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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.


+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.


+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


+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


+ve Removes human error

Able to do multiple tasks at once

Efficient



Need to be maintained


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


+ve Removes human error

Efficient and reliable

Runs 24/7

Can be updated quickly



Loss of skill in the work force


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.


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.



Does not need direct sunlight to generate electricity.

Panels last for 25 years.


Does not work well if north-facing.

Will not work at night.

Invertor may need to be replaced.


Reduces carbon emissions.

Does not cause air or water pollution.


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.



Reliable source of energy, especially when used with dams.

Generally low-maintenance.

Can react very quickly to changes in demand.


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.


Does not produce air pollution.

Can create habitats for wildlife.


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.



Very reliable source of energy.

Energy is free once system constructed.


Limited locations where it is efficient.

Possible that the heat source may not produce steam for a length of time.


Produces no pollution.

No fuel is needed.


Hazardous gases may be released with drilling.

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