TO THE

1
WELCOME
TO THE
RESISTANT MATERIALS
REVISION SESSION
2
ABOUT THE SESSION.
TO GIVE YOU BITESIZE CHUNKS OF INFORMATION
RELATED TO THE MAIN CONTEXT OF YOUR YEAR 11 EXAM
YOU WILL NEED TO TAKE NOTES ON EACH SECTION WRITE
DOWN ANY QUESTIONS YOU HAVE FOR THE END OF THE
SESSION
DONT PANIC - THE EXAM IS NOT TO TRICK
YOU! ONLY TO FIND OUT WHAT YOU ALREADY KNOW ABOUT
THE WORK YOU HAVE DONE IN KEY STAGE 4.
3
RECYCLING CONTAINERS AND THE ENVIRONMENT
MATERIALS FOR MAKING CONTAINERS MANUFACTURING
PROCESSES INDUSTRIAL PRACTICES SCALE OF
PRODUCTION HEALTH AND SAFETY SORTING OF WASTE
MATERIAL ENVIRONMENTAL ISSUES
ERGONOMICS AESTHETICS ICT CAD/CAM CNC -
CIM COSTS, PARTS COMPONENTS MAINTENANCE SUITABIL
ITY DESIGN REQUIREMENTS SOCIAL CONSIDERATIONS
THIS THE CONTEXT OF SOME QUESTIONS FOR SECTION
A. MAKE A STUDY OF WASTE DISPOSAL AND STORAGE
USED AROUND YOUR HOME AND OR SCHOOL. YOU MUST
TAKE COLOURED PENCILS IN TO THE EXAM.
4
MATERIALS
THERMOPLASTICS !!!
STUDY THE METHODS IN WHICH WASTE CAN BE SORTED
AND STORED LOOK AT THE EXAMPLES ON THE BACK OF
YOUR PREP SHEET HIGHLIGHT THE MATERIALS CHECK
THE PROPERTIES WITH YOUR TEXT BOOK.
LONG CHAIN MOLECULES !! GOOD AVAILABILITY
!! VARIETY OF COLOURS !! QUALITY FINISHES
!! EASY TO WORK WITH !! HIGH IMPACT STRENGTH
!! EASY TO CLEAN !! RESISTS CORROSION !! LOW IN
COSTS !! GOOD STRENGTH TO WEIGHT RATIO !!
QUALITY MATERIALS QUALITY PRODUCTS.
5
PROPERTIES
HARDWOODS.
SOFTWOODS.
BROADLEAF OR DECIDUOUS TREES GROW IN WARM
TEMPERATURES LOSE THEIR LEAVES IN WINTER GROW
SLOWLY 100YEARS MORE EXPENSIVE BETTER GRAIN
STRUCTURE FOR IMPROVED QUALITY FINISH
CONIFEROUS TREES GROW IN COLDER TEMPERATURES KEEP
THEIR LEAVES ALL YEAR ROUND GROW QUICKLY - 30
YEARS LESS EXPENSIVE READILY AVAILABLE GOOD
CONSTRUCTIONAL TIMBER AND GENERAL WOODWORKING
PROJECTS
6
PROPERTIES
NON-FERROUS
FERROUS
CONTAINS NO IRON LESS VULNERABLE TO CORROSION
RUST MAINLY PURE METALS CAN BE MIXED WITH ONE
ANOTHER TO OBTAIN REQUIRED CHARACTERISTICS. ALL
ARE GENERALLY EASY TO WORK WITH
CONTAINS IRON VULNERABLE TO CORROSION
RUST MIXED WITH CARBON TO OBTAIN ALLOY STEELS OF
VARYING STRENGTHS ONLY MILD STEEL IS EASY TO WORK
WITH
COMMON TO BOTH ELASTICITY PLASTICITY MALLEABILITY
DUCTILITY HARDNESS TOUGHNESS
7
DESCRIPTIONS
DUCTILITY THE ABILITY TO UNDERGO COLD PLASTIC
DEFORMATION
ELASTICITY THE ABILITY TO FLEX AND BEND WHEN
FORCED.
