exam theor design y · metal common uses and properties aluminium kitchenware, power cables, drinks...
TRANSCRIPT
A systems approach
•A systems approach is where you break down the stages of a process into a series of steps.
•Systems have three sections. They are connected together so they make a product function:
INPUT PROCESS OUTPUT
PROCESSES
•Microcontrollers
•PICs
•Timers
The are basically programmed components that make decisions within a circuit so the circuit knows what it needs to do!
OUTPUT DEVICESWe know that electronic systems have three sections: input, process and output.
The input is processed into an electronic signal, which then makes the output device work.
Examples of OUTPUTS are:
•Speakers
•Buzzers
•Lamps
•LEDs (Light emitting diodes)
FORCES and STRESSES
•All materials need to be able to withstand a variety of forces and stresses.
•A force is a load that has been applied.
•It is measured in newtons (N).
•As the load is applied to a material, it produces a stress. This may cause the material to deform (bend).
COMPRESSION
TENSION
BENDING
TORSION
SHEAR
FORCES and STRESSES
BENDING•This force creates tension and compression.
TENSION•This is a pulling force.
COMPRESSION•This is a force pressing onto a material.
LOAD
FORCES and STRESSES
TORSION•This is a twisting force, often along the length of the material.
SHEAR•This is when two parallel forces are acting against each other.
METALS AND ALLOYS
•Ferrous metals –contain iron
Non-ferrous –contain no iron
Alloys – a mixtureof two or more metals
DO rust
DON’T rust
CAN rust
TIMBER(and Timber composites)
•Hardwoods from deciduous trees
(slow growing / lose their leaves)
Softwoods from coniferous trees
(grow faster / evergreen/ cheap)
Manufactured boards
(made from wood particles + glue
man-made / cheap)
•Thermoforming plastics(can be reheated and moulded)
•Thermosetting plastics(cannot be reshaped)
POLYMERS (Plastics)
NAME WHAT IS IT USED FOR?
Mild Steel
Nuts, bolts, washers, car bodies, panels for cookers, appliances
etc.
Medium carbon steel
Springs, general gardening tools
High carbon steel
Hand tools, scribers, dot punches, chisels,
plane blades.
Cast ironMachine parts, brake
discs, engines
FERROUS METALS
METAL COMMON USES AND PROPERTIES
AluminiumKitchenware, power cables, drinks cans,
aircraft bodies.
Copper Electrical contacts, electrical cable and wire
Gold Jewellery, electrical contacts
Lead Soft but heavy metal, used on roofs, durable
PlatinumPrecious metal used in jewellery, but also to
make wires
Silver Cutlery, decorative items, jewellery.
TinUsed to coat steel in food cans to protect it
from rusting
TitaniumSurgical applications (very clean) such as hip
replacements
ZincUsed for coating steel (galvanising), again to
stop air or water getting to the iron in the steel and causing rust
NON-FERROUS METALS
NAME COMMON USES
PEWTER Jewellry
BRASSValves and
taps, ornaments
BRONZE Statues, coins
HARDWOODS
o Come from deciduous trees (lose their leaves)
o Take longer to grow
o Much denser wood (harder/heavier)
o More expensive than softwood
o Available in planks/boards (stock forms)
OAK WALNUT
MAHOGANY CHERRY
BIRCH OAK
SOFTWOODSo Come from evergreen trees (don’t lose their
leaves)
o Quicker to grow
o Cheaper than hardwood
o Available in planks/boards (stock forms)
MANUFACTURED BOARD
o Is man-made
o Made of wood particles and glue pressed together
o Much cheaper than wood
o Available in sheets that come in different thicknesses (stock form)
PLYWOOD
CHIPBOARD
BLOCKBOARD
MDF
Paper and board TRACING
PAPERThin, see through Art work
LINED PAPER Cheap, can be bleached or dyed to any colour
Everydayuse
DUPLEX BOARD Cheap, strong board Cheappackaging
SOLID WHITE BOARD
Expensive, white on both sides
Expensive packaging
FOIL INED BOARD
Cardboard lined with foil (waterproof)
Drinks
CORRUGATED CARD
Two layers of cardwith flutes in between. Good protector/insulator
Product packaging
Smart materials can think for themselves, and react to their environment, and change their properties.
Shape memory alloys change to their original shape when they are heated / cooled. Uses include spectacle frames, dental braces
Thermo-chromic pigments can change colour depending on the temperature they are exposed to. Uses include Flexible thermometers, Babies bottles and cutlery etc
Photo-Chromic pigments alter depending on light intensity. Uses include lens in glasses, signage,
Smart Materials
NATURAL FIBRES
Natural fibres are renewable fibres that come from plants and animals.
Because they are natural, it makes them suitable for clothing.
They have properties such as:
MODELLING
Models are used by designers so they can test out their ideas before they make a final prototype.• It allows them to get ideas of the aesthetics.• They can get customer feedback on modifications• It is cheaper than using expensive final materials.• They can be easily developed.
