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Engineering Manufacturing Knowledge Organiser - Contents
Unit R109- Engineering materials, processes and production
Learning Outcome 1: Know about properties and uses of engineering materials- Pages 2-4Learning Outcome 2: Understand engineering processes and their application- Pages 5-7Learning Outcome 3: Know about developments in engineering processes- Page 8Learning Outcome 4: Understand the impact of modern technologies on engineering production- Pages 9,10
Unit R110- Preparing and Planning for Manufacture
Learning Outcome 1: Be able to plan for the making of a pre-production product and interpret information from 2D and 3D drawings- Page 12-13Learning Outcome 2: Be able to use processes, tools and equipment safely to make a pre-production part- Page 14-15Learning Outcome 3: Be able to modify a production plan for different scales or production-Page 16
Unit R111- Computer Aided Manufacture
Learning Outcome 1: To plan the production of components on CNC machines- Page 18Learning Outcome 2: To be able to interpret information from CAD to manufacture components on CNC machines –Page 19Learning Outcome 3: To set up and use a CNC machine to manufacture components - Page 20Learning Outcome 4: Learn about practical applications of computer controlled processes used to manufacture products - Page 21
Unit R112- Quality Control of Engineered Products
Learning Outcome 1: Understand the importance of quality control - Page 23-24Learning Outcome 2: Be able to assess product quality from inspection and quality control techniques- Page 25Learning Outcome 3: Know how modern technologies can be used in quality control- Page 26Learning Outcome 4: Know the principles of lean manufacturing- Page 27
Page 1
Learning Outcome 1: Know about properties and uses of engineering materials
Materials
Metals – materials that are made by processing an ore (an ore is usually an oxide of a metal in the form of a rock)
Ferrous metals - contain iron are usually magnetic and rust.
Common examples; Cast Iron, Low carbon steel, High carbon steel, Stainless steel
Non-Ferrous metals - do NOT contain iron, are not magnetic and tend to rust less.
Common examples; copper, brass, bronze, aluminium alloys, zinc, tin, lead, titanium.
Alloys – metals that are commonly made up from two or more metals
Polymers – are made up of a large number of similar chemical units that are bonded together. Polymers are usually made from crude
oil.
Thermoplastics – Become soft when heated and can be reheated and shaped many times. They can normally be recycled when melted
down.
Common examples; Acrylonitrile-Butadiene-Styrene (ABS), Polyethylene, High impact polystyrene (HIPS) Polyvinyl chloride (PVC), Nylon,
Polycarbonate, Polypropylene (PP)
Thermosetting plastics – Can only be heated and shaped ONCE. They CANNOT be recycled.
Common examples; Polyester resin, Urea-formaldehyde, Epoxy resin, Phenol-formaldehyde.
Page 2
Other Materials
Ceramics – typically an oxide, nitride or carbide of a metal. They are very hard, usually resistant to corrosion and are good insulators.
Common examples; tungsten carbide, glass, ceramic bearing material
Composites – Materials that are made by combining different materials to make a new material with specific properties.
Common examples; Glass reinforced plastic, Carbon fibre, concrete.
Smart materials – Materials that react to stimulus from their environment such as light or heat.
Common examples; shape memory alloys, thermochromic materials, shape memory plastics, Quantum tunnelling composite (QTC)
New and emerging materials - Materials that have new enhanced properties such as Nanotechnology, advanced metal alloys.
Learning Outcome 1: Know about properties and uses of engineering materials
Keywords Properties of Engineering Materials
Hardness Ability to resist surface scratches
Ductility Ability to be stretched out into a wire using tensile force
Plasticity Ability to be shaped or moulded
Elasticity Ability to return to original shape after being stretched or compressed
Malleability Ability to be shaped without breaking
Toughness Ability to withstand impact
Machinability Ability to be easily cut by machinery
Conductivity/Resistivity
Ability to conduct or resist electricity or heat
Brittleness Ability to be easily damaged
Materials Testing Processes
Non-Destructive Testing (NDT)Crack Testing, Conductivity Testing
Destructive Testing- Tensile Testing, Crash Testing
Page 3
Learning Outcome 1: Know about properties and uses of engineering materials
Characteristics of Engineering Materials
Relative Cost- How expensive is the material to produce and source?Availability-Is it widely available and from a reliable sourceEase of Use- Is it easy to use or does it need specialist equipment?Safety in Use- What safety precautions need to be taken?Forms of Supply-What stock form does the material come in such as sheet or bar?Sustainability- Is the material from a sustainable supply and can it be recycled or reused after use?
