GCSE Engineering. Resources List

Transcription

1 GCSE Engineering Resources List

2 Resources and Web links to Support GCSE Engineering Books AQA GCSE Engineering by P Anderson, Nelson Thornes, Additionally, the following books were developed for previous GCSE Engineering Specifications. Whilst they contain information relevant to some areas of the new Specification, it must be noted that there are significant differences between the old and new Specifications, both in content and the level of detail: Engineering GCSE, N Godfrey & S Wallis, published by Nelson Thornes, 2004, ISBN Engineering GCSE, M Tooley, 2002, published by Newnes, ISBN GCSE Engineering, S Cushing, published by Hodder & Stoughton, 2004, ISBN X. Electronic Media Electronic support materials for AQA GCSE Engineering, will be published by Nelson Thornes in Summer These have been developed to specifically support the new GCSE Specifications. Electronic Support Materials for AQA-City & Guilds Diploma in Engineering Levels 1 & 2 will be published by Nelson Thornes from November A comparable resource for Level 3 will be published from January These resources include a broad range of video-based and presentation-based case studies relevant to GCSE Engineering, along with detailed activities that examine several of the topic areas in great depth. Pneumatics Resource DVD for GCSE Engineering/Manufacturing. Produced by SEMTA, in association with FESTO, It is available through This provides a wide range of information on the use of pneumatics. GCSE Engineering & Manufacturing Resource was prepared by EEF West Midlands (The Engineering Employers Federation) in 2006, with support from SEMTA. It is available through This contains two video-based case studies. Manufacturing in Gloucestershire was circulated by SETPOINT Gloucestershire. It is available through This contains a range of industrial case studies, including video clips. Complete Resource DVD for GCSE Engineering/Manufacturing. Produced by SEMTA, It is available through This is a multimedia resource that includes assignments, technical drawings, manuals and image banks, along with a range of videos of industrial case studies. Whilst this was developed for a previous GCSE Specification, it still contains much useful information. Introducing Manufacturing, Developing Systems, Controlling Speed, Transmitting Power and Using Components are a range of electronic resources available from the Technology Enhancement Programme, These include a wide variety of manufacturing and product based case studies, featuring videos, animations and worksheets. CAD/CAM in practice is available from the Design & Technology Association, This contains a variety of resources for CAD/CAM. Engineering and Manufacturing are CDs complied by the Learning and Skills development Agency in 2002, with extended data and text-based case studies from a range of engineering and manufacturing companies klm Copyright 2009 AQA and its licensors. All rights reserved. 1

3 Material Selection and Processing, written by A M Lovett, H R Shercliff and P J Withers is available through the Technology Enhancement Programme, It includes very detailed information on the properties of a wide range of materials. Engineering at the Cutting Edge is a series of five 25-minute programmes which supported aspects of the previous GCSE Specification. It is available through It includes a variety of videos of manufacturing and engineering applications which may be suitable for use as case studies. How its Made is a series shown of the Discovery Channel. Each episode contains a series of short 5-minute case studies following the manufacture of a product. Extracts from some of these episodes can be found online (see web links below). Web links including content relevant to the Single Award The following is not a comprehensive listing, but provide a good starting point for many of the topic areas included within the specification. General is the AQA website for GCSE Engineering, including the Specification, and examples of the assessment materials and marks schemes. includes a wide range of downloadable materials and information to support the teaching of GCSE Engineering includes a wide range of relevant topics. is a searchable site with information on a wide range of different products. is the website of the Technology Enhancement Programme, containing information on a broad range of new materials and technologies and support for GCSE Engineering projects. contains a range of downloadable resources to support the teaching of engineering and technology. is an online, searchable encyclopaedia which can be used to source information on a wide range of engineering topics. Video Case Studies accesses a (very) large searchable bank of video clips, most of which are not related to engineering. However, using the search facility it is possible to locate many case studies following the design and manufacture of engineered products. For example: o shows how electric violins are made, including the use of several templates. o shows how a cello is made, including the use of templates and moulds. CAD & CAM is an overview of Computer Aid Design is an overview of Computer Aided Manufacture 2 Copyright 2009 AQA and its licensors. All rights reserved. klm