Modelling materials include:•Cardboard•Styrofoam•Balsa wood•Calico (a natural cotton)
PLANNED OBSOLESCENCE
Some products are designed to have a short life span. Companies plan for their products to become obsolete (run out).They do this by:• Choosing parts that may not last very long• Release upgraded versions• Launch new products to replace old ones.
PLANNED OBSOLESCENCECustomers are encouraged to buy new products, even though they shouldn’t need to. This leads to:• Wasted materials and resources• More pollution/waste/landfill
EFFICIENT WORKINGEfficiency is how quickly you can make something, compared to how long you think it should take. Better efficiency means saved money and energy.
Better efficiency can be achieved by:• Lean manufacturing• JIT production• Improved transport systems• Efficient factory layout
This type of manufacturing helps achieve
EFFICIENT WORKING
LEAN MANUFACTURINGThis is a method used to get rid of waste throughout the manufacturing process. It includes:• Having minimal storage – so materials only
delivered when orders are placed• Making sure production is well set up so there are
no delays• Reducing the amount of materials needed• Using labour efficiently.
FLEXIBLE MANUFACTURING
Flexible Manufacturing Systems (FMS) means delivering expensive products
as quickly as possible (eg. cars).
This type of manufacturing helps achieve
EFFICIENT WORKING
FLEXIBLE MANUFACTURING
• Systems are effective (so they work well)
• Machinery is grouped together (to be more efficient)
• Computers are used to speed up processes.
• Close relationships with suppliers allow fast delivery.
JUST IN TIME (JIT)
JIT helps companies meet orders quickly and minimise time.New stock is only ordered when needed so storage space isn’t wasted.It means that:• Materials/components are in the
right place at the right time• Storage costs are reduced• Production is cost effective
• A break in the supply chain can cause delays
This type of manufacturing helps achieve
EFFICIENT WORKING
Non renewable energy sources are sources that will eventually run out.
The main examples are:
• FOSSIL FUELS
• NUCLEAR POWER
Renewable Energy Sources
Renewable energy sources are SUSTAINABLE and will not run out. They are sources that can replenish themselves. Examples include solar, wind, hydro electrical, biomass and tidal sources.
1. Oil is basically dead sea plants and animals that have fossilised and broken down.
2. We build oil rigs in the sea so we can get to the oil
3. This is done by drilling down to where the oil is, and bringing it up to the surface.
4. The oil is shipped to shore on an oil tanker
5. It is then sent through a pipeline to the oil refinery.
6. The refinery then cleans (refines) the oil, and turns it into different types of polymer granules.
7. These granules are then sent to a manufacturing plant (factory) to be made into sheets of plastic, or into plastic products.
Iron ore, coke and limestone go IN to the blast furnace
Pure molten iron OUT
Impurities OUT
Extraction by carbon reduction
CONVERSIONThis is when the tree trunk is sawn along its length into planks.
SEASONINGThis when the planks of wood are dried out to reduce moisture. This can be done naturally or in a kiln.
What does
Sustainable mean?
It means being as environmentally
friendly as possible, to make
resources last as long as possible.
• Design products that are made
form renewable materials.
• Design products that use as little
energy as possible.
• Buy products made from
renewable materials.
• Don’t buy products that you don’t
need.
• Turn off lights when you leave a
room.
• Use a Bag For Life when shopping.
Properties
This means what a
material HAS and CAN
DO.
For example copper is
heavy, yellowish, is
malleable and is a
good heat and
electrical conductor.
Aesthetic
This means HOW
SOMETHING LOOKS.
Is it pleasing on the
eye?
Does it have a good
shape, style, colour,
texture etc
Anthropometrics
The study and use
of human
measurements
used when
designing products.
Ergonomics
How products and
spaces are
designed to be
EFFECTIVE and
COMFORTABLE.
5th – 95th
percentile
Ignore the extreme
data.
Class the rest as
AVERAGE RANGE.
Use data to design
effective products.
If we are trying to use the least amount of material possible, pieces should be placed right
up against each other
TESSELLATION
DESIGN SPECIFICATION
A design specification is important because it:• Allows a designer summarise
their research in a useful way.• It gives a clear criteria to
work from.• It makes sure the product
meets the customers needs.• It provides a criteria that you
can test models against.• It allows you to evaluate your
final product against it, to see if it has been successful.
MASS PRODUCTION ITEMS
STEEL CAR DOOR
•Steel is bought in rolls (large amounts can be stored.
•The material is press formed into shape.
•This is done by automation (fast and efficient).
•Welding of other parts can also be done via automation.
The following products are all made using mass production. They are suitable for this type of production because:
MASS PRODUCTION ITEMS
POLYMER TOY INSTRUMENT
• Injection moulding is used which means many identical products can be made at low cost.
• Injection moulding means reduced assembly after production.
•This complex shape can be easily produced over and over with injection moulding.
• Injection moulding allows colour to added easily during the production phase.
MASS PRODUCTION ITEMS
NEWSPAPER
•Paper can be bought in large rolls so that designs can be continuously printed.
•Lithography is used to print – it is quick and ensures identical prints.
•Lithography is high quality and cheap.
•Manufacture is totally automated.