Uses of Specific Materials
Page 4
Keywords
Material RemovalSawing To form by cutting with a saw
Filing Material removal by applying a reciprocating force using a file
Threading The cutting of an internal or external thread by using a tap or a die
Hand FormingForging To make a shape in metal by heating in a furnace and hammering it
Casting To make an object by pouring molten metal into a mould
Bending Using force to shape or bend into a curve or angle
Joining MethodsSoldering Method of joining metals together, usually electrical components, using a soldering iron
Brazing Method of joining metal parts together using heat
Welding Method of joining metal parts together by heating to the point of melting
Riveting Join or fasten plates of metal with pins or rivets
Adhesives Substance applied to surface of materials to bind them
Threaded Fasteners Has a screw thread to enable assembly and disassembly of parts
Self Tapping Screws Screw that cuts its own thread when tightened
Learning Outcome 2: Understand engineering processes and their application
Page 5
Learning Outcome 2: Understand engineering processes and their application
Keywords
Heat TreatmentHardening Heating metals to make them get harder
Tempering Heating and cooling metals to make them less brittle
Annealing Heating and cooling metal to make it tougher
Normalising Heating of a metal and cooling at room temperature
Nitriding Case hardening a metal by diffusing nitrogen into the surface
Surface Finishes
Electroplating Process of coating a metal with a layer of another metal using electricity
Galvanising To cover a metal with zinc
Painting To cover a metal/material with paint to protect it
Plastic/Powder Coating Applying powdered plastic to heated metal to give it a protective coating
Linishing To polish or remove access material using an abrasive belt
Polishing To make a surface smooth and shiny
Page 6
Keywords
Machining Processes (material removal)Drilling Removing material by making a hole with a drill
Turning Material removal by using a centre lathe
Milling Material removal by using a rotating cutter on a milling machine
Grinding Material removal by abrasion using a rotating abrasive wheel
FormingForging To make a shape in metal by heating in a furnace and hammering it
Die and Investment Casting To make an object by pouring molten metal into a precision mould
Press Forming Using force to shape or bend into a shape in a machine
Shell Moulding Using resin covered sand to make a more accurate cast shape
Extrusion Heated metal/plastic pushed through a die of a given shape
MouldingVacuum Forming A process where a sheet of plastic is heated and forced over a mould
by vacuum
Injection Moulding Heating up plastic and forcing into a mould to make parts
Blow Moulding A process of forming hollow plastic parts
Rotational Moulding A process combining heat and bi axial rotation
Compression Moulding Heated plastic is pushed into a mould to create a given form
Learning Outcome 2: Understand engineering processes and their application
Page 7
Safe Use of Tools and Equipment• Features of
controls of machines
• Risk Assessment• Appropriate PPE
(Personal Protective Equipment)
• Safety precautions
Learning Outcome 3: Know about developments in engineering processes
Keywords
Applications of computer controlled processes
Computer Numerical Control
The automated control of machine tools
CNC lathe/milling/router machines
Centre lathes, milling machines and routers that are automatically controlled by computer programmes
Multi-axis machining centres
A manufacturing process that involves tools that move in 4 or more directions
Water jet cutting A machine tool capable of cutting metals using a high pressure jet of water and abrasive materials
Punching machines Automatic or semi automatic machines for punching shapes into sheet metal
Press brake machines Used for bending sheet and plate material
Laser ApplicationsLaser Cutting/Welding
Automatic computer controlled machines that cut material or join metal together using a high powered laser
Additive manufacturing and rapid prototyping processes
Additive manufacturing is process by which digital 3D design data is used to build up a component by depositing material. Examples of this are:Selective Laser Sintering (SLS), Stereolithography (SLA), Direct Metal Laser Sintering (DMLS), Fused Deposition Modelling (FDM), 3D printing, Electron beam melting
Page 8
Learning Outcome 4: Understand the impact of modern technologies on engineering production
Examples of digital communication
Video conferencing;
Skype / facetime;
Digital transfer of technical data;
SMS/texting
Use of Internet websites;
Social media;
Messenger apps
CAD
Internet research
Electronic communication of drawings
Email and video conferencing
Uses in supply and demand
• Use of barcoding computerised stock control systems;
• Can automatically order more stock when required – humans don’t need to do it.
