Quiz questions
Write 15-20 quiz questions with answers on
the Engineered World
Remember to write down the answers
Use your notes and the revision booklet to
help you
AerospaceThe design development and manufacture of products through flight
ProductsMilitary aircraftPassenger jetsHelicoptersRockets
AutomotiveThe design, development and manufacture of vehicles
ProductsCars, Motor bikesVansLorries
CommunicationsThe way information is used around the globe
ProductsMobile phonesRoutersSatellitesComputers
ElectricalThe design, development and manufacture of vehicles
ProductsTelevisionsDVD playersCalculatorsMicrowaves
MechanicalThis is a branch of engineering that can be found in many different sectors and is associated with the design, manufacture and testing of machines and other mechanical devices
ProductsEnginesRobotsLifts Machine tools
BiomedicalThis is a sector that specialises in developing devices/ procedures that solve medical problems using science and engineering knowledge
ProductsArtificial limbsMedical instrumentsXray machines
ChemicalThe design and processing of equipment for the chemical industry as well as the manufacture of chemical products
ProductsPetrolMedicinesCleaning fluidsPaint
DescriptionDrilling is a process that creates circular holes in a workpiece. The cutting device is called a drill bit.
Applications Threads, counter sunk holes, through holes
Health and safety Remove loose clothingTie hair backWear PPE (Personal protective equipment)Lower the guardUse a G clamp
Advantages/disadvantages+ve Adaptable, accurate, reliable-ve Minor burns caused by hot materials
Flying pieces of materialHand or arm could come into contact with revolving parts
DescriptionThis is a process used to shape products by excess material to produce a range of simple and complex shapes. A milling machine has a spindle that holds rotating cutter in place. The material is held in a vice and the machine cuts from both horizontal and vertical angles.
Applications • Flat surfaces• Groves and slots• Holes• Rounding offEngine and machine parts
Health and safety Remove loose clothingTie hair backWear PPE (Personal protective equipment)Lower the guardUse a clamp
Advantages/disadvantages+ve Adaptable, accurate, reliable-ve Minor burns caused by hot materials
Flying pieces of materialHand or arm could come into contact with revolving parts
DescriptionTurning involves the use of a lathe to produce a given shape, usually cylindrical. Lathes have one thing in common the workpiece is held in a chuck and rotated while being machined to shape and size using a cutting tool.Applications • Facing off• Drilling• Parting off• Parallel turning• Taper turningEngine and machine parts, plumb bobs etcHealth and safety Remove loose clothingTie hair backWear PPE (Personal protective equipment)Lower the guardUse a clamp Advantages/disadvantages+ve Adaptable, accurate, reliable-ve Minor burns caused by hot materials
Flying pieces of materialHand or arm could come into contact with revolving partsYears of training
Casting is a process that involves pouring or injecting a liquid into a mould. The mould contains a cavity that takes the shape of the desired object.
DescriptionUsed for large parts where dimensional accuracy is not important. It’s a quick and relatively cheap casting process.
Step 1- The component halves are pressed into two boxes of sandStep 2- The component is removed from the mould halves. The runner and riser gates are then cut into the top half of the mould. Step 3- The mould halves are fitted togetherStep 4- Molten metal is poured into the runnerStep 5- Once the metal has cooled the sand is removed and the component revealed
Applications Man hole coversHealth and safety PPEWorking with molten metal can be hazardousAdvantages/disadvantages+ve Quick, cheap, little waste is produced-ve The mould can only be used once
Surface finish is poor
Forging is a process that involves a metal being heated up and shaped. This shape is usually achieved by applying a squeezing pressure or force e.g hammer blows
DescriptionComponents are made by hammering metals into a dieApplications Engine cam shaftsHealth and safety PPEAdvantages/disadvantages+ve High production rates
DescriptionUses a slow squeezing action to form the metal that penetrates the whole object- this makes it suitable for forging large objectsApplications Aircraft landing gearHealth and safety PPEAdvantages/disadvantages+ve Can produce large components
Welding is one of the most efficient methods of permanently joining two pieces of metal together. It can be done in many different ways but most methods use intense heat to fuse the metal together.
Welding
process
Description Advantages
MIG
welding
MIG welding uses electricity to
create heat to weld the two
metals together
• Suitable for large
scale production
• Varying thickness of
materials can be
joined
Oxy-
acetylene
A gas welding process where a
flame is produced using a mixture
of oxygen and acetylene gas.
