D T C D+TD+T Dartford Technology College Design & Technology Department CONTAINERS Tool images...

D T C

D+TDartford Technology College

Design & Technology Department

CO

NTA

INER

S

Tool images reproduced with kind permission of Axminster Tools. Www.axminstertools.co.uk for all your Resistant Materials equipmentand CR Clarke & company www.crclarke.com Designers and manufacturers of thermoforming equipment for education.

Safety in the workshop is the responsibility of everyone. Make sure you are not the cause of

someone else's accident.

.ALWAYS wear an apron when using tools and equipment in the workshop to protect your

clothes.

2. DO NOT allow clothing, long hair to hang loose. Remove all jewellery before starting practical work. (These can easily become trapped in machines)

3. WEAR strong shoes. (Trainers or open toes shoes are NOT allowed in the workshop.)

4. NEVER run or push other people. (Accidents may be caused to others by running or pushing.)

5. CONCENTRATE on what you are doing and LISTEN carefully to instructions.

6. CARRY tools and equipment in the correct manner. (Be especially careful with hot materials)

7. Keep hands AWAY from the sharp edges of tools. (always use tools in the way that you have been shown.)

8. ALWAYS wear goggles when using machinery to avoid eye injuries.

9. IF you have an accident tell the member of staff immediately.

Workshop health & safety Ref.HandS7

The Design Cycle Ref.Des cycl 7

•General instructions to the designer for the project.

Explain what will need to be done to solve the problem.

You may make reference to the client / target audience.

Design Brief

Who? Who is it designed for?

What? What will it be used for?/made from?

When? When will it be used?

Where? Where will it be used?/ stored? Sold? Etc.

Why? Why is the product needed?

How? How will it be made?/ sold?/ used?

Analyse the problem

Use a variety of sources for your research. Include primary research (e.g. talking to customers / users, disassemble products) and secondary research (e.g. magazines, books, internet).

Research

Existing designs – explore them for ideas

Disassembly – take products apart to find out how they work or are made.

Interviews – speak to people how use or make the product.

Questionnaires – use questionnaires to gather information from users.

Libraries – books, magazines, videos are useful sources of information.

Internet – the internet has masses of information waiting to be used.

Letters – Advice – write to companies/shops and ask about their products

Visits, etc …… visit museums and shops to look at past and existing products

The Design Cycle

Specification

Ideas

Development

A set of criteria for the product agreed between designer and client.

The product must be…

The product should have…

The product must not….

Create as many ideas as possible that meet the brief.

Sketch ideas in 3D where possible. Label parts that can’t be clearly seen on the sketch.

Evaluate your ideas against the specification criteria.

Improve your ideas.Combine best ideas to make a final design.Add technical details. Make sure that it meets all specification points

Planning

Make your product.

Pay attention to detail and the finish / presentation of your product.

Making

Evaluation

Evaluate the design against the specification.Be critical, it is a prototype.Suggest modifications and improvements. Test your product.Does your target market think the same as you?

Plan how you are going to make your product and in what order.Include tools and equipment.

NB Someone else should be able to make the product from your planning instructions.

Timber Ref.TIM8Timber is the general name used for wood materials. There are three main types of timber:-

Softwoods come from coniferous trees which have needles instead of leaves. They grow faster than hardwoods and are softer to work with than hardwoods. They are supplied in standard sections which can be rough sawn or planned smooth.

Complete the following

1.Write down the name of three different types of hardwood.

2.Write down the three main reasons that industry uses manufactured boards.

Softwoods

Hardwoods come from deciduous or broad leaved trees. They are slower growing than softwoods and tend to be harder to cut. Hardwoods are sold by the cubic metre and then rough sawn to the required size.

Hardwoods

Manufactured boards are made from gluing together layers of wood or gluing and compressing wood fibres together. Manufactured boards are used frequently by industry because they are large in size, of consistent quality and stable.

Manufactured boards

Manufactured boards Ref.man8These are boards that are made in factories from materials such as wood chippings

or dust.

BLOCKBOARD

This is built up with a core of softwood strips glued together and covered with a sheet of plywood on either side.

Used as a building material and for furniture manufacture including fitted kitchens / bedrooms.

CHIPBOARD

This is made up of small chips of wood glued together and formed into sheets by compression.

It is not as strong as plywood and block board but it is not expensive. Chipboard is often covered with a plastic laminate or wood veneer and used in furniture.

HARDBOARD

This is made from wood fibres that have been pulped.