• Use of RFID (Radio frequency identification), for stock control;
https://www.youtube.com/watch?v=PwCqKvHWRNk
• Use of online ordering is quicker – Just in time inventory
• Electronic transfer of data
http://www.ifm.eng.cam.ac.uk/ research/dstools/jit-just-in-time-manufacturing/.
Page 9
What are Modern Technologies?
CNC machinerySmart productsArtificial intelligence3D scannersLasersTouchscreensCAD packagesBroadband…there are loads more examples.
Advantages of modern technology
Greatly Increased production: Increased output and reduced production times meaning it can get to market quicker. They do the job within the minimal time but with maximum accuracy and efficiency.
Reduced human effort/ welfare; Modern technologies can do dangerous jobs or heavy lifting, meaning humans don’t have to –improving welfare/ working conditions would improve.
Reduced cost of the actual production once machinery has been purchased.
Precision & consistency – Product are more accurate and are all the same compared to human production techniques (incur errors) - consistency – zero defects, Right First Time.https://www.lockheedmartin.com/en-us/news/features/history/zero-defects.html
Quality – products can be constantly monitored throughout the production process to spot problems early on (use of lasers and 3D scanners to check quality of products)
Enhanced communication -. Skype, Whatsapp, Facebook Messenger are all the examples of modern technology communication service providers.
Page 10
Unit R110- Preparing and Planning for Manufacture
Learning Outcome 1: Be able to plan for the making of a pre-production product and interpret information from 2D and 3D drawings- Page 12-13Learning Outcome 2: Be able to use processes, tools and equipment safely to make a pre-production part- Page 14-15Learning Outcome 3: Be able to modify a production plan for different scales or production-Page 16
Page 11
Learning Outcome 1: Be able to plan for the making of a pre-production product and interpret information from 2D and 3D drawings.
Isometric View
Sectional View
Plan View
Engineering Drawing
CAD Solidworks 3D Drawing
To create a Production Plan you must first know how to make each part of the component
Page 12
Learning Outcome 1: Be able to plan for the making of a pre-production product and interpret information from 2D and 3D drawings.
Order Task – explain in detail Tools/ equipment / materials and processes(show pictures)
Materials/Components
Quality Control Measures H&S control measures
Step number Describe the task Tools, equipment etc used for this task
Material the component is made from
What measure is put in place to ensure the part is made correctly?
Health and Safety needed, such as PPE etc
Page 13
Keywords
Centre Lathe Machine tool used for making cylindrical components, known as turning.
Quality Control A process of checks ensuring the product is made accurately
Measuring Equipment Digital callipers, rules, thread gauges etc used to check manufactured dimensions against given drawing dimensions
Photo Diary A record of the manufacturing process
Manual Operated by hand
CNC Computer Numerical Control (computer operated via programming)
Accuracy Comparison of dimension to size on given drawing
Set Up Setting up a machine for use in manufacturing
Tapping Cutting an internal screw thread
Die cutting Cutting an external screw thread
Consistency Being able to repeat the same sizes over and over again
Prototype One off part
Chamfer Angled corner of component
PPE Personal Protective Equipment
Health and Safety Measure Control put in place to minimise risk to health and safety
Learning Outcome 2: Be able to use processes, tools and equipment safely to make a pre-production part.
Page 14
Learning Outcome 2: Be able to use processes, tools and equipment safely to make a pre-production part.
Centre Lathe diagram
Page 15
Learning Outcome 3: Be able to modify a production plan for different scales or production
Keywords
Modify Make a change to the original plan/idea
Scale of production 3 main types-One off - used for prototypes, bespoke products, expensive but unique, skilled, manualBatch – products made as specified groups or amounts moving through stages of production. Autonomous and semi autonomous production. Cheaper unit cost than one off productionMass/Continuous – Products made in large quantities on production lines, expensive to install but cheaper unit cost. Mainly autonomous.
