Design and Technology

End of year exam

Tools and equipment used to make your acrylic clock:

Acrylic, hand file, flat file, three square file, round file, half round file, Swiss file, hacksaw,
Junior hacksaw, abrafile and a band saw.

Types of plastic and their uses

Material Properties Uses
Acrylic Stiff and brittle. Used to make signs and small 2D and
3D forms
Polyvinyl sheet Stiff, strong, tough and resists Used to make 2D and 3D shapes and
(PVC) scratching may be used for vacuum-forming
High-density PVC Stiff, hard, tough and Machining of 2D and 3D shapes
foam lightweight, with a good
resistance to chemicals

Polystyrene Lightweight, hard, Used for vacuum-forming

sheet (or styrene stiff, transparent and brittle.
sheet) Good water resistance

Corrugated Lightweight and tough. Stiff, but Used for making large constructions
polypropylene not very strong. Hard but
scratches easily. Resistant to
chemicals.

Acrylonitrile Strong, tough, hard, Used to make square or round shaped

butadiene lightweight, and durable. A tubes and is good for making
styrene (ABS) good surface finish and structures. Corrugated polypropylene
resistant to chemicals. is available in a range of shapes and
colours

Polystyrene foam Brittle in tension, lightweight, Available in blocks and used for
(Styrofoam) with good heat and sound product-modelling
insulation

Cellophane Tough, hard, stiff, lightweight, Used for wrapping round products
transparent, and non-
flammable

Polythene Hard, stiff and able to be Used to make bottles and for shrink-
sterilised wrapping products.
Simple Electronic Circuits and their symbols:

Conductors- allows the electricity to flow

Batteries supplies electricity

Insulators- stops electron flow

Bulb- illuminates

Resister- controls electron flow

LED, light emitting diode- indicates, lights up, illuminates

PTM, push to make switch

Safety in the workshop:

BEFORE USING TOOLS YOU MUST:

1. Only use tools you have been trained to use

2. Wear protective clothing
3. Carry with blade/ cutting tip pointing downwards
4. Check condition of tool prior to use
BEFORE USING THE PILLAR DRILL/ MILLING MACHINE YOU MUST:

1. Be trained to use the machine

2. Put on eye protection/ protective clothing
3. Secure loose clothing and tie back long hair
4. Remove jewellery
5. Check the work area is clean
6. Centre punch before drilling

BEFORE USING THE LINISHER YOU MUST:

1. Be trained to use the machine

2. Put in ye protection/ protective clothing
3. Secure loose clothing and tie back long hair
4. Remove jewellery
5. Check the work area is clean
6. Ensure extraction is on
7. Ensure work piece is big enough to hold (min length= 70mm long)

TO WORK SAFTEY

Hand tools

1. Work as shown
2. Ensure workplace is secured as directed
3. Keep the work area clean
4. Files must not be used without a securely fitted handle
5. Keep hands out of the way of cutting path- saw and chisel tips are sharp
6. Pay full attention while working
7. Return to tool cupboard when finished

Pillar Drill/ Milling Machine:

1. Have only one person at the machine
2. Select and fit correct drill bit
3. Ensure chuck key is removed
4. Check all guards are fitted and in place
5. Secure workplace as directed
6. Do not use unsupervised
7. Pay full attention whilst working
8. Do not handed swarf
9. Switch off when finished
Linisher:
1. Have only one person to a machine
2. Keep fingers in front of the slot
3. Only use to remove small waste
4. Do not use unsupervised
5. Keep work piece moving
6. Keep work piece flat on the table
7. Have a minimum gap between the belt and the table rest
8. Pay full attention whilst working
9. Switch of when finished

IF IT GOES WRONG

Hand tools:
1. Stop what you are doing
2. Place tool in the centre of the bench
3. Inform a member of staff

Pillar Drill, Milling Machine

1. Turn machine off immediately
2. Move away to safety
3. Inform a member of staff

Bridges and structures

The suspension bridge- 0 triangles

The suspension bridge is a type of bridge in which the deck is hung below the suspension
cables on vertical suspenders
The Girdir bridge- 6 triangles

This bridge has got a structure with triangles in; this means that it is very sturdy

Brick arch- 0 triangles

Arch bridges work by transferring the weight across the bridge

Triangles are stable structures

Polygons are non stable structures

Types of energy

Capital energy sources

Capital energy sources are sources of energy that, once used, cannot be replaced. This
energy store was created many millions of years ago. The fuels are in a very concentrated
form and are easily converted into readily useable energy. For example, a lump of coal could
have taken 10 million years to form, but only takes a few minutes to burn on a fire

Fossil fuels
Coal
Coal was formed by the decomposition of large plants which existed 350 million years ago.
When the died they formed a large mass of vegetable material, in a similar manner to a
compost heap built by a gardener.
These plants grew in a swamp environment, which slowly dried out to become solid land.
This was, in turn, covered by sand and rocks washed down from the mountains to the valley
bottom.
The pressure of the layers of sand over many millions of years compressed the material,
squeezing out the moisture to form a rock like material. Later earth movements have
caused some of these layers to become folded and buried deep below the present day
surface. Extracting these seams requires deep mining and high costs. Other coal seams are
very close to the present surface and can be extracted by quarrying in open cast coalmines,
which provides cheaper coal.
At the present rate of world use there should, with known resources be sufficient coal to
cover our needs for the next five or six hundred years. Coal is one of the main source
materials for the plastics industry. The use of coal for burning may well not be the best use
of this important resource.