COMMON TO BOTH ELASTICITY PLASTICITY MALLEABILITY
DUCTILITY HARDNESS TOUGHNESS
PLASTICITY ABILITY TO BE CHANGED PERMANENTLY
THROUGH EXTERNAL BLOWS
HARDNESS THE ABILITY TO RESIST WEAR AND
ABRASION USUALLY BRITTLE
MALLEABILITY THE EXTENT TO WHICH A MATERIAL CAN
PERMANENTLY DEFORM IN ALL DIRECTIONS WITHOUT
CRACKING
TOUGHNESS THE ABILITY TO WITHSTAND SUDDEN
SHOCKS OR IMPACT. RESISTS CRACKING WHEN BENDING
8
PROPERTIES
THERMOSETTING
THERMO
LONG CHAIN MOLECULES THAT ARE ENTANGLED BUT
FLEXIBLE CAN BE RE-SHAPED WITH LITTLE
HEAT VARIETY OF COLOURS PLASTIC MEMORY THAT
ALLOWS THEM TO RETURN TO ORIGINAL SHAPE
LONG CHAIN MOLECULES THAT ARE CHEMICALLY BONDED
TOGETHER RIGID AND NON FLEXIBLE HIGH RESISTANCE
TO HEAT GOOD ELECTRICAL INSULATORS
9
CONSTRUCTION TECHNIQUES.
PLASTICS
WOODS
METALS
TENSOL CEMENT INJECTION MOULDING VACUUM
FORMING STRIP / LINE HEATING ULTRA-SONIC WELDING
FRAME JOINTS BOX JOINTS EDGE JOINING NAILS
SCREWS KNOCK DOWN
SOLDERING WELDING RIVETTING NUTS BOLTS
10
MORTISE AND TENON REQUIRES A TENON SAW AND
ACCURATE MARKING OUT
DOWELLED JOINT BUTT JOINTS REINFORCED WITH
DOWELS FOR STRENGTH
WOODS
TENON
FRAME JOINTS BOX JOINTS EDGE JOINING NAILS
SCREWS KNOCK DOWN
DOWEL
MORTISE
NAILS SCREWS USED TO HOLD ITEMS TOGETHER
WHILST GLUE SETS TEMPORARY FIXING
COMB JOINT ATTRACTIVE JOINT WITH STRENGTH FROM
LARGE GLUEING AREA
HOUSING JOINT USED FOR SHELVES AND
PARTITIONS. POSITIVE SUPPORT
FINGER
HOUSING
POSITIVE SUPPORT
11
METALS
SOLDERING INCLUDES - SOFT SOLDERING SILVER
SOLDERING BRAZING SOFT SOLDERING QUICK AND
EASY METHOD OF JOINING COPPER, BRASS AND TIN
PLATE SILVER SOLDERING JOINTS ARE BUILT UP IN
DECREASING TEMPERATURES BRAZING ALLOY OF COPPER
AND ZINC. VERY HIGH TEMPERATURE ALL REQUIRE FLUX
TO HELP KEEP JOINT CLEAN AND STRONG.
RIVETTING NUTS BOLTS - ROUND HEAD REQUIRES
AN ENGINEERS (BALL PEEN HAMMER) AND RIVET SET
(DOLLY) TO ROUND OVER THE HEAD OF THE RIVET POP
RIVET QUICK AND EASY METHOD OF JOINING THIN
PLATE. WEAKER THAN A SOLID ROUND HEAD RIVET. NUTS
BOLTS A TEMPORARY FIXING THAT RELIES ON
FRICTION TO HOLD PARTS TOGETHER. HOLDING THROUGH
MECHANICAL ADVANTAGE OF SCREW THREADS.
SOLDERING WELDING RIVETTING NUTS BOLTS
WELDING INCLUDES FOLLOWING OXYGEN ACETYLENE
VERY HOT FLAME USING BURNING GASES TO MELT BOTH
PARENT METAL AND FILLER ROD MAINLY THIN PLATE
WORK. ELECTRIC ARC USES ELECTRICAL CURRENT
(ARC) TO CREATE HEAT ENOUGH TO FUSE TOGETHER
PARENT METALS CAN BE USED FOR LIGHT AND HEAVY
PLATE WORK.
