GCSE ENGINEERING REVISION GUIDE

Your exam paper will be 1 hour long and will contain 8 questions

OCR J322 GCSE ENGINEERING

This unit will be assessed by a written examination. Questions will be a mix of short answer and free response styles, and will require candidates to demonstrate practical application of knowledge related to products and engineering environments.

Do lots of practice past papers Look at how similar the questions are from year to year You must try to get every one of the first four questions completely correct. This is not difficult as the questions are repeated but just put in a slightly different format These can be found at:

http://www.ocr.org.uk/qualifications/gcse-engineering-single-double-

award-j322-j344-from-2012/

Watch TV

Watch as many ‘How its made’, ‘Extreme Engineering’ and ‘How do

they do that’ type programs, these will show specifically how not only

are products made but how automation and computer control effects

the production of every modern day product from design, througn to

manufacture and finally onto dispatch and delivery. These can be

found on

Discovery Channel

Quest Channel Channel 38

Engineering Sectors Aerospace • wing • rotors • passenger aircraft doors Automotive • wheels • glass (privacy, quickclear, laminated) • safety features Chemical & Process • coatings (paint, plastics) • cement • shampoo Computers,Communication and IT • portable data storage • webcams • radio Electrical and Electronics • electric toothbrush • smoke alarm • radio-controlled car Medical and Pharmaceutical • blister packs • wheelchairs • monitors (heart, blood pressure) Rail and Marine • passenger information systems • power sources (wind, electricity, fossil fuels, human, solar) • safety features Structural and Civil • tunnels • artificial environment domes (e.g. eco-domes, arboretum, leisure, winter sports domes) • wind power generators

Materials

• ferrous and non-ferrous metals and alloys; Mild steel High Carbon Steel Stainless steel Aluminium Duralumin Copper Zinc Brass Lead Tin Bronze • polymers; Melamine Formaldehyde ABS Acrylic (PMMA) HIPS Polyethylene Polypropylene PVC PET Epoxy Resin

• ceramics; Glass porcelain pottery brick • composites that combine the properties of different materials

GRP (glass fibre and epoxy resin) concrete (sand, cement, aggregate)

carbon fibre (carbon strand polymer) silicon carbide

• smart materials

Shape memory alloys thermo-chromic materials/paint polymorph Piezo-electric materials

Function of components

• mechanical components; Bearings cam gears pulleys machine screw chain/sprocket rack and pinion • electrical/electronic components; Relay fuse solenoid capacitor transistor resistor switch • pneumatic/hydraulic components.

single acting cylinders non return valves

The properties, characteristics and features of materials

• ability to be shaped and formed; • ability to be treated; • ability to be given a surface finish; • ease of handling; • cost implications; • availability, form and supply.

Engineering processes

• material removal; • shaping and manipulation; • joining and assembly; • heat and chemical treatment; • surface finishing.

Quality control techniques

• checking task outcomes against design brief; • sampling; • comparing results with intended results; • action to be taken.

New technology used in and by the engineering industries

• information, communications and digital technologies – research, digital communication with clients, suppliers; • modern and smart materials and components – which are used in products manufactured in a chosen sector; • systems and control technology to organise, monitor and control production – basic control

systems and technology in terms of input/output (IO) and feedback.

Impact of Modern Technologies: • when manufacturing an engineered product – impact on workforce, company and local environment; • on engineered products – to end user; • on engineering industries – sustainability. Stages in manufacturing an engineered product • design; • marketing; • production planning; • material supply and control; • processing and production; • assembly and finishing; • packaging and dispatch; • disposal. Advantages and disadvantages that the use of modern technology has brought to society • redundancy; • working conditions; • cost; • availability of products; • impact on the environment; • training; • transport; • lifestyle; • health and safety. Engineered products

• a variety of engineered products that use modern technology; • the impact of modern technology on the design and production of a range of engineered products.

Question 1 is always about Engineering sectors and the products they

make.

Engineering Sectors

Aerospace • wing • rotors • passenger aircraft doors

Automotive • wheels • glass (privacy, quick-clear, laminated) • safety features

Chemical & Process • coatings (paint, plastics) • cement • shampoo

Computers,Communication and IT • portable data storage • webcams •

Electrical and Electronics • electric toothbrush • smoke alarm • radio-controlled car radio

Medical and Pharmaceutical • blister packs • wheelchairs • monitors (heart, blood pressure)

Rail and Marine • passenger information systems • power sources (wind, electricity, fossil fuels, human, solar) • safety features

Structural and Civil • tunnels • artificial environment domes (e.g. eco-domes, arboretum, leisure, winter sports domes) • wind power generators

Question 2 is always about Personal protection equipment (PPE) and

quality control checks:

The machine/process they may ask you about could be: Milling

machine, centre lathe, welding, brazing, buffing/polishing, grinding,

casting, Drilling, CNC machines,

Remember Personal protection equipment is about what you wear

(Visor, Goggles, face mask, overalls, leather apron, gloves, gauntlets,

steel toe cap boots, etc..) , not about chuck guards, holding down work

or applying coolents, making sure long hair is tied up, loose clothing

etc..

However, section B could be about more general Health and safety and

ensuring a good quality finish and how this can be checked eg. Using

video scope, checking with digital calipers, visual inspection checks,

checking against a pre made master copy, testing,

Question 3 is always about Engineering Materials

Make sure you know the difference between:

Ferrous metals: Mild Steel, High Carbon Steel, Stainless Steel, Cast Iron

Non Ferrous metals: Aluminium, Copper, Tin, Tungsten, Gold, Silver, Titanium

Polymers: Thermosetting (these plastics once formed cannot be remoulded): Bakelite, Melamine, Epoxy

Resin (Araldite), Poyurethane

Polymers: Thermoplastics (these can be remoulded and therefore recycled): Acrylic, Polystyrene,

Polycarbonate,ABS, Nylon, Polyethylene, Polypropylene, PVC

Ceramics: Able to take very high temperatures eg. Silicon Carbide, Porcelain Alloys: Mixture of metals:

Duralumin, Brass, Bronze,

Composites: a combination of materials that on their own are weak but when combined are extremely

strong: Carbon Fibre, Fibreglass, Plywood, MDF,

Question 4 is always about New technologies and how computers help

in the Engineering industry

You need to know what the following do, and where they are used, and

how computers help within all these engineering areas

Spreadsheets Word processors Control systems Databases

Packaging and distribution CAD e-mail

Question 5 is always about Systems and control technology, Robotic

manufacturing or describing how an engineering process might be

done

Question 6 is always about Engineering components

You need to know the names of several engineering components and

what they do e.g.

You need to know what some of the above components are and what

they do, Look them up

Question 7 is always about the selection, storage, use and availability

of materials

J.I.T. production: Just in time production , allows companies to just oreder in the stock they need so they don’t need large storage facilities

and spend money on extra stock theyu may not need.

Question 8 always requires you to write a detailed answer, you need to

make three points and justify your answer