The pulp is put under pressure until the fibres bond to produce a tough board that is smooth on one side and rough on the other.

MEDIUM DENSITY FIBRE BOARD (MDF)

A quality board, relatively cheap. T

his board is composed of fine wood dust and glue pressed into a board. It is easy to shape and machine. Used in buildings and for making furniture.

PLYWOOD

This is made from veneers (layers) of timber with each grain layer being at right angles to each other and glued together under pressure. A number of different types of plywood are available, designed to suit a variety of situations.


1.Write down the name of each board and make a colour sketch of each one.

2. Write down three things that are made from each type of board.

Wood uses

BEECH

A straight grained hardwood. Very easy to work with.

Furniture, tool handles, benches

OAK

Very tough, light brown in colour. Difficult to work.

High quality furniture, ships and veneers

ASH

Open grained, easy to work.

Tool handles and sports equipment.

MAHOGANY

Easy to work, reddish brown in colour.

Furniture, veneers and window frames.

TEAK

Durable, golden brown in colour. Good water resistance.

Outdoor furniture, lab tables etc.

SCOTTS PINE

A straight grained softwood. Inexpensive and easy to work with.

Commonly used for DIY work. Mainly used fin buildings for construction work.

PARANA PINE

Hard and fairly strong but expensive.

Used to manufacture doors and staircases

Adhesives Ref Adh 8

PRITT STICK

Sticky white gel pushed onto the material to be glued rather like using a lipstick.

PVA

A white fluid that can be watered down. Non toxic to use as it is water based. Takes 24 hours to dry completely.

IMPACT ADHESIVE

Give off fumes so must be used in a well ventilated area. Both surfaces to be glued must be coated and left for 20 minutes before firmly pressing them together.

EPOXY RESIN

Equal amounts from two tubes are mixed together to make the glue. One tube contains resin and the other a catalyst. The catalyst speeds up the hardening of the resin.

GLUE GUN

Heat melts the glue which is then applied to the materials to be glued. Fingers can be burnt if the glue gun is not used carefully.

TENSOL CEMENT

Used to glue together Acrylic. It must be used in a well ventilated room and the lid must be firmly screwed back on so the glue does not go off.

SUPER GLUE

Comes in small tubes and glues very quickly. Dangerous if it gets on your hands. First used in the Vietnam war to bind wounds together.

USES

PAPERCARD

ALL WOODSCARD

POLYSTYRENE

A WIDE VARIETY OF MATERIALSBUT NOT

POLYSTYRENE

DIFFERENT TYPES ARE

AVAILABLE FOR DIFFERENT MATERIALS

WOOD PLASTIC CARD

ACRYLIC

CAN BE USED ON A RANGE OF

MATERIALS

Hand tools Ref HandT1.8

Saws are the main cutting tools. Different saws have teeth that are designed for cutting different materials.

Tenon saws, cross cut saws and ripsaws are used to cut wood.

Coping saws can be used to cut wood or plastic and are mainly for cutting out curved shapes.

Hacksaws and junior hacksaws are used to cut metal but can also be used to cut plastic.

To work properly saws need to be kept sharp. Some saws have blades that can be replaced. Others have blades that need to be sharpened.

Cutting tools

Cross cut saw Tenon saw Coping saw Hacksaw

The bench planes is used to shave off thin layers of wood. It is used on wood to shape and smooth the surface.

Bench plane

Files come in different shapes and cuts. They have hundreds of small teeth to cut away the material.

Rough cut files are used to remove material while smooth cut files are used to finish the surface of the material.

For wood a special file called a Rasp can be used.

Files

Images reproduced with kind permission of Axminster Tools. Www.axminstertools.co.uk for all your Resistant Materials equipment.

Hand tools Ref HandT2.8

Hand Drills

GougesCold chiselWood chisel

Hand drills, carpenters braces and bradawls are used for making holes. There are also hand held power tools and bench mounted drills.

All drills turn a drill bit that is pressed against the material.

Twist drills are used for drilling small holes in wood metal and plastic.

Flat bits are used to make larger holes and can produce a hole with a flat bottom that does not go all the way through the wood.

Countersink drill bits are used to make holes for screw heads to sit in.

Different bits are used for different materials. Auger bits are used for wood. High speed steel twist drills are used on metal and plastics.

Bradawl Carpenters brace Hand Drill

Twist drill Flat bit Countersink

Chisels are used to carve and shape wood. Bevel edge chisels, firmer and mortise chisels are used with a mallet.