12
PLASTICS
TENSOL CMENT 70
TENSOL CEMENT 12
A SOLVENT BASED ADHESIVE. NOT VERY STRONG. WORKS
BY ATTACKING THE SURFACE OF THE ACRYLIC TO BOND
THEM TOGETHER. SUPPLIED READY TO USE AND SETS
QUICKLY
A POLYMERISING ADHESIVE LIKE LIQUID ACRYLIC
THAT LINKS WITH THE MATERIAL RESULTING IN A JOINT
THAT IS NEARLY AS STRONG AS THE ACRYLIC ITSELF.
NEEDS CAREFUL MIXING AND A LONGER SETTING TIME.
TENSOL CEMENT DRILLED AND JOINED WITH MACHINE
SCREWS
MAKE SURE YOU SUPPORT THE UNDERNEATH OF THE
PLASTIC BEFORE DRILLING DO NOT OVER TIGHTEN TO
AVOID CRACKING THE MATERIAL.
13
PROCESSES
WOODS
METALS
PENCIL, RULER, TRY SQUARE, MARKING GAUGE, MARKING
KNIFE.
SCRIBER, ENGINEERS SQUARE, STEEL RULER, CALIPERS,
DOT PUNCH, DIVIDERS.
HACKSAW, TIN SNIPS, COLD CHISELS, ABRAFILE
TENON SAW, COPING SAW, FRET SAW, BENCH HOOK,
MITRE BLOCK
COMMON TO ALL MARKING OUT CUTTING TO
SIZE SHAPING/FORMING JOINING FINISHING
FORGING, PRESSING, BENDING, TURNING, MILLING,
DRILLING
SANDING MACHINE, JACK PLANE, CHISEL, MALLET,
SPOKESHAVE, TURNING, DRILLING.
GLASS PAPER, VARNISH, PAINTS, POLISH, WAX.
EMERY CLOTH, WIRE WOOL, PAINT, POLISH, DIP
COATING.
14
PLASTICS
MUST HAVE PAPER BACKING LEFT ON. - PENCIL,
CHINAGRAPH OR SPIRIT PEN, SCRIBER, RULER, TRY OR
SET SQUARE, MOST METAL WORK MARKING OUT TOOLS.
STRIP BENDER/HEATER, VACUUM FORMER, INJECTION
MOULDING, CASTING. GO TO TECHNOLOGYSTUDENT.COM TO
SEE VIDEOS OF THESE PROCESSES.
DRAW FILING, EMERY CLOTH, WET AND DRY, POLISH,
HACKSAW, COPING SAW, BAND SAW, HAND FILES,
COMMON TO ALL MATERIALS JIGS AND FORMERS USED TO
MAINTAIN ACCURACY FOR MARKING OUT, CUTTING AND
SHAPING. ESSENTIAL TO REPEAT ACCURACY OF PARTS
THAT GO TOGETHER TO MAKE COMPLETE UNIT.
MARKING OUT CUTTING TO SIZE SHAPING/FORMING JOININ
G FINISHING
15
SCALE OF PRODUCTION
ITEMS THAT ARE PRODUCED (MADE) SINGLY. POSSIBLY
DUE TO THE NATURE OF THE PRODUCT, E.G. BRIDGES,
SATELLITES, JEWELLERY, WEDDING DRESSES, MACMILLAN
COLLEGE AND OF COURSE YOU - SAFETY AND
RELIABILITY ARE OFTEN OF HIGH PRIORITY THAN
COSTS, ALSO HIGH AESTHETIC CONSIDERATIONS.
ONE OFF PRODUCTION
A SYSTEM OF PRODUCING IDENTICAL ITEMS IN FIXED
NUMBERS FOR A SPECIFIC CLIENT. E.G. SCHOOL TIES,
FURNITURE, DESIGNER CLOTHING, ITEMS WITH CLIENT
LOGO RATHER THAN MAKERS LOGO. WHEN THE BATCH IS
COMPLETE, THE TOOLS USED CAN BE USED TO PRODUCE A
BATCH OF DIFFERENT PRODUCTS.