• Easier to control the
low and high
temperatures needed
for welding
• Inexpensive
Spot
welding
Two electrodes trap the sheet
metal and fuse the two together
• Process is free from
fumes
• Cost effective
• Requires little
maintenance
Health and Safety-Wear PPE
Wear a welding mask to protect from sparks and arc eye
Process
1. Designing the layoutCircuit boards are designed using computer software
2. Producing the art workThe artwork is printed onto clear acetate
3. PCB EtchingTransfer the artwork to the board by exposing it to UV light. Place the board into ferric chloride to remove the exposed copper.
4. Drilling the boardDrill the centre of the pads.
5. Populate the board and solderPush the component legs through the board and solder them into place
Virtually all of todays electrical components are produced using SMT. The process involves attaching electrical components to the surface of a conductive board rather than drilling holes for the component legs
Advantages of SMT
Reduced cost of
components and labour
Components are much
smaller and lighter
High automation
reduces human error
Complex circuits can
be produced on small boards
Increased production
speeds
The way products are manufactured depends on the
quantity required, this is known as Scales of
Production. There are 4 main types of production:
Continuous
For the exam you will need to be able
to:
• Describe the production process
• List the advantages and
disadvantages of the process
• Name product made using the
process
Description
Involves designing and making a single product such as a
wedding ring a designer suit or an individual chair. Typically, one
off production involves highly skilled workers who undertake a
broad range of tasks using generalised tools and equipment.
Advantages and disadvantages
+ve- Products are unique
Skilled workers lively hoods are maintained
-ve High unit costs
Products take a long time to produce
Labour costs are high
Products
Wedding cakes, Suits, Prototypes
Description
Batch- produced products are identical and made at the same
time in either large or small numbers. Once these products have
been made, more of the same products may be made using the
same equipment. The machinery can be adapted easily for the
next product.
Advantages and disadvantages
+ve- Machines can be adapted
Labour cost are medium
Flexible production process
-ve Initial investment of machines can be high
Products
Chairs, magazines, books and small electrical products are
usually batch- produced.
Description
Involves the product going through many stages of a production
line. It deals with the high- volume manufacture of products that
may or may not be identical, allot of specialist equipment is
needed. The workers and machines at each stage are
responsible for making certain parts of the product. Workers
tend to specialise in a small range of tasks.
Advantages and disadvantages
+ve- Production efficiency is high
Labour costs are relatively low
-ve Initial investment of machines is high
Products
Computers, Cars, Televisions
Description
In continuous production the products are produced over a
period hours , days, weeks or even years. The production line
never stops running 24 hours a day 7 days a week. Continuous
production usually relies on high levels of automation and very
few workers are used.Advantages and disadvantages
+ve- Production efficiency is very high
Labour costs are low
-ve Initial investment of machines is high
Products
Paper clips, machine screws, paper, bottles, bricks
Continuous Production
Robots come in all shapes and sizes. Robots are mechanical devices that
can move in every direction. Robots are used for a variety of tasks but
they mainly feature in production. They are able to produce products
quickly, accurately and consistently over log periods of time.
There are 4 main functions of Robots:
Packaging and Dispatch
Description
Robots are now used for exploration, they are sent to the bottom of the
sea and into space. Robots are able to go where humans aren't. These
robots are called ROV’s- remote operated vehicles. These robots are
fitted with cameras and a variety of devices based on the job they will be
fulfilling e.g on Mars gathering samples.
Applications
Sea exploration
Space exploration
Advantages and Disadvantages
+ve They can travel long distances
Be used in dangerous environments
Wont get tired
-ve Exspensive
Description
Production lines use robots to perform repetitive, dangerous and precise
tasks. These robots are usually in the form of arms and replace the need
for workers, they able to perform dangerous tasks such as welding.
Applications
Spray painting
Car production
Creating circuit boards
Making biscuits
Advantages and Disadvantages
+ve Can be adapted to perform multiple tasks
Can be updated quickly
Are very reliable and accurate
Can run 24/7
-ve Initial set up cost are high
Can lead to a loss of jobs
Need to be maintained
If anything goes wrong production stops
Description
Post offices and airports use PLCs- Programmable logic controllers.
These robots are used to control the movement of packages and luggage
through a series of sensors, cameras and conveyor systems. These
systems ensure the packages end up in the right location. They remove
human error and increase efficiency.
Applications
Post offices
Airport luggage
Online orders sorting offices
Advantages and Disadvantages
+ve Removes human error
Able to do multiple tasks at once
Efficient
-ve Initial set up cost are high
Can lead to a loss of jobs
Need to be maintained
If anything goes wrong production stops
Packaging and Dispatch Robots
Description
CNC stands for computer numerically controlled, it is the same as
Computer Aided Manufacture (CAD).
