Materials processing (3)
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1.
Question 1
A product design brief requires a lightweight, strong component with complex curved surfaces. The material is 6061 aluminium. Discuss how you would select and justify the use of appropriate processing techniques from the list below to manufacture this component. Consider the advantages and disadvantages of each technique in relation to the brief's requirements. Your answer should address at least four different processing techniques.
Processing Techniques: Wastage (cutting with hand and machine tools, including laser cutter, vinyl cutting machine, drilling, turning), Forming (vacuum forming, line bending), Addition (fabrication), Finishing (paints, polymer coatings, varnishes), Printing (digital printing, screen printing).
To manufacture a lightweight, strong component with complex curved surfaces from 6061 aluminium, a combination of processing techniques would be most suitable. Here's a breakdown of my proposed approach and justification:
- Wastage - Laser Cutting: Laser cutting is ideal for creating the complex curved shapes. It offers high precision and can handle intricate designs in 6061 aluminium. The advantage is the ability to achieve fine detail and smooth edges. A disadvantage is the potential for heat-affected zones and the need for appropriate ventilation. The laser cut parts would likely require minimal secondary operations.
- Wastage - Turning (CNC Lathe): A CNC lathe would be used to create any cylindrical or conical features within the component. This allows for precise dimensional control and repeatability. The advantage is high accuracy and efficient material removal. A disadvantage is the limited complexity of shapes compared to laser cutting.
- Forming - Line Bending: Line bending could be used to create specific contours or features that require bending. This is particularly useful if the design incorporates angled sections or defined edges. The advantage is creating specific shapes and angles. A disadvantage is the material needing to be suitable for bending and potential for springback.
- Finishing - Polymer Coating (Powder Coating): A polymer coating, such as powder coating, would be applied to enhance the component's durability, corrosion resistance, and aesthetic appeal. This is particularly important for aluminium to prevent oxidation. The advantage is a robust, even finish. A disadvantage is the need for proper surface preparation before coating.
Justification Summary: The combination of laser cutting for complex shapes, CNC turning for cylindrical features, line bending for specific contours, and polymer coating for durability provides a comprehensive manufacturing solution. The selection prioritizes precision, strength, and lightweight properties, directly addressing the design brief's requirements. Each technique's advantages and disadvantages were carefully considered to ensure optimal outcome.
2.
Question 3
A product design brief requires a decorative panel for a furniture piece. The panel needs to incorporate both cut-out shapes and raised relief detailing. The material is hardwood (e.g., oak). Discuss how you would use wastage and forming techniques to manufacture this panel. Consider the advantages and disadvantages of each technique in relation to the panel's requirements. Your answer should address at least two different techniques.
Processing Techniques: Wastage (cutting with hand and machine tools, including laser cutter, vinyl cutting machine, drilling, turning), Forming (vacuum forming, line bending), Addition (fabrication), Finishing (paints, polymer coatings, varnishes), Printing (digital printing, screen printing).
To manufacture a decorative hardwood panel with cut-out shapes and raised relief detailing, a combination of cutting and potentially some forming techniques would be most effective. Here's a detailed explanation:
- Wastage - Cutting (CNC Routing): CNC routing is the primary technique for creating both the cut-out shapes and the raised relief detailing. A router can precisely cut complex profiles into hardwood. The advantage is high accuracy, the ability to create intricate designs, and consistent results. A disadvantage is the need for a suitable router bit and potential for tear-out on the edges of the wood.
- Wastage - Drilling (Hand or Powered Drill): Drilling would be used to create pilot holes for any joinery methods required to attach the panel to the furniture piece. This could include dowels, screws, or other fasteners. The advantage is creating precise holes for assembly. A disadvantage is the potential for splitting the wood if the drill bit is too aggressive.
Justification Summary: CNC routing is the ideal choice for achieving both the intricate cut-out shapes and the raised relief detailing. The ability to program the router allows for complex and precise designs. Drilling provides the necessary holes for assembly. The use of hardwood necessitates careful consideration of router bit selection to minimize tear-out. The combination of these techniques provides a robust and aesthetically pleasing solution for the decorative panel.
3.
Question 2
A student is designing a lightweight, strong container for transporting fragile items. The container needs to be easily assembled and disassembled for storage. The primary material is plastic (e.g., polypropylene). Discuss how you would use forming and wastage techniques to manufacture this container. Consider the advantages and disadvantages of each technique in relation to the container's requirements. Your answer should address at least three different techniques.
Processing Techniques: Wastage (cutting with hand and machine tools, including laser cutter, vinyl cutting machine, drilling), Forming (vacuum forming, line bending), Addition (fabrication), Finishing (paints, polymer coatings, varnishes), Printing (digital printing, screen printing).
For a lightweight, strong, and easily assembled container made from plastic (e.g., polypropylene), a combination of vacuum forming and cutting techniques would be most appropriate. Here's a detailed explanation:
- Forming - Vacuum Forming: Vacuum forming is an excellent choice for creating the container's body. The plastic sheet is heated and drawn over a mould, creating the desired shape. This is ideal for producing complex, hollow shapes with consistent wall thickness. The advantage is rapid production of complex shapes and low tooling costs. A disadvantage is the need for a precise mould and potential for warping if the plastic isn't heated evenly.
- Wastage - Cutting (Laser Cutting): Laser cutting would be used to cut out the base and lid of the container. It offers high precision and can handle plastic effectively. The advantage is clean, accurate cuts and the ability to create intricate patterns. A disadvantage is potential for melting or warping of the plastic if the laser settings are not optimized.
- Wastage - Drilling (Hand or Powered Drill): Drilling would be used to create holes for joining the lid and base together. This could involve using screws, clips, or other fasteners. The advantage is creating precise holes for assembly. A disadvantage is the potential for cracking the plastic if the drill bit is too aggressive.
Justification Summary: Vacuum forming provides the structural integrity and lightweight nature of the container's body. Laser cutting ensures accurate dimensions for the base and lid. Drilling provides a reliable method for assembly. This combination balances ease of manufacturing, structural strength, and ease of assembly/disassembly, making it suitable for transporting fragile items. The choice of polypropylene is also appropriate due to its strength and durability.