BATCH PRODUCTION
MASS PRODUCTION
PRODUCING ITEMS IN VERY HIGH QUANTITIES THAY CAN
RECOVER THE COSTS OF TOOLING UP. COST OF
MANUFACTURE IS AS LOW AS POSSIBLE. E.G. CARS,
BIROS, CHOCOLATE BARS, SCHOOL SHIRTS, CDS. NO
FIXED NUMBER AND NO SPECIFIC CLIENT.
16
DISABLED ACCESS REQUIRED
HEALTH AND SAFETY
THE EXAM WILL BE LOOKING FOR MORE THAN JUST THE
BASIC UNDERSTANDING OF WEAR GOGGLES, TIE YOUR
HAIR BACK, WEAR AN APRON. IT WILL BE CONCERNED
WITH RESPONSIBILITY FOR HEALTH AND
SAFETY I.E. AWARNESS OF SAFETY SIGNS AND THEIR
MEANINGS LEGISLATION REGARDING ROOM
LAYOUT POSITIONING OF SAFETY EQUIPMENT SAFETY
GUARDS AND USAGE SPEEDS OF MACHINERY TRAINING
PROGRAMMES
ADEQUATE SPACE FOR WALKWAYS BETWEEN TABLES
WHERE THE EMERGENCY STOP BUTTONS AND FIRE
EXTINGUISHERS ARE LOCATED.
THAT THEY ARE IN TACT AND MOVE FREELY. SIGNS IN
PLACE INFORMING THEIR USAGE
THAT REVOLVING CUTTERS CAN BE ADJUSTED MANUALLY
ACCORDING TO THE SIZE OF MATERIAL OR HOLE TO BE
CUT
MAKING USE OF TRAINING TO ENABLE SAFE USE OF
MACHINERY AND EQUIPMENT GET SUPERVISION.
17
MARKETING
USING COMPUTERS IN DESIGNING
INTERNET RESEARCH - VISITING THE CLIENT .
GRAPHICAL RESULTS OF YOUR QUESTIONNAIRE
INFORMATION FOR YOUR SPECIFICATION LIST.
LETTERS TO CLIENTS FINDING OUT THEIR NEEDS .
FEEDBACK TO LET YOU KNOW THAT YOUR IDEAS ARE
ACCEPTABLE BY THE CLIENT/CUSTOMER VALUABLE
INFORMATION BEFORE YOU GO TO MANUFACTURING STAGE.
QUESTIONNAIRES TO CUSTOMERS. FINDING OUT WHAT
THEY WANT COSTS, MATERIALS, SIZES, APPEARANCE,
COLOUR ETC.
WORKING DRAWINGS. INFORMATION TO HELP MAKE YOUR
IDEAS.
IS THE STORAGE SYSTEM SUITABLE FOR A PROMOTIONAL
GIVE AWAY?
18
ERGONOMICS AND ANTHROPOMETRICS

• THE SCIENCE CONCERNED WITH MEASURING PEOPLE AND
  HOW THEY WILL FIT THE PRODUCT.
• STATIC DIMENSIONS TAKEN WHEN A PERSONS BODY IS
  IN A FIXED POSITION. STANDING, HOLDING TOOLS ETC.
• DYNAMIC DIMENSIONS TAKEN DURING MOVEMENT.
  CONCERNED WITH THE AREA OF REACH FOR ARMS AND
  LEGS.

• THE PRODUCT IN RELATION TO ITS ENVIRONMENT (E
  E) AND ITS USER.
• HUMAN PHYSIQUE HEIGHT, WEIGHT, RANGE OF REACH
  AND MOVEMENT.
• HUMAN ABILITIES STRENGTH, POSTURE, RANGE OF
  MOTION.
• HOW THE PRODUCT FITS IN WITH ITS SURROUNDINGS
  LOOKS, SIZE, FEEL, COMFORT ETC.

ERGONOMICS USES ANTHROPOMENTRICS YOU CANNOT
DESIGN A PRODUCT WITHOUT FIRST MEASURING THE
USER THIS WILL BE IMPORTANT WHEN THINKING ABOUT
THE HAND ACCESS TO ALLOW RETRIEVAL OF THE CD BOXES
19
AESTHETICS
IT IS NOT JUST HOW THE PRODUCT LOOKS.
