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.

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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

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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

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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

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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

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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

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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

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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/.

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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