Some revision websites to test you.

http://www.bbc.co.uk/schools/gcsebitesize/design/resistantmaterials/http://yacapaca.com/py/teacher/assignment/new/tca/step2/213847/

Assessment revision

Make sure you revise for Theory paper and Design paper

Theory paper – Important informationOne hourOnly answer one question from Section B – Resistant Materials

questions

Design paperDesign paper – Important informationOne hour 15minOnly answer one question (Answer the resistant materials

question!!!)

Year 10 theory

Week Syllabus Activities

Part 2 - Resistant Materials

Section 1: Practical applications • design and make practical products

 

Types of material • understand the physical and working properties and application in relation to plastics, woods and metals  

     

     

 Plastics – thermoplastics (nylon, polythene, polyvinyl chloride (PVC), acrylic, polystyrene, polypropylene) physical and working properties lamp, thingy

     

 

– thermosetting plastics (polyester resin including GRP, melamine, urea, formaldehyde and phenol formaldehyde) physical and working properties  

     

     

 

Woods - natural timbers (soft wood and hard wood) - focus on just main ones. classification, properties and uses thingy

     

  Process - understand why timber is seasoned and how to care for timber during storage and construction thingy

     

  Manufactured boards:  

 plywood, blockboard, chipboard, hardboard and MDFclassification, properties and uses lamp/ pewter

     

  Metals - show a working knowledge of the following metals:  

  – ferrous metals (mild and high carbon steels)  

 – non-ferrous metals (aluminium, duralumin and other common casting  

  * alloys (copper and its alloys, zinc, lead and tin) pewter

 

  Section 2 - Preparation of materials

 

 * What types of materials can you buy - in original forms, types and sizes lamp

 * cutting by use of hacksaw, guillotine, tenon saw, cross-cut saw, panel saw and portable power tools lamp/pewter

 

• understand the use of datum surfaces/lines/edges and be able toproduce them by planing or filing

 

 • explain the preparation for machine processes and safe methodsof securing materials to work surfaces, work tables, faceplates, chucks and between centres on a lathe  

 * Setting/marking out - measure and/or mark out work using ruler, pencil, marker pen, scriber, try square, bevel, dot/centre punch, dividers, marking gauge, cutting gauge and mortise gauge thingy

  • accurately measure using a micrometer and a vernier gauge  

 

  Section 3a - Shaping - Deforming/reforming (processes)

 

 bending, simple casting, lamination; vacuum forming; blow moulding; injection moulding;extrusion  

 

  Section 3b - Shaping - Wastage/addition (produce require shape, form or contour

 

  – use hand snips, saws, files, basic planes and abrasive cutters lamp, thingy

  – simple hole boring by hand or machine including pilot, clearance, lamp

  tapping, countersunk and counterbored holes  

  – use taps and dies for screw cutting by hand  

  – use planes, chisels, gouges, saws, files and raspslamp, thingy, pewter

  – use abrasive mops, discs and belts lamp, thingy

 

 Section 4 - Special treatments (processes that change molecular structure of a material making it more or less suitable for the task it has to perform).

 

  – work hardening  

  – annealing all metals  

  – case hardening of mild steel  

  – hardening and tempering tool steel (HCS)  

  • understand the term plastic memory and its significance  

 • understand steaming and bending of timbers and have knowledge of adhesives’ curing times and strengths  

     

 

 

 

  Section 5 - Joining and assembly (join parts of a design structure permanent or temporary)

 

  • understand methods of carcase, stool and frame construction Thingy, lamp

  using permanent and temporary joints  

  • use holding devices, formers and jigs to assist joining and  

  assembly  

  • understand the use of KD (knock-down) fittings for use with  

  modern materials such as veneered chipboard  

  • use a variety of fittings and adhesives thingy, lamp

 

  Section 6 - Finishing (surface treatments on materials)

 

  • Finishes - oils, paints,lacquers, stains, satin polishes, dipcoating thingy, lamp

     

 • be aware of surface finishes available for both interior and exterior use thingy

     

 • be aware of the special finishes available that will prevent corrosion or stains, or withstand heat or liquids  

     

MaterialsRevise physical properties and working properties and application inrelation to plastics, woods and metals. Thermoplastics (nylon, polythene, polyvinyl chloride (PVC), acrylic,Polystyrene, polypropylene)Question: Give examples of products made for each thermoplastic and one of theproperties that makes it a good use of material.Thermosetting plastics (polyester resin including GRP, melamine, urea,formaldehyde and phenol formaldehyde) Question: Give examples of products made from each thermosetting plastic and one of theproperties that makes it a good use of material.Classification, properties and uses of natural timbers.Show a working knowledge of the following manufactured boardsPlywood, blockboard, chipboard, hardboard and MDF.Question: Classification, property and use of MDF.Show a working knowledge of the following metals: Ferrous metals (mild and high carbon steels)Question:Non-ferrous metals (aluminium, duralumin and other common casting alloys, copperand its alloys, zinc, lead and tin) Question:

