Some  revision  websites  to  test  you.    

h2p://www.bbc.co.uk/schools/gcsebitesize/design/resistantmaterials/  

h2p://yacapaca.com/py/teacher/assignment/new/tca/step2/213847/  

Assessment  revision  Make  sure  you  revise  for  Theory  paper  and  Design  paper  

Theory  paper  –  Important  informa,on  

One  hour  Only  answer  one  ques,on  from  Sec,on  B  –  Resistant  Materials  

ques,ons  

Design  paper  

Design  paper  –  Important  informa,on  

One  hour  15min  Only  answer  one  ques,on  (Answer  the  resistant  materials  

ques,on!!!)  

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 MDF classification, 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 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, 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 rasps lamp, 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

Materials  Revise  physical  properJes  and  working  properJes  and  applicaJon  in  relaJon  to  plasJcs,  woods  and  metals.    ThermoplasJcs  (nylon,  polythene,  polyvinyl  chloride  (PVC),  acrylic,  Polystyrene,  polypropylene)  QuesJon:  Give  examples  of  products  made  for  each  thermoplasJc  and  one  of  the  properJes  that  makes  it  a  good  use  of  material.  ThermoseTng  plasJcs  (polyester  resin  including  GRP,  melamine,  urea,  formaldehyde  and  phenol  formaldehyde)    QuesJon:  Give  examples  of  products  made  from  each  thermoseTng  plasJc    and  one  

of  the  properJes  that  makes  it  a  good  use  of  material.  ClassificaJon,  properJes  and  uses  of  natural  Jmbers.  Show  a  working  knowledge  of  the  following  manufactured  boards  Plywood,  blockboard,  chipboard,  hardboard  and  MDF.  QuesJon:  ClassificaJon,  property  and  use  of  MDF.  Show  a  working  knowledge  of  the  following  metals:    Ferrous  metals  (mild  and  high  carbon  steels)  QuesJon:  Non-­‐ferrous  metals  (aluminium,  duralumin  and  other  common  casJng  alloys,  copper  and  its  alloys,  zinc,  lead  and  Jn)    QuesJon:  

Thermoset  plasJcs  

•  Polyester  resin  – With  carbon  fibre    

h2p://www.designboom.com/weblog/cat/8/view/13310/audi-­‐carbon-­‐ski-­‐update.html  

Wastage/addiJon  and  joining  methods  Select  and  perform  the  following  forms  of  cuTng  and  removal  of  material,  and  joining  and  adding  to  a  material  to  produce  the  required  shape,  form  or  contour:  –  use  hand  snips,  saws,  files,  basic  planes  and  abrasive  cu2ers  –  simple  hole  boring  by  hand  or  machine  including  pilot,  clearance,  tapping,  countersunk  and  counterbored  holes  –  use  taps  and  dies  for  screw  cuTng  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  64/65  AcJvity:  Students  draw  isometric  drawings  showing  how  two  pieces  of  two  by  one  pine  can  be  joined  using  –  nails,  screws  (look  at  two  types  of  screws  –  slot  and  phillips  head),  

nuts  and  bolts  AcJvity:  Students  draw  isometric  drawings  showing  how  two  pieces  metal  can  be  joined  using  nuts  and  bolts,  rivets  (page  71),  do  sketch  acJvity.  

Milling  machine  and  CNC  milling  h2p://www.youtube.com/watch?v=sxbiIpXZfG8&feature=related  

h2p://www.technologystudent.com/equip1/vert1.htm  h2p://www.technologystudent.com/equip1/vert2.htm  

QuesJon:    1.  Draw  a  simplified  diagram  of  the  verJcal  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  verJcal  miller  in  one  of  your  projects.  

Shaping  -­‐  Deforming/reforming    

•  understand  the  following  processes:  bending,  simple  casJng,  laminaJon;  vacuum  forming;  blow  moulding;  injecJon  moulding;  extrusion  

•  Watch  videos:  

•  QuesJons:  Vacuum  forming  

•  h2p://www.technologystudent.com/equip1/vacform3.htm  •  (check  answers)  -­‐  

h2p://www.technologystudent.com/equip1/vacfor3b.htm  

Case  study:  Cutlery  tray  

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

•  What  plasJc  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  

h2p://www.technologystudent.com/joints/hinge1.htm  

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

Tongue  and  groove  joints,  biscuit  joints  

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

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

h2p://www.technologystudent.com/joints/stglu1.htm  

Joining  and  assembly  

•  understand  methods  of  carcase,  stool  and  frame  construcJon  using  permanent  and  temporary  joints    

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

Movie  on  riveJng:  h2p://www.youtube.com/watch?v=8AZxlQwbrr4  

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

SeTng/marking  out    

measure  and/or  mark  out  work  using  ruler,  pencil,  marker  pen,  scriber,  try  square,  bevel,  dot/centre  punch,  dividers,  marking  gauge,  cuTng  gauge  and  morJse  gauge    AcJvity  –  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:  

CreaJng  surfaces  

•  understand  the  use  of  datum  surfaces/lines/edges  and  be  able  to  produce  them  by  planing  or  filing  •  explain  the  preparaJon  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  plasJcally  deforming  the  material  and  changing  its  shape.    

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

•  Pipe  bending  h2p://www.technologystudent.com/equip_flsh/pipe1.html  

Finishing  and  protecJng  materials  

•  be  aware  of  a  range  of  different  finishes  including  oils,  paints,  lacquers,  stains,  saJn  polishes,  dipcoaJng    

AcJvity:  

Watch  video  -­‐  dipcoaJng  

Finishing  and  protecJng  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    

AcJvity  –  answer  quesJons  on  metal  finishing.