Gouges are used to carve or sculpt wood.

For metals a cold chisel can be used with a hammer to remove small amounts of the material.

Chisels


Machines Ref Machine1.8

Machine tools do the same job as hand tools but are quicker and more efficient.

They are often bolted to the floor or a bench.

They can be used to process large quantities of material quickly and accurately.

Machines used to cut and shape wood are connected to a dust extractor

Safety rules MUST always be followed when working with machines.

Dust extractor

There are different types of machine saw.

The Circular saw or Bench saw has a round blade and is used to cut wood and sheet material like plywood.

They only make Straight cuts.

Automatic saws

Band saw

The band saw has a blade that is made in a long loop and can be used to cut wood, plastics and soft metals.

The blades come in different widths and can be used to make straight and curved cuts.

1.Name and sketch a handsaw that is used to make straight cuts.

2.Name and sketch the saw that can be used for curved cuts.

3.What are chisels used for?

4.Sketch two different types of automatic saw.

5. Make a list of safety rules for using automatic saws.



Machines Ref Machine2.8

METAL WORK LATHE

Lathes are used to “TURN” round shapes from metal bar. The work is held in a chuck and spins as a very hard metal tool is used to scrape off metal until the correct shape is made. All types of metal can be turned and drilled in this way.

WOOD TURNING LATHE

The wood turning lathe is used to make round and bowl shapes from wood. The work is held between centres and spins. A sharp tool like a chisel is pushed against the wood to remove unwanted material.

Chair and table legs, fruit bowls and dishes can be made using this machine.

CNC ROUTER/ENGRAVER

In this machine a cutting tool spins very quickly against the material as the machine follows a pattern controlled by computer.

Very useful for repeating the same task again and again.

LAZER CUTTER

Laser cutters are fairy new state of the art technology. They can be used to cut a wide range of materials including wood, plastics, MDF, card, cloth and paper.

Work that is to be cut is drawn on computer and then the Laser cutter produces the design straight from the computer without the need for you to cut and shape the material. Accurate every time.


1.What are the advantages of using computer controlled machines?

2.If you wanted to make a round wooden chair leg which machine would you use?

3. Which automatic saw would you use to cut sheet material?


1. Never use the pillar drill _______________.

2. Always ask an adult to check that you are using

the correct _____________.

3. Always have a sacrificial piece of _________

underneath your work piece.

4. Your work piece has to be held _____________.

5. When drilling metal, be aware of sharp ___________.

6. Mark out metal with a ________________ before drilling.

7. When drilling plastic be extra careful not to apply too much _______________ to prevent the plastic from cracking.

The following terms are missing:

drill bit , unsupervised, securely, centre punch, pressure, swarf, wood

Dress code while drilling

1. Always wear _______________.

2. Wear an ______________ to protect your clothes.

3. Check that there are no lose bits of _______________ that could get drawn into the drill.

4. _______________ has to be tied back.

5. Remove all jewellery.

The following terms are missing: long hair, apron, jewellery, clothing, goggles

1. Trace or sketch the diagram of the pillar drill and add the labels.

2.Write down the safety rules and fill in the blanks.

3.Copy the dress code and complete the missing with words from the list.


Safe use of the drill.

The Pillar drill Ref pillardrill7


Disk sander Ref.DiskS7

Safety instructions

Missing words

Secure firmly burn unsupervisedtie dust extractor

Fingers Goggles protect loose

1.Never use the Sander ______________.

2.Always check the table is ________ and at the correct angle for your work.

3.When sanding always turn on the ___________.

4.Always hold the work _______ and on sander the table.

5.Keep your ___________ well away from the spinning disk when it is in use.

6.Move the work backwards & forwards across the sander so the wood does not ________.

7. Always wear __________

8. Always wear an apron to ____________ your clothes.

9. ______ back your hair and remove all jewellery.

10. Tuck in all _________ clothing.


1.Trace and label or Draw and label a disk sander.

2. Copy the safety rules and fill in the missing words from the list at the top.

Motor

On/Off switch

Sanding disk Table

Table adjusting bolts

Guard


Quality Assurance systems Ref.QA /QC8

Quality assurance checks the method of manufacture before, during and after a product has been made.

It ensures that products are made to the same standard all the time.

Quality assurance

Quality control is a series of checks that are made on a product as it is manufactured.

The checks are made to make sure that each product meets a specific standard.