MASS PRODUCTION ITEMSFlat pack furniture
•Manufactured board is used, which have an even appearance. This means each piece will look the same.
•C.A.M is used to cut pieces – ensures repeatability.
•C.N.C machines are used to create assembly holes and slots. Using C.N.C ensures accuracy and speed.
COMMERCIAL PROCESSESThe properties of thermoforming polymers mean they can be softened with heat and reformed into different shapes.
Injection mouldingThis process is used to turn polymer granules into specific shapes. It is used on a large scale with high accuracy. It works by• The polymer granules
are melted• The melted granules
are injected (pushed) into the mould
• As it cools it takes the shape of the mould
COMMERCIAL PROCESSESScreen PrintingThis process is used to print images and graphics onto t-shirts.
1. A stencil of an image is placed onto a mesh screen.
2. Ink is poured on top3. A squeegee is used to push
the ink through a stencil and mesh.
4. The ink is pushed through and onto the fabric.
5. The fabric is then left to dry.6. The process is repeated on
the next t-shirt.
LithographyThis process is used to print graphics onto newspaper, leaflets, packaging etc.• Ink goes onto the roller• This roller then
transfers the ink onto the pattern plate
• The inked pattern is transferred onto another roller
• Paper is then passed under this roller and the image is printed onto it.
COMMERCIAL PROCESSES
DesignersM
ARY Q
UA
NT
• British fashion designer.• Famous in 1960’s for youthful ‘mod’
fashion.• Designed the mini skirt and hot pants.• Used geometric shapes.• Encouraged people to dress to please
themselves.• Treated fashion as a game.
NO
RM
AN
FO
STER
• British architect• Designed high tech buildings• His buildings are environmentally
friendly.• They include a lot of glass and steel.• His buildings have a clear structure.• Famous buildings include the Gherkin
and Wembley.
VIV
IEN
NE
WESTW
OO
D
• British fashion designer.• Influential in the 1970’s punk style.• Combined traditional (tartan and
tweed) with historical (corsets) to create modern designs.
• Influential in the New Romantic pop fashion in the 1980’s too.
Designers
COCO CHANEL
• French fashion designer.• Her brand specialises in luxury items.• She challenged the post-war
traditional corset wear.• Instead she used practical designs
with clean lines.• Her clothes included cropped skirts
and the famous CHANEL SUIT.• The clothes were feminine,
comfortable and natural.• As well as clothing the brand designs
fashion accessories and perfumes.
PHILIPE STARCK
• French product designer• He designed furniture as well.• He wanted to create products that were
durable yet fashionable.• His designs were influenced by fashion
and novelty.• His products are ‘over-designed’ and
stylised.• He worked for Alessi in the 1990’s.• His most famous product is the ‘Juicy
Salif’ lemon squeezer.
Step 5
LASER CUTTINGLaser cutters are capable of very accurate work, a laser is used to etch or cut material precisely. Laser cutting is an example of CAM (Computer Aided Manufacture).
Step 1
An Idea is created on a computer using a CAD package like COREL DRAW, the idea is then sent to the laser cutter
Step 2
Material that is being cut or etched is placed on the laser bed (wood, plastic, metal, material) the laser settings are programmed according to material thickness and type
Step 3A vacuum of air hold the material still ready to extract the fumes that are created
Step 4An intense laser is focussed onto the material being cut using a series of mirrors
The laser moves over the material cutting or etching as it goes. Once the process is finished the lid can be opened to remove the parts.
Advantages Disadvantages Uses:
Cuts quickly, accurately, good standard. Can run for hours.
Expensive to buy and maintain. Need the right software and training
To cut parts or full products or basic models in Paper, Card, Plastics, Metals, Glass and various textiles
Laminating involves “layering or covering materials”. By doing this the end product will be improved eg made waterproof , stronger, more flexible etc.
Step 1
Card or paper is put into a plastic laminating pouch making sure there is space around the outside.
Step 2
Once in the pouch the card, paper is passed through a laminator using rollers, this works by heating the pouch as it passes through, it softens the plastic enough so the parts at the edges fuse together to seal in the card / paper
Step 3
The laminated card / paper leaves the laminator and cools.
Advantages Disadvantages Uses:
Cheap , easy to use,relatively fast
Sizes restricted to A sizes, can be slow if doing multiples. Takes time to heat up
To waterproof, to protect, to last longer, easy clean. Gives a glossy finish to card / paper products. Uses are menus – signs etc
LAMINATING (paper)
LAMINATING WOOD
•Laminating is when two or more layers are joined.
•This means a stronger material is created
YOU CAN ALSO REFORM/DEFORM THE LAYERS AS THEY ARE BEING STUCK TOGETHER:
•Adhesives is applied to the layers of wood
•The wood is then placed in a former and clamped up
•Once dried the laminates are glued and set in shape
3RD ANGLE ORTHOGRAPHIC PROJECTION
• This is a style of technical drawing where you can see the plan (birds eye), front and side view of a product.
• They should all line up with each other.
• You must use guidelines, and a 45 line to make sure this happens.