples to help explain.2) Why is it important to know how modern products are manufactured?3) Describe each of these identifying features. Split Lines Break Lines Tapered Sides Radiused Corners Webs Surface Texture

  3. Choosing a Material1) How can a design team structure their work to avoid problems with material choice ahead of time?2) What factors should designers consider to get the right material?3) What properties can a material possess? Explain what each term means.4) What is the purpose of Value Engineering?5) Describe the 5 steps in Value Engineering.CAD/CAM/CIMFor each of CAD, CAM, and CIM:1) Explain the term 2) Give three advantages3) Give three disadvantagesRapid Prototyping1) Describe what role rapid prototyping plays in modern industry. Why is it an advancement from older methods of model making?2) What does the term ‘clean manufacturing’ mean?3) Describe Stereolithography.4) Name two other methods for RP.Plastics1) What are the main raw materials for plastic? Plastics cont.2) Describe some of the ecological issues surrounding man’s continuing use of plastics.3) What can be added to plastic to improve/modify its performance? What does each do?5) In what forms can plastic be delivered (by a supplier)?Thermosetting Plastics1) Describe in detail what is meant by thermosetting plastics. Use an analogy to aid your explanation.2) When is it useful to use thermosetting plastics over other materials?3) What material might you use for: a) tough fittings that must have good insulation? b) hard surfaces that must stay hygienic and stand up to knocks and scratches from sharp objects? c) tough curving forms that will have to withstand large forces? d) bonding surfaces together?Thermoplastics1) Describe in detail what is meant by thermoplastics, use an example in your answer.2) Describe what the term plastic memory means.3) What plastic might you choose for : a) lighting covers? b) covering cables? c) casing for a kettle?4) What are elastomers and what are they used for?

  4. Identifying Plastics1) Explain where the names of plastics come from, and why some plastics have multiple names.2) Copy the codes and symbols from p1373) Explain why testing sometimes needs to be doen to identify plastics.Composite Materials1) Describe what is meant by composite materials and why they are used.2) Give an example of one composite material and explain why it has benefits over an individual material.Plastic Processes:Injection Moulding1) Explain the process of Injection Moulding2) What are the advantages of injection moulding?3) What is the main disadvantage of injection moulding, and what must be done for the process to be viable? Injection Moulding cont.1) What are the possible identifying features of an injection moulded product?2) What materials are suitable for Injection Moulding? Compression Moulding1) Describe and illustrate the process steps.2) What materials can be compression moulded.3) Explain the identifying features of compression moulding, in particular flash.4) What can compression moulding be used to manufacture?Extrusion 1) Extrusion is best suited for what sort of product?2) Describe and illustrate the general process steps.3) Explain the identifying features of extrusion moulding4) What can extrusion be used to manufacture?

  5. Vacuum Forming1) Explain three advantages of using Vacuum Forming2) Describe and illustrate the general process steps.3) Which materials are best suited to vacuum forming?4) Explain the identifying features of vacuum forming5) What can vacuum forming be used to manufacture?Rotational Moulding1) Explain three advantages of using Rotational Moulding2) Describe and illustrate the general process steps.3) Which materials are best suited to rotational moulding?4) Explain the identifying features of rotational moulding.5) What can rotational moulding be used to manufacture?Blow Moulding1) Explain the advantages of using Blow Moulding over Injection Moulding2) Explain a disadvantage of using Blow Moulding over Injection Moulding3) Describe and illustrate the general process steps.4) Which materials are best suited to blow moulding?5) Explain the identifying features.6) What can blow moulding be used to manufacture? Metals1) Where does metal come from?2) What are the three categories of metal? Explain the differences.3) Why is it important that metals are available in a variety of forms?4) Where does aluminium come from?5) What are some of the advantages for using aluminium?7) How can the properties of aluminium be improved?8) Why is copper such an important metal?Die Casting1) What are the two types of die casting?2) Describe the process of die casting.3) What materials are suitable for die casting?4) What identifying features do die cast parts have?Sand Casting1) What sort of production is sand casting suitable for?2) Describe the process of sand casting.3) Name two metals (one ferrous & one non-ferrous) suitable for sand casting?4) What identifying features do sand cast parts have?

  6. Press Forming1) Describe and illustrate the process of Press Forming2) What materials can be press formed?3) Explain why press forming is an expensive process.4) What are the identifying features of press forming?5) What products can be press formed?Piercing and Blanking1) Explain and illustrate the process of Piercing.2) Explain and illustrate the process of Blanking.3) What materials are good for Piercing and Blanking?4) Explain the identifying features of Piercing and Blanking.5) What products can be made in this method?Drop Forging1) Explain and illustrate the process of drop forging.2) What can happen to the products made as the dies get worn?3) Why are High Alloy Steels used in the die construction?4) What materials are suitable for Drop Forging?5) What are the identifying features of drop forged products?6) What products can be drop forged? Adhesives1) Explain why the choice of an adhesive is important. 2) For each of the following write down two or three bullet points to summarise the type of adhesive: a) PVA b) Tensol Cement c) Epoxy Resin d) Contact Adhesive e) Hot Melt Glue (Glue gun) f) Double sided tape Joining Materials 1) Explain the difference between Permanent, Non-permanent, and Semi-Permanent methods of joining materials 2) Write bullet points to summarise the following: a) Welding (2 types) b) Riveting c) Fitted Joints d) Fixed Joints e) Bolts f) Screws Recycling 1) What are the considerations a designer must make when dealing with ‘green’ issues? Explain each. 6

  7. Production Costs1) Explain what is meant by the term Fixed Costs, give examples.2) Explain what is meant by the term Variable Costs, give examples.3) What are stepped fixed costs?4) What are prime costs? Give an example of why they have to be a major consideration of a company.Manufacture Systems1) What does the term TQM stand for and why is it important? • Sequential and Concurrent Engineering • Explain what is meant by the term Sequential Engineering. • Explain the advantages and disadvantages of such a system. • How do teams involved in sequential engineering work? • Explain the term Concurrent Engineering. • How do teams in these projects work? • What are the benefits of Concurrent Engineering? • What is required of a team using a concurrent engineering model from the very start of a project? 7

  8. Front cover image credits: Roller Coaster http://www.flickr.com/photos/thomashawk/2941551448/ Jet Engine http://www.flickr.com/photos/icatus/1800268463/sizes/l/ Spanners http://www.flickr.com/photos/tashland/428577287/ Abesses Metro Station http://www.flickr.com/photos/stevecadman/771216725/ Scrap Metal http://www.flickr.com/photos/28481088@N00/4380174213/ Hallway School Chairs http://www.flickr.com/photos/28481088@N00/2874575218/ Burst Balloon http://www.flickr.com/photos/tonyonflickr/3436288903/ Dyson http://www.flickr.com/photos/mr_t_in_dc/2367913342/ Ferrari http://www.flickr.com/photos/mnadi/19399882/ Playstation controller http://www.flickr.com/photos/kwl/3010180401/ Barcelona chair http://www.flickr.com/photos/jamison/107301751/ Beer kettle http://www.flickr.com/photos/setaou/503719614/ Vintage kettle http://www.flickr.com/photos/h_is_for_home/2185739593/ Booklet written May 2010

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