Some tests that could be used are shown below. Tests are an important part of the manufacturing process and can take place at any time.

Quality assurance

Weight Electrical safety Accurate sizes Flammability tests

Not every product can be guaranteed to be exactly the same size when large quantities are made, a tolerance has to be applied.

This specifies the maximum and minimum measurements a product or part can have.

Tolerances

Testing the diameter Too large OK Too small

Scale of production Ref.ScaleP1.8Jobbing production

1.This is where you are making a single product.

2.Every item made will be different to meet the customers individual needs.

3.This type of product is very labour intensive and requires skilled workers.

1.This is where you make a set number of a product.

2.Batches can be repeated as many times as required.

3.The machines used need to be flexible so they can be changed from making one type of product to another quickly.

4. The time between batches when machines and tools are changed is called Down time and needs to be as small as possible.

Batch production

Mass production

Continuous production

1.Making products on a really large scale like cars and electrical goods.

2.Often uses expensive specialist equipment.

3.You also need a large workforce. The different stages of manufacture are broken down into smaller repetitive tasks that can be learnt easily.

4. Staff do not need to be skilled to make the system work.

1.This involves non stop uninterrupted manufacturing.

2.The specialist equipment used cost so much that it would be expensive to turn it off so it is kept running all the time.

3.Examples of continuous production include oil production and electricity production.

Scale of production Ref.ScaleP2.8

1.Copy each of the pictures below.

2.Under each picture write down if the method of manufacture is:-

Jobbing production Batch production Mass production Continuous production

3. Under each answer write a simple explanation.


—————— —————— ———————————–– —————— ———–——–—————— —————— ———–————————— —————— ——————

—————— —————— ——————————–—– —————— ————–——–—————— —————— ————–——–—————— —————— ————–——–

—————— —————— ——————————–—— —————— ————–—–—————— —————— ————–—–—————— —————— ————–—–

Corner joints Ref.Joints8BUTT JOINT

Used to make quick joints on non decorative products. This joint is not suitable for use on quality products inside the home. The two pieces of wood butt against each other and are glued or pinned together.

MITRE JOINT

A decorative joint that allows the grain of the wood to run around the outside of the box uninterrupted. Quick to make but difficult to fit together accurately and not very strong.

REBATED JOINT.

This joint cab be made easily. The advantage over butt joints is the increased glue area and strength that the rebate provides.

LAPPED OR HOUSING JOINT

This type of joint is strong and resists breakage through pulling. The groove in the wood can be made with a special plane or a router.

DOVETAIL JOINT.

The slots are cut with a taper that looks like a doves tail. The pegs that fit the slots are also cut with a taper. A very strong decorative joint that requires skill to make successfully.

FINGER JOINT

Similar to a dovetail joint but with parallel “fingers” on each part of the wood that fit tightly together. Used to make desk draws.

Holding work Ref.Hold8The sketches below show some of the common ways of holding materials while they are cut

and drilled. Always make sure that your work is held firmly, you will find the job easier and achieve better results.

Holding tips.Always keep the cut or hole close to the vice to reduce vibration.

There are many different types of wood screw.

1.COUNTERSINK SLOTHEAD.

Used for general purposes such as fitting hinges. Because it is countersunk the screw head sits flush with the surface.

2.ROUNDHEAD SCREW.

Used for fixing pieces of material together.

3.RAISEDHEAD SCREW.

Used to fit door handle plates and decorative fittings.

4.POZIDRIVE HEAD.

Used with a special screwdriver. Useful when fitting screws in corners or confined spaces.

5.DOME HEAD SCREW.

Used to fit fixtures such as mirrors. The screw slot iscapped with a decorative chrome dome.

SELF TAPPING SCREWS.

Normally used on metal. The screw cuts it’s own thread in a drill hole that is slightly smaller than the screw itself.

Wood screws Ref.Wscew8

1

2

3

4

5

6

FITTING SCREWS.

1.Mark the position on the wood.

2.Drill a clearance hole in the top piece of material the same diameter as the shank.

3.Drill a smaller hole in the second piece of material.

4.Countersink the first hole if you are using a countersink screw.

5. Fit the screw and tighten carefully with a screwdriver.


1.Draw one method of holding work in a vice.

2.Explain the difference between a DOVETAIL joint and a FINGER joint.

3.Draw three of the most common types of screw and give examples of their use.

D T C D+TD+T Dartford Technology College Design & Technology Department CONTAINERS Tool images...

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