CNC machines use a CAD document an converts it into plots,
dimensions and cutting speeds.
Milling machines and lathes are commonly CNC operated.
Applications
Machine components
Decorative products
Engine parts
Advantages and Disadvantages
+ve Removes human error
Efficient and reliable
Runs 24/7
Can be updated quickly
-ve Initial set up cost are high
Can lead to a loss of jobs
Loss of skill in the work force
If anything goes wrong production stops
Optical fibres
Surface nanotechnology
Hydrogen fuel cells
Telematics
Blended wing bodies
Bionics
Often used in the communications sector, have replaced copper
wires.
Combines ICT with communications technology to
allow vehicles to be tracked.
Chemical energy in hydrogen is converted to electricity. Now an
alternative to petrol engines.
Advanced aircraft designs consisting of large aerofoil wings
joined to an aircraft body.
Chemical coatings are applied to the surface of materials to improve their properties.
Medical problem solutions using small devices that combine
electronics and mechanisms.
Description-
Optical Fibres have replaced copper wire. They are able to produce
much faster speeds, with greater bandwidth. Much more information
can be transmitted along the same size of cable.
Positives
The ability to transmit data at higher speeds.Often used in the communications sector, have replaced copper wires
Description-
Hydrogen can be used to power most devices, the key to this is the
hydrogen fuel cells. A Hydrogen fuel cell is an energy conversation
device that captures and uses power of hydrogen efficiency.
Positives
Heat and water are the only waste material
It’s a green energy source
They operate very quietly and efficiently
Fewer moving parts mean very simple construction and therefore
costs are low
Description-
This a chemical coating that can be coated on a range of surfaces e.g
trainers, wind screens, metals.
Positives
Makes products water resistant
Produces hygienic surfaces
Makes cleaning process quicker
Corrosion resistant
Description-
Often known as GPS and SATNAV. It provides an opportunity to
monitor the location or movements of vehicles across the world.
Positives
Allows us to monitor packaging locations
Black box insurance
Description-
Advanced aircraft designs consisting of large aerofoil wings joined to an aircraft body. Much more aerodynamic than existing designs. Wings of the aircraft are blended in to a tailless body.
Positives
Reduces fuel consumption by a third
Reduces drag and turbulent air flow
Able to fly faster
Description-
Small electronic devices can be used for medical purposes to improve the medical condition of individuals. A pacemaker fitted to regulate a person’s
heartbeat is a good example.
Positives
Enhances the quality of life
Prolongs life
Description
Metal foams are cellular structures made with metal such as aluminium.
The key properties of metal foam are as follows:
• Ultralight material (75–95% of the volume consists of void spaces)
• Very high porosity
• High compression strengths combined with good energy absorption
characteristics
• Thermal conductivity is low
• High strength
Production
Metallic melts can be foamed by creating gas bubbles in the liquid
Three ways of foaming metallic melts are listed below:
•Injecting gas into the liquid metal from an external source
•Causing the precipitation of gas that had just been dissolved in the liquid
•Causing an in-situ gas formation in the liquid by admixing gas-releasing
blowing agents to the melt
Applications
Sound dampening in cars or aircraft
Energy absorption to improve passenger safety in cars
Heat absorption on circuit boards
Prosthetics
Disadvantages
High cost
Once crushed they don’t spring back
Production
Produces consistently shaped components by blending metal powders
together. The powders are then compacted into a die and then heated in a
furnace, the metal particles then blend together.