4 is a listing of web links and information sources for CAD is the home page of CAD/CAM in schools, including a wide range of support materials, resources and (school based) case studies. Electronic components and are two areas of the BBC GCSE Bitesize website, which provide details on electronic components and their uses. part of the Technology Student website, has details and examples of a wide range of electrical components. explains the functions of common electrical components. is the online wikipedia entry which explains the functions of common electrical components. is also a useful source of information on electrical and electronic components. Pneumatic components is part of the BBC GCSE Bitesize website, containing information on pneumatic components and their uses gives a detailed explanation of pneumatic and hydraulic systems. Mechanisms is the Flying Pig website, which includes animated graphics of a wide range of mechanisms. is part of the BBC GCSE bitesize website, containing information on gears and a range of mechanisms. is part of the Technology Student website, containing details and examples of a range of cams and other mechanisms. Jigs and Fixtures and explains why jigs and fixtures are used. gives links to examples of a number of different templates, jigs and fixtures, and explains their use. explains how Go-No Go gauges work. shows the manufacture by pupils in a school of a wind turbine, including the use of templates (p12, 13) and jigs (p17, 18). and include a few examples of some very complex fixtures used in the automotive and aerospace industries. klm Copyright 2009 AQA and its licensors. All rights reserved. 3

5 Web links including content relevant to the Double Award This includes all of the above web links relevant to the single award, plus the following. Volumes of Manufacture includes links for one-off, batch and continuous production introduces approaches to one-off manufacture gives examples of one-off manufacture Explains approaches to batch manufacture gives a general introduction to batch manufacturing explains what is meant by batch manufacturing gives examples of batch manufacturing Explains approaches to mass production gives a definition of mass production explains the history of mass production explains approaches to continuous production gives examples of continuous production Smart Materials is an introduction to smart materials gives examples of a range of smart materials and their applications is an introduction to shape memory metal explains how shape memory alloys work gives the history and applications of shape memory alloys lists some applications of shape memory alloys is an introduction to smart fluids lists applications of smart fluids shows a further application of smart fluids is an introduction to thermochromic materials explains how thermochromic textiles work 4 Copyright 2009 AQA and its licensors. All rights reserved. klm

6 shows an application of thermochromic materials gives an introduction to photochromic materials shows an application of photochromic materials shows an application of photochromic materials Energy and the Environment gives an overview of methods of generating electricity outlines world energy consumption is document prepared by the nuclear industry summarising the environmental effects of different approaches to generating energy. is a document prepared by Greenpeace detailing the energy capacities of a range of power generation approaches, including the economics of nuclear power lists the disadvantages of using fossil fuels gives a detailed overview of using fossil fuels to generate power, including environmental impact is a document prepared by the nuclear industry summarising energy needs and the case for nuclear power. gives a detailed overview about applications of nuclear reactors as power sources explains how nuclear power works gives a detailed overview of power generation using wind turbines explains how wind power works gives a detailed overview of the use of solar energy explains how solar cells work gives a detailed overview of power generation using tidal sources explains how wave energy works and describes methods of harnessing wave energy is an explanation of the history and use of recycling, including energy savings and recyclable materials describes the history and benefits of recycling klm Copyright 2009 AQA and its licensors. All rights reserved. 5

7 Engineering Glossary Term "Smart" Materials Abrasive Adhesive Aesthetics Alloy Analyse Anneal Annotation Anodising Anthropometrics Appliance Assembly Assembly Drawing Description A material which has one or more properties which can be controlled through an external input. A hard and wear-resistant material that is used to wear, grind or cut away other material. Otherwise known as 'Glue,' is a substance that adheres or bonds items together. Also spelt 'esthetics;' how various design features combine to make something beautiful. A metallic substance formed from the combination of two or more metals, or a metal and non metal. Brass, Bronze and Steel are alloys. To break down a design problem or product into manageable parts and learn from them. A process where metals are heated to a specific temperature and then allowed to cool slowly. The process allows molecules within the metal to realign making the material more soft and ductile; this makes it easier to shape and machine. A process of adding detailed comments to design solutions. Normally in the form of written notes. A process where an electrical charge and specific chemicals are used to oxidise the surface of a metal, then dyed a different colour. The oxidised surface makes the material slightly harder (surface hardness only) and more resistant to corrosion. The study of the measurements of the human body. A machine or product. Where component parts are joined together to make products, or sub-assemblies. A diagram, technical drawing or picture of a product, that clearly shows how all separate parts assemble together. It should also help to demonstrate assembly order. 6 Copyright 2009 AQA and its licensors. All rights reserved. klm

