Engineering sectors. Learning aim A (Topic A1)

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1 Activity sheet 1 Engineering sectors Learning aim A (Topic A1) In this activity you will look at the different engineering sectors and identify a range of products associated with them. Task 1 Complete the table below by writing down examples of products produced by each sector. Sector Product 1 Product 2 Product 3 Product 4 Aerospace Automotive Biomedical Chemical Communications Electrical/ electronic Mechanical Task 2 Choose a product that you think is designed and made by more than one engineering sector. Write the name of the product in the space provided, name the sector that is mostly associated with the product, then list all of the other sectors you think are involved with the production of that product. Product Main engineering sector Other sectors 1

2 Activity sheet 2 Engineering processes Learning aim A (Topic A2) Task 1 Which pieces of machinery would be used for each of the following machining activities? Put yes or no in the relevant boxes. Cutting round holes Centre lathe Milling machine Pillar drill Cutting slots Knurling Cutting shoulders Shaping round bar Shaping square bar Cutting a thread Task 2 Name four hazards associated with all machining processes. Hazard 1 Hazard 2 Hazard 3 Hazard 4 2

3 Task 3 Investigate the following forming processes. For each, give: a short description of the process examples of products made using that process reasons why the process is used for your named product. Casting Sand casting Description Examples Reasons Die casting Investment casting Permanent mould casting Forging Drop forging Description Examples Reasons Press forging Upset forging 3

4 Activity sheet 3 Electronic circuit construction Learning aim A (Topic A2) Electronic circuits are usually produced using a printed circuit board (PCB). The production can be split into five stages. These are listed in the box below (not in order). Stages of production Drill holes in the board. Produce the artwork. Etch the PCB. Solder components on to the board. Design the layout. Instructions: Write the stages out in the table in the correct order, and give a short description of each stage. Stage Description Many smaller electronic products use surface mount technology. What are the advantages and disadvantages of this process? Advantages of surface mounting Disadvantages of surface mounting 4

5 5

6 Activity sheet 4 Scales of production Learning aim A (Topic A3) The four scales of production are: one-off/jobbing batch mass continuous. Complete the table below using either the internet or other sources of information. Description One-off Batch Mass Continuous Typical products Tools and equipment Labour type Production efficiency Unit costs Labour costs 6

7 Activity sheet 5 Modern and smart materials Learning aim B (Topic B1) Materials such as aluminium and steel have been used in the engineering industry for many years. As technologies have improved and demands on materials have increased, new and more advanced materials have been developed. These can be divided into three groups: composite materials, smart materials and high performance materials. Complete the following tables by researching the different materials. Modern composite materials Material Properties of the material Examples of typical uses Reasons for use Improvements on traditional materials Carbon fibre Kevlar GRP 7

8 Modern high performance materials Material Properties of the material Examples of typical uses Reasons for use Improvements on traditional materials Tungsten Titanium Nickel-based super alloys Cobalt-based super alloys Ceramics boron carbide Ceramics cubic boron nitride Ceramics zirconia 8

9 Smart materials Material Properties of the material Examples of typical uses Reasons for use Improvements on traditional materials Shape memory alloys Shape memory polymers Electrochromic materials Piezoelectric actuators Piezoelectric transducers Why are these materials useful in engineering? 9

10 Activity sheet 6 Modern materials and processes Learning aim B (Topics B2 and B3) Many modern materials and processes are being developed to replace traditional methods. You need to know about how these materials are made, and what the processes are and how they are used. Task 1 Produce a fact sheet about metal foams that can be used to explain what they are to others. Your fact sheet should contain the following: how metal foams are made the properties of metal foams the engineering applications of metal foams the advantages of metal foams compared to other materials why metal foams are used images of metal foams, both in use and during production. Task 2 A modern method of producing metallic objects is to use powder metallurgy. Working as part of a small team, produce a presentation about the use of powder metallurgy. You will need to choose your method of presentation: it could be a report, a series of slides, a poster or a talk. You should think about the following in your presentation: the stages of manufacturing an object using powder metallurgy the equipment needed for the processes the types of product that are made in this way the typical scale of production associated with powder metallurgy any processes that need to be done after completing the sintering stage the advantages and disadvantages of using powder metallurgy. 10

11 Activity sheet 7 New technologies in engineering Learning aim B (Topic B4) Many new technologies have been invented in recent years that are utilised by the engineering sector. In a lot of these cases, the technology has only been possible because of the development of new materials. Task 1 Investigate the following different new technologies: optical fibres in communication hydrogen fuel cells in vehicles surface nanotechnologies. New technology Technology replaced How the technology works Advantages Disadvantages Carbon fibre Kevlar GRP 11

12 Task 2 Investigate the following technologies: telematics blended wing bodies bionics. For each you need to explain what how the technology works, then identify possible uses for the technology. Give reasons why. Telematics How does it work? Possible uses Blended wing bodies How does it work? Possible uses Bionics How does it work? Possible uses 12

13 Activity sheet 8 Life Cycle Assessment Learning aim C (Topic C1) Instructions: You have been asked to prepare a presentation on Life Cycle Assessment (LCA). There are six stages that need to be considered. These are shown in the box (not in order). Life Cycle Assessment Disposal/recycling Material production Production of parts Assembly Raw materials extraction Use Use this information, plus your notes and internet research, to complete the planning sheet for your presentation. Stage Notes for your presentation 13

14 Activity sheet 9 Reducing waste Learning aim C (Topics C2, C3) No matter how hard an engineering company tries, there will always be some wastage. There are many ways in which waste can be reduced, both in making processes and also in the design of products. Task 1 Complete the table below to explain how each of the four Rs Reduce, Reuse, Recover, Recycle can be used to prevent waste. Reduce materials and energy Describe how this can be achieved. Example: Reusing materials and products Explain what this means. Give an example of how products can be reused. 14

15 Recovering energy from waste Describe how this can be achieved. Example: Recycling Identify two products which can be recycled Product 1 Product 2 Materials used: Materials used: How is it recycled? How is it recycled? What are the recycled materials used for? What are the recycled materials used for? 15

16 Task 2 As well as using the four Rs to reduce waste, the manufacturing process can be made more efficient through lean manufacturing. Explain what is meant by the term lean manufacturing. Use the internet to research the key features of the three different lean manufacturing methods listed in the table. Method Key features Who is involved How does it reduce waste? Kaizan Poka-yoke Just-in-Time (JIT) What are the similarities between the three methods you have researched? Choose one of the methods you have researched, and explain how an engineering company of your choice uses that method to make their production more efficient. 16

17 Activity sheet 10 Instructions: Renewable energy Learning aim C, Topic C4 Research two types of renewable energy, then explain your research to another member of your group. You will then be taught what they have found out about two other types of renewable energy. Record information about each type of renewable energy here: Wind energy Basic description of how it works: Typical locations and types of use: Advantages Reliability and efficiency Disadvantages Reliability and efficiency Environmental benefits Environmental disadvantages 17

18 Solar energy Basic description of how it works: Describe the two different types of solar power: Advantages Reliability and efficiency Disadvantages Reliability and efficiency Environmental benefits Environmental disadvantages 18

19 Hydro energy Basic description of how it works: Describe the difference between a tidal barrage and using a dam: Advantages Reliability and efficiency Disadvantages Reliability and efficiency Environmental benefits Environmental disadvantages 19

20 Geothermal energy Basic description of how it works: Typical locations and types of use: Advantages Reliability and efficiency Disadvantages Reliability and efficiency Environmental benefits Environmental disadvantages 20

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