Jig Device for quickly and accurately setting a workpiece to make repeated operations
Fixture Device for holding a workpiece more easily to be able to carry out an operation
Increased Production An increase in the amount made in a given time
Workshop layout How the machine tools and working areas are arranged to give maximum production efficiency
Page 16
Unit R111- Computer Aided Manufacture
Learning Outcome 1: To plan the production of components on CNC machines-Page 18Learning Outcome 2: To be able to interpret information from CAD to manufacture components on CNC machines – Page 19Learning Outcome 3: To set up and use a CNC machine to manufacture components - Page 20Learning Outcome 4: Learn about practical applications of computer controlled processes used to manufacture products - Page 21
Page 17
Learning Outcome 1: To plan the production of components on CNC machines.
What is CNC?CNC stands for Computer Numerical Control
There are many types of CNC machines but you will be using a CNC lathe called a Boxford
CNC machines are quicker, more accurate, more versatile and require less skill than manual machines but they are more expensive and require special training to use properly
Order Task – explain in detail Tools/ equipment / materials andprocesses(show pictures)
Materials/Components
Quality Control Measures H&S control measures
Page 18
Learning Outcome 2: To be able to interpret information from CAD to manufacture components on CNC machines
Information to create a CNC programme
Example of CNC programme
Example of Engineering Drawing
Page 19
CAD –Computer Aided DesignCAM – Computer Aided ManufactureCNC-Computer Numerical ControlCNC Programming – software creates program codesand instructions used to run a machine tool controlled by a computer. Each unique part requires it’s own CNC program. CNC has been aroundsince the early 1970s
G Codes – is a language in which people tell computerised machine toolshow to make something. The “how”is defined by g-code Instructions provided to a machine controller (industrialComputer) that tells the motors where to move, how fast to move and what paths to follow.Co-ordinate system- is a system that uses one or more numbers, orco-ordinates, to uniquely determine the position of the points or
other geometric elements.Datum- Any reference point of known or assumed co-ordinates from whichCalculation or measurements may be taken.
Learning Outcome 3: To set up and use a CNC machine to manufacture components
Keywords
MakingBillet Piece of material used to make a component
Mark out Using a ruler to measure out a length to be cut
Cut to length Material removal process using hand tools
Tapping Cutting an internal thread
CNC Machining Machine tool operated by a computer programme
Comparison between Manual and CNC methods of makingPlanning/Set Up Difference between setting up a standard manual centre lathe and a CNC lathe. CNC set
up is highly skilled
Operator Skill Operator skill is high on a manual lathe
Origins of Error Where are errors/mistakes likely to occur?
Cycle Time How long it takes to make one component
Visual Quality What the overall appearance looks like
Dimensional Accuracy Accuracy of product to the size on drawing
Consistency Being able to repeat the same sizes over and over again
Limitation Things that each type of machining can’t do
Page 20
Learning Outcome 4: Learn about practical applications of computer controlled processes used to manufacture products
Keywords
Scales of ProductionOne Off Production Single, custom made product/prototype- Using CAD/databases/Rapid Prototyping techniques etc
Batch Production Set number/quantity of products made as a group-Additionally using CNC machinery/inspection
Mass Production Large volume of identical products-Additionally using Robotics for manufacture/assembly/inspection
Robotics in Engineering Description, Application of
Articulated, Delta (or Parallel), SCARA, Polar, Cartesian and Cylindrical robots
Advantages/Disadvantages of Robotics in Engineering ManufactureVery accurate, precise, less labour intensive, does not need breaksExpensive to purchase and set up, training needed to operate, only good for mass production
Additive Manufacture/Rapid PrototypingLaminating Process of manufacturing a material in multiple layers
3D Printing The construction of a 3 Dimensional object from a CAD model
Stereolithography A form of 3D printing using photochemical processes by which light causes monomers and oligomers to cross link to form polymers
Laser Sintering An additive manufacturing technique that uses a laser to sinter, or fuse together powdered material into a 3D object/modelAdvantages/Disadvantages of these processes in Engineering ManufactureGood at making 3D prototypes/models, accurateExpensive to purchase and run, can be relatively slow, additional software and training needed
Page 21
Unit R112- Quality Control of Engineered Products
Learning Outcome 1: Understand the importance of quality control - Page 23-24Learning Outcome 2: Be able to assess product quality from inspection and quality control techniques- Page 25Learning Outcome 3: Know how modern technologies can be used in quality control- Page 26Learning Outcome 4: Know the principles of lean manufacturing- Page 27