8 Automatic Automotive Brass Brazing Brief British Standards Institute Bronze BSI CAD CAD Rendered Drawing CAM Capacitance Capacitor Cast Iron Casting Something carried out without human intervention. To do with mechanical transport (cars, motorbikes, lorries etc). An alloy containing Copper and Zinc. Brass is very malleable and easy to cast. A method to join close fitting metals or alloys together, whereby a non-ferrous metal or alloy 'filler' is heated above 450 degrees to melting point, then distributed between close sections of material. This molten filler interacts with the metal or alloy it is joining, then cools forming a very strong bond. A clear statement of the design objective/design task. The organisation responsible for preparing codes of practice, within Computer Aided Design or technical drawing for instance. An alloy containing Copper and Tin. Bronze is used a lot within sculpture. British Standards Institute Computer Aided Design A computer generated design which has been coloured, textured and lit to look realistic. Computer Aided Manufacture The ability of a body to hold an electrical charge. The value of capacitance is measured in Farads. An electronic component consisting of two conductive plates separated by a non-conductive material. When connected to a power source, capacitors will gain and hold charge. An alloy containing Iron and more than 1.7% Carbon. There are two basic types of Cast Iron, 'White' and 'Grey'. A manufacturing process where a liquid material is poured into a mould then allowed to solidify; the material will then take the shape of the mould cavity. klm Copyright 2009 AQA and its licensors. All rights reserved. 7

9 Ceramics CIE CIM Circuit Diagrams Client CNC Coating Cold Working Component Composite Material Corrosion Cross linked Polymer Density Design Brief A non-metal solid, containing ionic and covalent bonds. Modern production processes have seen the rise of 'Advanced Ceramics', produced with heat and pressure. These advanced ceramics have extremely good strength, wear resistance and heat resistance among other characteristics. Computer Integrated Engineering Computer Integrated Manufacture A simplified pictorial drawing of an electrical circuit. Circuit diagrams are drawn using standardised symbols to represent components, this means it can be understood world-wide! The person, company or organisation you are working for. Computer Numerical Control A covering that is applied to the surface of an object. Painting, Anodising and Powder Coating are all types of coating. Altering the shape or size of a metal without the application of heat. Cold working processes include rolling and drawing. A single part, of a larger product or assembly. A material created from two different materials. The decay of a material as a result of chemical reactions with its surroundings. Within polymers the long polymer chains are linked to one another, however, in certain situation this 'cross linking' is much stronger. In 'Cross linked Polymers' this bonding is much more ordered and the connections between chains is via covalent or ionic bonds. Cross Linked Polymers are therefore much stronger, but less flexible. Mass per unit volume of a given substance. A comprehensive written document, composed by the client and designer. The document should outline specific focuses and key requirements, also including formal details such as budget and due date for example. 8 Copyright 2009 AQA and its licensors. All rights reserved. klm

10 Design Specification Development Dielectric Dispatch Disposability Domestic Drawing (Production Process) Drawing Orthographic Perspective Drawing Drilling Ductility Efficiency Embedded system Provides precise and explicit information about the requirements for a product design. A design specification provides in-depth detail about the functional and non-functional design requirements. Normally written in list format. The process by which initial ideas are progressively improved to achieve a final design that meets all requirements. Development also includes physical prototyping. Any non-conducting substance, an insulator. To send out a finished product to the customer. How easily the product is thrown away when obsolete. Taking into consideration dangerous materials and components, to both the user and environment. To do with the home. A production process for metals, where sections of sheet metal called 'blanks' are stretched around a 'plug' and pushed through a die. Through the use of 'drawing' complex shapes can be achieved, metal kitchen sinks are drawn. The process is repeated numerous times for 'deep drawn' objects. A formal drawing technique that shows three or more 2D views of a product on one drawing. These views would normally be the Front, Side and Plan. 3rd and 1st angle projections are most common. A formal drawing technique where a horizontal line is drawn with typically 1, 2 or 3 vanishing points upon the line. The drawing is then produced accordingly using the vanishing point/s, generating an impression of depth. A cutting process to produce holes within solid materials. Different drills, 'drill bits,' rotation speed and drilling technique must be used depending upon the size of the hole and material being drilled. A measure of how much a material will deform before fracturing. This deformation is said to be within a 'plastic' region, where the change to a materials shape is permanent. Not to waste energy or resources. A computer built into a product to control its operation. klm Copyright 2009 AQA and its licensors. All rights reserved. 9