Thermoset plastics

• Polyester resin– With carbon fibre http://www.designboom.com/weblog/cat/8/view/

13310/audi-carbon-ski-update.html

Wastage/addition and joining methods

Select and perform the following forms of cutting and removal of material, and joiningand adding to a material to produce the required shape, form or contour: – use handsnips, saws, files, basic planes and abrasive cutters – simple hole boring by hand ormachine including pilot, clearance, tapping, countersunk and counterbored holes – usetaps and dies for screw cutting by hand – use planes, chisels, gouges,saws, files and rasps – use abrasive mops, discs and belts

Show tools: Pilot hole, Countersunk hole, Taps and dies - Page 64/65Activity: Students draw isometric drawings showing how two pieces of two byone pine can be joined using – nails, screws (look at two types of screws – slot and phillips head), nuts and

boltsActivity: Students draw isometric drawings showing how two pieces metal can be joined usingnuts and bolts, rivets (page 71), do sketch activity.

Milling machine and CNC millinghttp://www.youtube.com/watch?v=sxbiIpXZfG8&feature=related

http://www.technologystudent.com/equip1/vert1.htmhttp://www.technologystudent.com/equip1/vert2.htm

Question:1. Draw a simplified diagram of the vertical miller and label all the important parts.2. Explain the need for safety when using this type of machine. You may wish to describe the type of safety clothing required.3. Describe how you could use a vertical miller in one of your projects.

Shaping - Deforming/reforming

• understand the following processes: bending, simple casting, lamination; vacuum forming; blow moulding; injection moulding; extrusion

• Watch videos:• Questions: Vacuum forming• http://www.technologystudent.com/equip1/vacform3.htm• (check answers) -

http://www.technologystudent.com/equip1/vacfor3b.htm

Case study: Cutlery tray

• What forming/reforming process could be used to make this product?

• What plastic would this product be made from?

• Draw what the former would look like in isometric.

• What material would the former be made from and why?

• How would we make the former from on sheet of MDF.

• List factors to consider for the former in order to have a successful vacuum form.

Joining and assembling methods

Wood joints – edge joints

Ways of assembling moving parts – using hinges

Piano hinge Tee hinge

Other examples of hinges

http://www.technologystudent.com/joints/hinge1.htm

Question: Draw the hinge types and list two products that would include each hinge.

Tongue and groove joints, biscuit joints

Question: Draw the edge joints and name two products that would join wood in this method

• Starter activity – link up the different materials to adhesive types

http://www.technologystudent.com/joints/stglu1.htm

Joining and assembly• understand methods of carcase, stool and frame

construction using permanent and temporary joints

Show example products and talk about joints used – screw threads, rivets, screws, nuts and bolts

Movie on riveting:http://www.youtube.com/watch?v=8AZxlQwbrr4

Knock down fittings, permanent joints and adhesives, welding metals.

Setting/marking out

measure and/or mark out work using ruler, pencil, marker pen, scriber, try square, bevel, dot/centre punch, dividers, marking gauge, cutting gauge and mortise gauge Activity – collect images of tools:

Special treatments

• understand how the following processes can change the molecular structure of a material making it more or less suitable for the task it has to perform: – work hardening – annealing all metals – case hardening of mild steel – hardening and tempering tool steel (HCS)

• Find videos and research in workbooks:

Creating surfaces

• understand the use of datum surfaces/lines/edges and be able to produce them by planing or filing • explain the preparation for machine processes and safe methods of securing materials to work surfaces, work tables, faceplates, lathe chucks and between centres on a lathe

• Find video: on using a wood or metal lathe

Joining and assembly

• Use holding devices, formers and jigs to assist joining and assembly

Draw examples of jigs

Working with metals

• Bending is a process by which metal can be deformed by plastically deforming the material and changing its shape.

• Activity – find the other types of bending with metals.

• Pipe bending http://www.technologystudent.com/equip_flsh/pipe1.html

Finishing and protecting materials

• be aware of a range of different finishes including oils, paints, lacquers, stains, satin polishes, dipcoating

Activity:Watch video - dipcoating

Finishing and protecting materials

• be aware of surface finishes available for both interior and exterior use

• be aware of the special finishes available that will prevent corrosion or stains, or withstand heat or liquids

Activity – answer questions on metal finishing.