Blend, mixing, pressing and sintering
Applications
Small machine components
Tools
Advantages
No waste
Low processing temperatures
Produces a uniform structure
Complex parts can be produced
High volume production
Little or no finishing
http://www.youtube.com/watch?v=O7U4HWjYcqo
Material Properties/ Characteristics Applications/uses
Modern composite materials
Glass reinforced
plastic (GRP)
Good strength- to- weight ratio, easily moulded, resistant to corrosion,
durable, electrical insulator, relatively inexpensive
Garage doors, boats and custom
moulding to produce furniture
Carbon Fibre Amazing strength- to-weight ratio, easily moulded, resistant to corrosion,
rigid, electrical insulator, quite expensive
Monocoque structures of super cars
and specialist bicycle frames
Kevlar High tensile strength- to- low weight ratio, high chemical resistance,
extremely tough, very stable and non- flammable
Bullet proof vests, helmets, ropes and
cables
High performance materials
Titanium Low density, high strength, resistant to corrosion, low thermal conductivity Drill bit coatings, golf clubs and medical
implants
Ceramics Very hard but brittle, good wear resistance, corrosion resistant, very stable,
chemically inert
Glassware, catalytic converters and
electronic components
Super Alloys Excellent strength at high temperatures, very expensive, resistant to
corrosion, hard wearing
Jet engine turbine blades, valves and
piston engines and submarines
Smart materials
Shape memory
alloys (SMA)
Return to their original shape after heating and deformation, lightweight,
quite expensive
Spectacle frames, pipe and tube joining
systems
Shape memory
polymers
Return to their original shape after heating and deformation, lightweight,
resistant to corrosion
Sportwear, surgical sutures and
orthopaedic surgery
Piezoelectric
actuators
Have an ability to generate electric charge when squeezed or pressed Sensors, actuators, high voltages and
power sources
Reduce energy used through more efficient processes.
Reduce number of materials used in manufacturing.
Select materials that have less impact on the environment.
Reduce amount of packaging used to protect products.
Make efficient use of materials.
Reuse small offcuts for other products/processes.
Transport finished products directly to the end user rather than wholesalers.
How can we reduce materials and energy?
Example:Instead of expanded polystyrene, use recycled paper pulp for packaging.Use energy-efficient light bulbs.Incinerate/burn offcuts to produce heat for the workplace.
Reusing materials and products
Using a product more than once, e.g. refilling a bottle.
Using a product in a different way from its original use.
Reuse means that no energy is used to remanufacture products.
Items can be cleaned and reused to extend their useful life.
Refilling milk bottles/ink cartridges, etc.Using fizzy drink bottles for water.Selling items on auction sites/charity shops.
Examples:
Recovering energy from waste
Waste can be incinerated to generate heat to turn turbines to produce electricity.
Waste can be converted to gas using high temperatures and oxygen.
The synthetic gas produced can then be used, which is more efficient than simply incinerating the waste products.
Example:Teesside EfW plant, Middlesbrough, burns 390,000 tonnes of waste per year to produce electricity for the National Grid.
Recycling
Recycling is the process of making or manufacturing new products from a product that has originally served its purpose. If these used products are disposed of in an appropriate, environmentally friendly way, the process of recycling has been set in motion.
http://www.youtube.com/watch?v=aH_HKeS1Ed4
http://www.youtube.com/watch?v=zyF9MxlcItw
Product 1 Car battery Product 2 PET bottle
Materials used:Lead, acid, polymers
Materials used:PET
How is it recycled?● Acid is neutralised.● Lead is separated from the polymers.● Polymers are ground down.● Lead is recovered to be used again.
How is it recycled?● Bottles are separated from general waste.● They are then separated by colour.● Then crushed and packed in bales.● PET is then crushed and shredded to make
flakes.● Flakes can then be used for other products.
What are the recycled materials used for?
New car batteries Polymer packaging
What are the recycled materials used for? Sheeting Fibres Bottles
Is the never ending effort to eliminate or
reduce waste or any activity that consumes
resources in design, manufacturing, and
product distribution.
Three main areas of lean manufacturing are:• Just- In- Time manufacturing• Kaizen• Poka- Yoke
This involves a strategic approach to the development and operation of a
manufacturing system. This means that the production process is organised in
a way that ensures parts are only available when they are needed.
Advantages:
• As products are made to customer orders, there is no overproduction,
reducing the build up of stock or inventory such as raw materials and
finished goods.
• A reduction in stock or inventory also reduces costs as there is less space
required for storage of materials or finished goods.
• It reduces production cycle times quite drastically through automation
and the use of minimal man power, further reducing costs.
• It recognises waste in the movement of materials within an organisation
and changes the layout of the manufacturing line to improve efficiency.
• Involves the workers
Description
Also known as continuous improvement, this is a policy of constantly
introducing small changes to improve quality and efficiency. This technique
puts the workers at the heart of the decision- making as they are the best
people to suggest improvements.
Advantages
Improvements are based on small changes rather than large changes as a
result of research and development.
As the ideas come from the workers they are less likely to be much
different than existing processes and are therefore easier to implement.
Small changes generally do not cost a great deal of money when compared
with any major process/ production changes.
It encourages workers to take ownership of their work and reinforces
team- working, leading to improved worker motivation.
Involves workers and managers.