HOW IT LOOKS IN RELATION TO OTHER ITEMS IN THE
ROOM E.G. COOKER, FRIDGE, WASHING MACHINE
COMPUTER, STERIO, IPOD ETC.
AESTHETICS
WHAT DOES IT FEEL LIKE TEXTURE, SMOOTH, CLEAN,
HYGIENIC ETC.
ARE THE SIZES CORRECT AND IN RELATION TO ONE
ANOTHER HEIGHT, WIDTH, THICKNESS. DO BOTTLES,
CANS, PAPER ETC HAVE SEPARATE STORAGE
APPEARANCE COLOURS, SHADES, STYLE, CULTURE,
THEME, VALUE FOR MONEY.
AN OPINION OF THE WHOLE PRODUCT I.E. IS IT
SUITABLE FOR THE PURPOSE???
20
COSTS
MANUFACTURING CUTTING TO SIZE, CLEANING, SHAPING,
ASSEMBLY, FINISHING, RUNNING COSTS.
SALES RECOVERING MAKING COSTS, MAKING A PROFIT,
REPLACING PARTS ETC.
MATERIALS RAW MATERIAL COSTS, TREATING COSTS, HOW
MANY COMPONENT PARTS CAN BE MADE?
HOW MANY CONTAINERS CAN BE MADE FROM ONE SHEET OF
MATERIAL??
DURABILITY
THE LIFE EXPECTANCY OF A PRODUCT OR MATERIAL THE
ABILITY TO WITHSTAND WEAR AND TEAR, WEATHERING
AND DETERIORATION THROUGH CORROSION PREVENTING
CHANGES IN APPEARANCE AND STRENGTH.
21
SOCIAL CONSIDERATIONS
CAN THE MATERIALS BE REPLACED? REUSED, RECYCLED.
WHAT IS THE TURNAROUND TIME?????
WHAT EFFECT ON THE ENVIRONMENT FEWER TREES,
FEWER NATURAL RESOURCES. DAMAGE TO OZONE LAYER
THROUGH SPRAY FINISHES ?????
WHICH ONE ??????
CAN EVERYONE AFFORD THE LUXURY IS THERE AN
ALTERNATIVE. ARE STANDARDS OF LIVING MORE
IMPORTANT THAN LIFE ITSELF?????????
22
A MILD STEEL JIG WILL HELP KEEP ALL PARTS
IDENTICAL. SIZE, SHAPE AND HOLES POSITION
A DEVICE THAT ENSURES REPEAT ACCURACY OF
COMPONENT PARTS. IT IS AS UNIQUE AS THE PRODUCT
OR PART ITSELF.
JIGS AND FIXTURES
ALL SECTIONS ARE IDENTICAL IN SHAPE, SIZE AND
HOLE POSITIONS.
LOCATING TABS
JIG OR FORMER
A more durable material Increases life
expectancy. Improved accuracy. Batch producing
facility Quality control check
TUBULAR MILD STEEL FRAME SHAPED AROUND JIG TO
MAINTAIN REPEAT ACCURACY
GRIPPED SECURELY USING MECHANICAL SCREW THREAD
BUT HOW CAN IT BE IMPROVED ???
HOLDING SECURELY!!
23
BASIC MECHANISMS

• ALTHOUGH DESIGNED TO DIFFERENT JOBS, ALL
  MECHANISMS HAVE 5 THINGS IN COMMON.
• THEY MAKE A JOB EASIER TO DO.
• THEY INVOLVE SOME KIND OF MOVEMENT.
• THEY INVOLVE SOME KIND OF FORCE.
• THEY NEED SOME KIND OF INPUT.
• THEY PRODUCE SOME KIND OF OUTPUT.

• EASY GRIP
• MOVING JAWS
• TURNING FORCE
• TWISTING HANDLE
• ROTARY TO LINEAR

RACK PINION
CAMS AND FOLLOWERS
CRANK ROTATES ANY DIRECTION TURNED USING A
HANDLE
FOLLOWS THE MOVEMENT OF THE CAM CHANGES ROTARY
MOTION TO LINEAR OR RECIPROCATING MOTION
TABLE MOVES UP AND DOWN WITH A RECIPROCATING
MOTION
THE CAM - TAKES IT NAME FROM ITS SHAPE E.G.