11 Engineering Environment Exploded-view Drawings Extrusion Fabrication Ferrous Metals Finishing Flow Diagram Forging Form Formal Drawing Galvanising Global Go/ No go Gauges The science of applying mathematical, scientific and technical knowledge to solve problems. A term used to describe a specific situation as well as the wider world we live in. See "Assembly Drawing". A process used to shape materials into lengths of fixed cross sectional profile. The process involves pushing material through a 'die' - the material then takes on the shape of the cross section. Polymers (Plastics), Metals and Ceramics can all be extruded. An industrial term describing the manufacture of metal products. Processes including cutting, drilling and welding are all typical in fabrication. Metals containing Iron, Ferrous Metals are all magnetic. The final stage of production, before the product is completed. Finishing could involve powder coating, plating, painting or polishing for example; the final finish can greatly affect the aesthetics of the piece. Otherwise known as 'Flow Chart', Flow Diagrams are a more visual representation of a process. They are clearly written and arranged; flow diagrams should include all stages of a process including decision points. A process where metals are shaped by compression - typically via hammer blows. Forging can be performed cold or hot; however working hot metal is much easier and less lightly to fracture. Shape and visual appearance. A drawing produced using a technical drawing method. Standardised or formal drawings are essential within industry. A process where iron is coated in zinc, making it far more resistant to corrosion. This can be achieved by dipping into molten zinc or electroplating. The entire world, World-wide. A phrase used to describe the use of inspection tools to check a piece of work against its planned dimensions. The phrase derives from pass or fail of the work-piece, Go or No Go. 10 Copyright 2009 AQA and its licensors. All rights reserved. klm

12 Hardness Hydraulics Impact Industrial Infrared Integrated circuit Isometric Drawing Laser Liquid crystal display Machining Manufacturing Material supply Mechanical Memory Microcontrollers Microprocessor A phrase used to describe a materials ability to resist plastic (permanent) deformation. A system used within engineering to produce and transfer power, via the pressurisation of liquids. Effect of something on something else. To do with industry (organised manufacture). The band of light in the electromagnetic spectrum that lies between the visible light range and the radar range. Electronic circuits contained in small standard packages. Isometric is a 3D drawing technique where lines are drawn at 30 degrees from the horizontal, generating perspective and depth. Light Amplification by Stimulated Emission of Radiation. Also known as LCD, they are flat panel electronic displays used to show information such as text and numbers. LCD's are used within common calculators. The use of power tools and powered machines to remove material until a component meets required dimensions. Pillar Drills, Lathes and Milling Machines all examples of tools used within Machining. To make a component or product. Organising the arrival and holding of materials for manufacture. Containing moving parts. Device to store information. A very small (micro) computer on an integrated circuit. They designed specifically for small decision making applications. A very small (micro) processor on a microchip, it is sometimes referred to as 'logic chip. klm Copyright 2009 AQA and its licensors. All rights reserved. 11

13 Milling Monitor Mosfet Non-Ferrous Metals Objective Testing Methods Packaging PIC Plastic Plastic Plasticizer Plating PLC Pneumatics Polishing A form of machining, milling is a process for removing material by feeding a work-piece through a rotating tool. Much like other forms of machining, milling has the potential to achieve an extremely high level of accuracy. To carefully measure the values of something that is variable. Also the name for computer display. Metal-oxide-silicon field effect transistor, an integrated circuit element. Metals that do not contain any Iron. A testing method where the testing methodology (method) does not influence the result. Otherwise known as a 'Fair Test'. The materials used to protect products in transit. Packaging is also an important means of advertising the product. Programmable Interface Controller. High polymeric substances, including both natural and synthetic products, but excluding the rubbers, that are capable in their manufacture of flowing under heat and pressure. A term to describe flexible and bendable. Materials described as 'Plastic' are typically polymers and can be cast, pressed and extruded. A chemical agent added to plastics to make them softer and more flexible. A process where metals coat a conductive surface. Plating can be performed to achieve improved corrosion resistance and improved aesthetics for example. Programmable Logic Controller. A system used within engineering to produce and transfer power, via the pressurisation of air. Smoothing the surface of a material to remove imperfections. Polishing can be achieved through manual or chemical abrasion. 12 Copyright 2009 AQA and its licensors. All rights reserved. klm