Description
This is a technique for simplistic human error in the workplace also known
as mistake proofing and fail safe work methods. The idea is to take over all
the repetitive process/ tasks performed by humans that rely on memory or
vigilance and replace them with a simple system to improve productivity
and quality.
Advantages
• Eliminating set up errors, therefore improving quality
• Decreasing set up time and improving production output
• Increased safety as workers do not get injured through lack of
concentration
• Reduced costs through improved production efficiencies and reducing
the need for skilled labour
• Improved motivation of workers, as tasks are not so mundane
• Involves workers
Basic description of how it works:1. The wind turns three blades.2. These are connected to a rotor housed in a box called the
nacelle.3. The nacelle turns to face the way the wind blows.4. The rotor is connected to a main shaft, which turns in the
generator housing.5. This turning action produces electricity.6. The electricity can then pass through a step-up transformer to
be transmitted across the national grid.
Typical locations and types of use:Upland areas where there is generally lots of wind, off shore where winds are strong.Electricity generated supplies the National Grid.Smaller turbines can be used for industry and domestic use to produce electricity for the user, surplus can be sold back to the supply company.
Advantages Disadvantages
Reliability and efficiency
Turbines are efficient in generating electricity, as most energy is converted to electricity.
Reliability and efficiency
Electricity is only produced when the wind is blowing strong enough to turn the turbine blades.
Environmental benefits
Energy produced is clean. There is no pollution to the air or water from the turbines.
Environmental disadvantages
Turning of the blades can be noisy.
Many people think they look unsightly and often spoil areas considered to be picturesque.
Some environmentalists say they have an adverse effect on wildlife, particularly birds.
https://www.youtube.com/watch?v=nlpD6BT0YuM
Basic description of how it works:1. Photovoltaic cells convert sunlight
into electricity.2. The more sunshine there is, the
more electricity is produced.3. Electricity is produced when
electrons move from one layer of silicon to another.
4. Concentrated solar power used mirrors to focus sunlight on to a small area.
5. The light is converted to heat to drive a turbine.
6. The turbine produces electricity.
Describe the two different types of solar power:Photovoltaic panels are made from layers of silicon. When sunlight shines, electrons move between the layers to produce electricity. There are no mechanical parts.
Concentrated solar power uses lenses and mirrors to produce heat to drive a mechanical turbine to produce electricity.
Advantages Disadvantages
Reliability and efficiency
Does not need direct sunlight to generate electricity.
Panels last for 25 years.
Reliability and efficiency
Does not work well if north-facing.
Will not work at night.
Invertor may need to be replaced.
Environmental benefits
Reduces carbon emissions.
Does not cause air or water pollution.
Environmental disadvantages
Unsightly.
Need to have batteries to store energy for night-time use.
Basic description of how it works:1. Running water is used to turn a turbine.2. As water passes through the turbine it spins.3. The turbine is connected to a generator.4. The generator turns to produce electricity.5. The greater the flow, the more electricity is produced.
Describe the difference between a tidal barrage and using a dam:A tidal barrage is similar to a dam but is built across a river estuary. Water can flow through it in both directions to turn the turbines. Using a dam creates a large reservoir of water, which provides water under pressure to turn the turbines, and can be made to flow faster by using narrower pipes.
Advantages Disadvantages
Reliability and efficiency
Reliable source of energy, especially when used with dams.
Generally low-maintenance.
Can react very quickly to changes in demand.
Reliability and efficiency
Tidal barrage can only be used on rivers where there is a good flow all year round.
When the tidal movement is low, the energy produced by the tidal barrage will be low.
Environmental benefits
Does not produce air pollution.
Can create habitats for wildlife.
Environmental disadvantages
Reservoirs and dams can take up large areas.
Habitats may be lost.
Can alter the local ecosystem.
Tidal barrages alter the ebb and flow of the tides.
Basic description of how it works:1. Makes use of the heat generated from volcanic activity.2. Holes are drilled into the crust of the earth.3. Water can be pumped down, or ground water used, to produce
steam.4. The steam is purified and then used to drive turbines.5. The turbines drive generators to produce electricity.
Typical locations and types of use:Italy, New Zealand, Iceland, Japan, the USA and the Philippines.In Iceland, geothermal energy is used to heat houses as well as produce electricity.
Advantages Disadvantages
Reliability and efficiency
Very reliable source of energy.
Energy is free once system constructed.
Reliability and efficiency
Limited locations where it is efficient.
Possible that the heat source may not produce steam for a length of time.
Environmental benefits
Produces no pollution.
No fuel is needed.
Environmental disadvantages
Hazardous gases may be released with drilling.