Gas-
Gas is found in conjunction with oil, trapped at the top of the pocket of oil. This resource
needs very little cleaning before it can be piped to the house or power station to be burnt.

Oil-
Oil was formed in the shallow seas around the landmasses. The seabed was covered with
the remains of plants and animals that lived in the water and as the land was steadily
washed into the sea these remains became covered with sandy material. Under the
pressure of the accumulating sand and rock, these seabed remains were converted to oil.
And gas. Unfortunately, these gasses and oils are squeezed and bubble through the
overlaying rock and escapes. However, sometimes the oil and gas becomes trapped. It is
these pockets of oil and gas that are drilled into to supply our needs.
The earliest oil wells were drilled on land. It is now recognised that oil and dry land. The cost
of extracting oil from the seabed is much higher in exploration and recovery costs then land-
based operations.
At present usage rates the worlds oil reserves will last less than 50 years. Some authorities
on the subject expect the oil to run out in the next 30 years, thus a convenient source of
energy could disappear in the very near future. Can you imagine cars without oil and petrol?
Oil is another major source of material for plastics industry.

Energy in the home

About 30% of the energy use in Britain is used to heat our homes and places of work.
Why do we need heating? Stone age man had no heating other than food; he did have
insulation, in the form of clothing, and furs from the animals he ate as food. Insulation is still
the solution to economical use of heat in our homes. Fig 6.25 shows the relative energy
needs of different types of housing. The energy required to heat a terrace house is almost
half that require to that a detached house; even less is required to heat a middle floor flat.
Perhaps we should all live in middle floor flats.
With a little thought and insulation the detached house could require inly as much as a
terrace house.
Heat can travel in one of three ways: conduction, radiation and convection. It can also be
transferred if the matter in which it is contained is physically removed forma building by
ventilation. Materials that are used in buildings all allow heat to escape through them, but
some are much better than others. The U value is a measure of this. Heat loss through the
building materials can be calculated.
Rate of loss = A x t x U (watts, W)
Where A= area of the material (m2), t= temperature difference, inside to outside (oC), U=
U value (W/m2/oC)
This will give the rate of heat loss not the quantity. The quantity can only be calculated if we
know for how long the heat is escaping.

Insulators
Materials that do not allow heat to travel through them are called insulators. Materials that
allow heat to pass through easily are called conductors. This is the same terminology that is
used when describing electrical conductors and insulators (see U' table above).
Good insulators include air, glass polyurethane fibre, wood, wool, cork, foam and straw
board.
All metals are good conductors.
If you place your hand on a material and it that is at normal air temperature feels cold, then
you can be sure that it s conducting away your body heat. It is a conductor. If it feels warm,
then it is likely to be an insulator.
If we clothe the walls, roofs and floors of our houses in an insulating material we will
conserve the heat inside.
The cost of installation of these insulators must be balanced against the cost of heating our
homes. Many people feel that the cost to the world in saved energy may be worth much to
future generations.

Files and Filing

Cross file-
Cross-file to remove all harsh to the acrylic already. If cross filing doesn't work use the
linisher the go back to cross filing.
Draw file-
Draw file to remove all scratches made by cross filing. You out the piece of acrylic in the
wood workers vice and file back and forth. Use a finer file while doing cross filing. After, you
use a wet and dry paper.

Round file- Round files have a cylindrical cross section and is used for rounder areas. The
body is cut with a series of parallel ridges, which removes material from the work piece
when the file is drawn across it
Half round file- Used for filing curved surfaces. A normal hand file with its flat cutting edges
is unsuitable for filing curved surfaces. However, the half round file has a curved surface,
which is especially useful for filing internal curves.
Three square file- Is triangular in section and very useful when filing tight corners / angles.
The sharp edges allow the file to fit into corners when filing.

Flat file- A steel hand tool with small sharp teeth on some or all surfaces. Used for metal and
wood

Hand file- Used for general filing of metals such as steel. They are rectangular in section and
are the most common type of file used in workshops.

Square file- the square file is quite thin and fits into corners well. They can be used to file
slots in metal or for filing where there is little space.

Marking gage- a marking gage draws a line parallel to the edge of the shape.

Wood working square- this tool is to draw lines accurately 90o

Backsaw- straight lines- these saws usually have stiffer backs and it is used for detailed work
rather than blades that flex. The most used backsaw is the tenon saw. The blade is 250mm
to 350mm long. It is not usually used in major works.

Coping saw- curved saw- the coping saw is the most commonly used saw for cutting curves
in wood and plastics. This blade can be broken but it is easily replaceable. The frame, which
this is held in, has teeth pointing backwards. They do this so you can only pull it because the
blade is too flexible to be pushed.

Piercing saw- this saw is used for curves in thin metal and plastics. Also this saw has a very
thin blade so it is similar to a coping saw.

Marking out the pocket. You need to have your shapes 20mm from the edge because the
bolts go that far in. you need to use a center punch. You always mark out with a pencil and
ruler

Bolting the table- you blot the wood/metal onto it, so it is sturdy and wont move. You need
to screw the bolts down with a spanner.

Milling he pocket- the milling machine is used for drilling squares and rectangles. The line
that you are drilling is parallel to the edge. When milling you need to be careful to not get
your fingers trapped in any of the machines