btec engineering unit 1 - greenacre academyunit 1: the engineering world learning aim a1: know about...
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BTEC ENGINEERING
UNIT 1
The Engineering WorldLA 1: Know about engineering
processes used to produce modern
engineered products
External Assessment
Name: ______________________
Group: ______________
START DATE:
COMPLETION DATE:
Practice test result:
1
Unit Introduction
What is “engineering”? Is it using materials and processes to manufacture a single item? Is it applying new technologies to mass production of well known products? Or is it implementing methods to reduce waste and improve the sustainability of energy sources? Engineering is all of these things and many more. It affects all aspects of our lives, from the daily use of time saving appliances to performance materials applied in ways we may never have imagined.
In this unit, you will discover the world of engineering. You will investigate the processes used to manufacture modern products within different engineering sectors.
You will also study some of the new developments in materials and engineering technology that have an impact on life today- or will have in the very near future.
Engineers must be aware that products and processes may require the use of scarce resources that could have an impact on the environment. When an engineered product is made, used and disposed of, any waste of energy and environmental damage must be minimalized at all stages. Therefore, you will also investigate waste reduction and sustainability issues from an engineering perspective, discovering how engineers can help control and reduce environmental damage.
Learning aims
In this unit you will:
A know about engineering processes used to produce modern engineered products
B know about developments in engineering materials and technologies
C understand how engineering contributes to a sustainable future.
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Unit 1: The Engineering World
Learning Aim A1: Know about engineering processes used to produce modern engineered products
There are several engineering sectors, investigate each sector and write in as much detail as possible what products are manufactured in each of the engineering sectors.
Task 1
1. Aerospace Sector:
• What is an aerospace engineer?
• What tasks do they carry out?
• What products are manufactured in the aerospace sector?
• What impact would this sector have on our everyday life?
2. Automotive Sector:
• What is an automotive engineer?
• What tasks do they carry out?
• What products are manufactured in the automotive
sector?
• What impact would this sector have on our everyday life? 3
Unit 1: The Engineering World
Learning Aim A1: Know about engineering processes used to produce modern engineered products
3. Communications Sector
• What is an communications engineer?
• What tasks do they carry out?
• What products are manufactured in the
Communications sector?
• What impact would this sector have on our everyday life?
4. Electrical/Electronic Sector
• What is an electrical/electronic engineer?
• What tasks do they carry out?
• What products are manufactured in the
electrical/ electronic sector?
• What impact would this sector have on our everyday life?
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Unit 1: The Engineering World
Learning Aim A1: Know about engineering processes used to produce modern engineered products
5. Mechanical Sector
• What is a mechanical engineer?
• What tasks do they carry out?
• What products are manufactured in the
mechanical sector?
• What impact would this sector have on our everyday life?
6. Biomedical Sector
• What is a biomedical engineer?
• What tasks do they carry out?
• What products are manufactured in the
biomedical sector?
• What impact would this sector have on our everyday life?
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Unit 1: The Engineering World
Learning Aim A1: Know about engineering processes used to produce modern engineered products
7. Chemical Sector
• What is a chemical engineer?
• What tasks do they carry out?
• What products are manufactured in the chemical sector?
• What impact would this sector have on our everyday life?
EXAM QUESTIONS
Which sector deals with the way information is used around the globe?
Which sector deals with the design, development and manufacture of vehicles?
Which sector deals with the design, development and manufacture of products through flight?
Name a typical product developed by the Biomedical sector
Name a typical product manufactured by the mechanical sector
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts , engineer’s must use several different processes to achieve a specific form, shape and finish.
Task 2
Machining:
You must describe with the use of diagrams the process of turning:
You must describe with the use of diagrams the process of drilling:
You must describe with the use of diagrams the process of milling:
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must be able to work safely, knowing about and following the relevant Safety legislation.
Task 3
Machining:
Can you name at least 5 Health and Safety issues that you have to consider when TURNING, MILLING or DRILLING?
1.
2.
3.
4.
5.
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish. In order to manufacture each component to its specification they must know the characteristics of each machining process.
Task 4
Machining:
Can you name at least 5 characteristics that you would find when turning?
1.
2.
3.
4.
5.
Can you name at least 5 characteristics that you would find when drilling?
1.
2.
3.
4.
5.
Can you name at least 5 characteristics that you would find when milling?
1.
2.
3.
4.
5.
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different processes to achieve a specific form, shape and finish.
Task 5
Machining:
Can you name at least 5 applications where you would use turning?