14 Polymer Process Product Product Specification Production Production planning Production Scale Programmable Logic Controller (PLC) Quality Quality Assurance Quality control Reclaimability Resistance A large molecule chain consisting of atoms typically connected by covalent bonds. Polymer 'chains' are apparent in the vast majority of commonly used 'plastics'; some plastics contain short polymer chains, while other contain long chains. To alter a material to meet a requirement, for example drilling holes or chamfering edges. A finished item from a production line. A description of what the product must do. Adhering to the product specification will ensure that the design meets the needs of the user. The making of a product. The means of production will differ depending upon scale. The act of careful planning of time, materials, tools and equipment and working environment prior to production of a product. The number of units being made of a particular product. Main production scales are (in order of scale): One off, Batch, Mass and Continues. A form of computer which is designed to control industrial processes such as assembling engines automatically. Being fit for its intended purpose. The implementation of specific stages in a production process that ensure the product meets the required quality. The emphasis behind quality assurance is to make sure the product is 'right first time.' To control the way a product is manufactured to make sure it is fit for purpose. The ability of a product to be broken down into its component materials so that they can be re-used. Property of a conductor that opposed the current flow produced by a given difference of potential. The ohm is the practical unit of resistance. klm Copyright 2009 AQA and its licensors. All rights reserved. 13

15 Rivet Robotics Routing Safety Sector Shape memory Shear Strength Soldering Standard Conventions Structure Sustainability Switch System Diagram Telecommunications Tensile Strength A permanent mechanical means of fastening material together. Traditional rivets are deformed on the 'bucktail' end by hammer blows to secure the material, however more modern 'blind' and 'pop' rivets do not require this. The use of robots - automatic mechanical handling. A machine that powers a high speed cutting bit, designed for shaping and cutting. Routers are available as hand-held power tools and CNC machinery alike. Not to cause injury. Branch of industry. Remembers the original shape and springs back when allowed. A strength value given to a material or component, showing how much stress it can take before fracture. A process where metals are joined by melting a 'filler' metal between them. The filler metal must have a lower melting point than the materials being joined. Methods and procedures that should be followed within engineering. Keeping procedure standardised across an industry ensures quality and repeatability. The form of a product from a physical point of view. Made from materials which can be replaced or re-grown. Component to turn electrical power on or off. A systematic description of the stages involved in an electronic process. System diagrams are clear and work around the structure of Input, Process, Output. To do with communication - voice or written. The amount of stress a material can withstand before permanent deformation. 14 Copyright 2009 AQA and its licensors. All rights reserved. klm

16 Thermoplastic Thermoset Third-angle Orthographic Drawing Tolerances Treated Turning Vacuum Forming Welding X,Y and Z Co-ordinates Plastics capable of being repeatedly softened by increases in temperature and hardened by decreases in temperature. These changes are physical rather than chemical. A classification of plastic resin that cures by chemical reaction when heated and, once cured, cannot be resoftened by heating. The most popular projection of orthographic drawings. Front, Side and Plan views are shown. The Front view is central, while Side and Plan views are shown to be facing towards. A figure given to inform how accurate a dimension must be on a part, e.g. 12mm +/- 0.5mm A term used to describe a raw material that has been altered in some way, often to improve its characteristics. Metals can be 'heat treated' for instance, to make them harder. A production process whereby a work-piece is spun, tools are then pushed into the material removing it. Turning can be done manually on a lathe or automated on a CNC lathe. A process for moulding plastic. Plastic is heated until soft, then lowered onto a mould; air is then pumped out causing a 'vacuum' forcing the soft plastic to take the shape of the mould. A metal fabrication process where, the work-piece is melted and a filler material is added, creating a very strong bond between the materials. Different types of welding must be used depending upon the available power supply and material being worked. Values that describe position. X, Y and Z relate to positioning on an axis, length, height and depth. These are values essential within CAM. klm Copyright 2009 AQA and its licensors. All rights reserved. 15