PEAR CAM
24
PROBLEM THE TASK IN HAND
THE DESIGN PROCESS
WHAT WOULD YOU DO DIFFERENTLY WHAT ARE THE NEW
PROBLEMS?
ANALYSIS INVESTIGATE WHAT NEEDS TO BE DONE
PROBLEM
ANALYSIS
EVALUATING
BRIEF WHAT YOU WILL DO
RECORD ANY CHANGES YOU MAKE
BRIEF
THE DESIGN WHEEL
MODIFYING
RESEARCH YOUR FINDINGS
RESEARCH
PROTOTYPE OF THE IDEA
MAKING
SPECIFICATION
SPECIFICATION WHAT THE PRODUCT MUST BE AND WHAT
IT MUST DO.
DEVELOPMENT
DESIGN IDEAS
ALL THE STEPS NEEDED TO MAKE YOUR CHOSEN
IDEA TOOLS AND EQUIPMENT ETC.
CHOSEN IDEA
SKETCHES OF POSSIBLE SOLUTIONS TO THE PROBLEM
THE BEST IDEA TO DEVELOP FURTHER
25
EXAM TECHNIQUE
IMPORTANT REMEMBER THE EXAM IS 2 HOURS LONG
GET PLENTY OF SLEEP THE NIGHT BEFORE
YOULL FEEL ON TOP OF THE WORLD
HAVE SOMETHING TO EAT
KEEP BODY AND SOUL TOGETHER TO ALLOW THE MIND TO
FUNCTION CORRECTLY
YOU CANT ANSWER CALLS OF NATURE ONCE THE EXAM
HAS STARTED
MAKE SURE YOU GO TO THE TOILET BEFORE THE EXAM
26
EXAM TECHNIQUE
Practice drawing using Isometric grids.
1. Start with a basic regular shape
2. Make the shape softer or rounder
3. Expand the product to include boxes in
different positions
Consider Dimensions, hidden detail,
construction lines, view points.
4. Label 5 points of Annotation and 5 points of
evaluation. Sizes, colour, processes, materials,
properties, functions etc.
5. Try producing an Orthographic drawing of your
final solution
27
EXAM TECHNIQUE
1. SCAN READ THE WHOLE PAPER BEFORE YOU ANSWER
ANY QUESTIONS THIS WILL GIVE YOU THE CONTEXT OF
THE PAPER.
2. USE A HIGHLIGHTER PEN TO IDENTIFY KEY POINTS
OF THE QUESTION.
3. READ 2 QUESTIONS AHEAD BEFORE ANSWERING THIS
WILL HELP AVOID REPEATING PREVIOUS ANSWERS AND
SAVE TIME.
4. LOOK OUT FOR QUESTIONS WITHIN QUESTIONS I.E.
WHERE MORE THAN ONE ANSWER IS ASKED FOR
5. NEVER LEAVE BLANK SPACES MARKS ARE ALWAYS
AWARDED FOR ATTEMPTED QUESTIONS YOU MIGHT GUESS
CORRECTLY!!
6. TAKE TIME BEFORE THE END TO PROOF READ YOUR
ANSWERS IF IT DOES NOT MAKE SENSE TO YOU IT
WONT TO THE MARKER
7. ABOVE ALL - DONT PANIC. IF YOURE STUCK,
MOVE ON TO THE NEXT QUESTION YOU CAN ALWAYS GO
BACK LATER.
28
REVISION WEBSITES

• http//www.btinternet.com/hognosesam/elpinands/ma
  inmenu.htm
• Google images of CD, DVD etc holders.
• BBC-GCSE BITESIZE.
• LEARN.CO.UK
• REVISION-NOTES.CO.UK
• TOPMARKS
• SAM LEARNING
• www.the-warren.org

29
BEST OF LUCK WITH ALL YOUR EXAMS
TODAY IS THE FIRST DAY OF THE REST OF YOUR LIFE
MAKE IT COUNT