1.
2.
3.
4.
5.
Can you name at least 5 applications where you would use drilling?
1.
2.
3.
4.
5.
Can you name at least 5 applications where you would use milling?
1.
2.
3.
4.
5.
10
Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish. It is important to know the advantages or disadvantages of each machining process.
Task 6
Machining: Turning
In the table below can you give the advantages and disadvantages of manufacturing of components by turning them?
Definition of Turning:
Advantages Disadvantages
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Machining: Milling
In the table below can you give the advantages and disadvantages of manufacturing of components by milling them?
Definition of Milling:
Advantages Disadvantages
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Machining: Drilling
In the table below can you give the advantages and disadvantages of manufacturing of components by drilling them?
Definition of Drilling:
Advantages Disadvantages
13
Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Task 7
Forming: Casting
In the table below can you give the advantages and disadvantages of manufacturing of components by casting them?
Definition of Casting:
Advantages Disadvantages
14
Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Task 8
Forming: Forging
In the table below can you give the advantages and disadvantages of manufacturing of components by forging them?
Definition of Forging:
Advantages Disadvantages
15
Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Task 9
Fabrication: Welding
In the table below can you give the advantages and disadvantages of manufacturing of components by welding them?
Definition of Welding:
Advantages Disadvantages
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Task 10
Fabrication: Shearing
In the table below can you give the advantages and disadvantages of manufacturing of components by using the shearing method?
Definition of Shearing:
Advantages Disadvantages
17
Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Task 11
Electrical/electronic:
In the table below can you give the advantages and disadvantages of PCB manufacturing?
Definition of PCB Manufacturing:
Advantages Disadvantages
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Unit 1: The Engineering World
Learning Aim A2: Mechanical and electrical/electronic engineering processes
During the manufacturing of components and parts engineer’s must use several different process to achieve a specific form, shape and finish.
Electrical/electronic:
In the table below can you give the advantages and disadvantages of surface mount technology used in electronics?
Definition of Surface Mount Technology:
Advantages Disadvantages
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Unit 1: The Engineering World
Learning Aim A3: Scales of Production
When products are manufactured in industry, there are several options engineers have to manufacture the specific product. In order for them to make an informed decision of the type of process they have to take into account the number of components, cost, environmental impact and time.
Task 12
One- Off/jobbing production
Write down the definition of one-off/jobbing production.
Explain with the use of examples in industry and diagrams how one-off/jobbing manufacture works.
Highlight advantages and disadvantages.
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Unit 1: The Engineering World
Learning Aim A3: Scales of Production
Batch Production
Write down the definition of batch production.
Explain with the use of examples in industry and diagrams how batch production in manufacture works.
Highlight advantages and disadvantages.
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Unit 1: The Engineering World
Learning Aim A3: Scales of Production
Mass Production
Write down the definition of batch production.
Explain with the use of examples in industry and diagrams how mass production in manufacture works.
Highlight advantages and disadvantages.
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Unit 1: The Engineering World
Learning Aim A3: Scales of Production
Continuous Production
Write down the definition of continuous production.
Explain with the use of examples in industry and diagrams how continuous production in manufacture works.
Highlight advantages and disadvantages.
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Unit 1: The Engineering World
Learning Aim A4: Modern Production Methods.
Task 13
In order for manufacturing companies to stay competitive and survive in the modern era, they have to modernise their equipment and work force. If they don’t it may lead to them not being able to fulfil their manufacturing obligation to the correct quality and in the required time, which might lead to the cancelation of contracts and eventually the close of business. To help companies to modernise they often will use Computer Aided Manufacture (CAM)
Computer Aided Manufacture (CAM)
Write down the definition of Computer Aided Manufacture (CAM)
Explain with the use of examples in industry and diagrams how Computer Aided Manufacture (CAM) could be used to manufacture components in industry.
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Unit 1: The Engineering World
Learning Aim A4: Modern Production Methods.
Task 14
Explain with the use of examples and diagrams how robots could be used in assembly, exploration and packaging/dispatch
In the table below write down the advantages and disadvantages robots can have in any use.
Advantages Disadvantages
25
Unit 1: The Engineering World
Learning Aim A4: Modern Production Methods.
Task 15
Explain with the use of examples and diagrams how Computer Numerical Controlled (CNC) machines could be used to manufacture components in industry.
In the table below write down the advantages and disadvantages Computer Numerical Controlled (CNC) machines can have in the production/assembly lines of manufacturing companies.
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Advantages Disadvantages