Page 22
Learning Outcome 1: Understand the importance of quality control
Quality assurance
DescriptionQuality assurance is a way of preventing mistakes and
defects in manufactured products and avoiding problems
when delivering products or services to customers;
which ISO 9000 defines as "part of quality management focused
on providing confidence that quality requirements will be fulfilled"
Quality control
DescriptionQuality control is a process by which entities review the
quality of all factors involved in production. ISO 9000 defines
quality control as "A part of quality management focused on
fulfilling quality requirements"Total Quality Management: a system of management based on the principle that
every member of staff must be committed to maintaining high standards of work in
every aspect of a company's operation
Quality standards are defined as documents that provide requirements,
specifications, guidelines, or characteristics that can be used consistently
to ensure that materials, products, processes, and services are fit for their purposeThese are : BSI Kitemark, CE Mark ISO 9000
Page 23
Learning Outcome 1: Understand the importance of quality control
Keywords Equipment used to carry out Quality Control
Micrometer A device incorporating a calibrated screw used for accurately measuring of components in engineering
Digital Caliper A device with an LCD display used for measuring internal and external distances
X Ray Testing A NDT that uses x-rays to examine the internal structure of manufactured components
Depth Gauge Micrometer A precision instrument used to measure depths
Ultra Sonic Testing A NDT process that uses ultra sonic waves to detect defects in materials or components
Dial Bore Gauge Used to measure the inner diameter of components
Jigs A device that holds a piece of work and helps locate other parts or cutting tools into a position
Fixtures A work holding or support device used in manufacturing
Page 24
Learning Outcome 2: Be able to assess product quality from inspection and quality control techniques
ORDERING THE RAW MATERIALS Stock material, order quantity, order number, receipt email
RECEIVING THE RAW MATERIALS Inspect upon receipt, check against order.
DURING THE MANUFACTURINGPROCESS
Inspect each stage of production, check measuring equipment
COMPLETION OF THE MANUFACTURE Inspect to product specification and engineering drawing
PACKAGING & DELIVERY Correct packaging and identification and traceability
AFTER SALES Disclaimer, statutory rights and customer service
Keywords and Key Stages
Creating a schedule of inspection to ensure the quality of a product
Page 25
Learning Outcome 3: Know how modern technologies can be used in quality control
Keywords
Destructive Testing Test carried out to understand a specimen or material’s performance by testing until failure
Crash Testing A form of destructive testing used to ensure safe design standards, usually in motor vehicles
Non-Destructive Testing A wide group of analysis techniques used in science and technology to evaluate the properties of material, component or system without causing damage
Coordinate Measuring Measuring (CMM)
A device that measure the geometry of physical objects by sensing points with a probe
Robotics Intelligent machines that can assist humans in their day to day lives
Computer Integrated Manufacturing / Computer Integrated Engineering
The manufacturing approach of using computers to control entire production processes.
Automatic Test Equipment (ATE)
A device that performs test on a product using automation to quickly perform measurements and evaluate test results
Page 26
Learning Outcome 4: Know the principles of lean manufacturing
Keywords
Lean manufacturing Enables businesses to increase production, reduce costs,
Improve quality, and increase profits by following five key principles: identify value,
map the value stream, create flow, establish pull and seek perfection
Principles of Lean manufacturing include: transport, inventory, movement, Over production, over processing, defects, skill
Waste Reduction Design for AssemblyHow products can be assembled in a way that reduces waste
Design for ManufactureCreate designs that use less material and create less waste product
Sustainable Design The philosophy of designing physical objects, the built environment and services to comply with the principles of economic, ecological and social sustainability
Principles of Sustainable Design/Design Considerations for Designers
Low-impact materialsEnergy EfficiencyEmotionally Durable DesignDesign for reuse and recyclingBiomimicryRenewabilityForm
The 6R’s of Sustainability Help designers create a product that considers it’s environmental impact during the design of it.The 6R;s are : Reduce, Recycle, Refuse, Reuse, Rethink and Repair
Life Cycle Analysis A method used to evaluate the environmental impact of a product through its life cycle, encompassing: extraction and processing of raw materials, manufacturing, distribution, use, recycling and final disposal
Waste Prevention The preventing of unnecessary production of waste material
Page 27
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