revision & course booklet, ks3 & ks4 - the bicester...

Revision & Course Booklet, KS3 & KS4

Bicester Community College ( 1)

KNOWLEDGE BANK This booklet is to be completed throughout KS3 & KS4 in conjunction with your course projects. The contents, worksheets on each piece of equipment and hand tool used with woods, metals and plas-tics, will enable you to not only learn about each item in detail through usage, but also to keep a rec-ord to refer to when revising for examinations.

Name

Date Grade Effort Positives Improvements and

Next steps



Knowledge Base: Checklist


Equipment Hand Tool Process

Wood

Wood Lathe Try Square Marking out board

Mortiser Marking Knife Marking out wood

Belt Sander Marking Gauge Process cutting

Band Saw Tenon Saw Straight cuts

Circular Saw Bench Hook Curved cutting

Planer/Thicknesser Coping Saw Planing

Router Jack Plane Lathing

Pillar Drill Smoothing Plane Mortising

Hand Drill Mallet Sanding

Hole Saw Lathe Cutting Tool Finger Joints

Flat Bit File Mitre Joints

Forstner Bit Chisel Halving Joints

Bench Vice Hand Drill Routing wood

Sash Cramp Hardwood

G-Cramp Softwood

Strap Cramp Plywood

MDF

Chipboard

Blockboard

Hardboard

Metal Equipment Hand Tool Process

Centre Lathe Scriber Marking out on metal

Brazing Forge Centre Punch Blueing

Chip Forge Engineers Square Cutting metal

Gabro Bender Dividers Smoothing Metal

Guillotine Hammer Brazing Process

Pillar Drill Hack Saw Flux

Twist Drill Junior Hack Saw Emery Cloth

Countersink File Carbon

Bench Vice Hand Drill Brazing Rod

Countersinking

Drilling




Plastic

Equipment Hand Tool Process

Strip Heater Junior Hack Saw Marking out on plastic

Plastic Oven Coping Saw Cutting Plastic

Injection Moulder Band Saw Smoothing Plastic

Gerbil Plastic Cutter Hand Drill Wet and Dry

Vacuum Former File Straight Bending

Hot Dip Press Moulding

Pillar Drill Vacuum Forming

Twist Drill Drilling

Countersink

Forstner Bit

Bench Vice



Name Process & How to use

Marking Knife

PVA Glue



In this section you will be asked to: produce a design specification produce a range of ideas develop one of your ideas evaluate your chosen idea.

Design Situation A survey carried out by a computer gaming magazine, has found that there is a real need for a storage unit that will hold a range of computer games equipment. Gamers have said that they often leave out their games equipment or store it in typical storage boxes, that are not always suitable. Design Brief A storage manufacturer has asked you to design a computer games equipment storage unit. The unit must hold the majority of the equipment shown below. It must be lockable, aesthetically pleasing and easy to transport.

Letter Specification Word Definition

A Aesthetics

C Cost

C Customer

E Environment

S Size

S Safety

F Function

M Material/Manufacture

Analysis of the Design Context Task: Read the design brief below, answer the examination style questions based on the design specification on the next page—10 minutes



You are advised to spend about 5 minutes on this question.

Give three design requirements of a computer games equipment storage unit.

Explain each of your answers.

An example has been completed for you.

Requirement: The storage unit should be designed/manufactured to protect the

contents.

Explanation: Protection of the contents is a key design requirement, especially if

the contents are expensive or easily damaged.

1 (a) Requirement 1 ................................................................................

Explanation .............................................................................................

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(2 marks) 1 (a) Requirement 2 ................................................................................

Explanation .............................................................................................

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(2 marks) 1 (a) Requirement 3 ................................................................................

Explanation .............................................................................................

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Question 1 is about the Design Specification.



Name Process & How to use

Emery Cloth

Layout Ink

Centre Punch



Isometric View Rendered View

Exploded View

Task: Attempt the exam questions on the following page – look at the mark allocation for each section and make sure that you read through them very carefully! – 30 Minutes.



Question 2 is about creative design.

You are advised to spend about 25 minutes on this question. Study the information given in the Design Brief ( p?/ ) a nd your Design Specification ( P ? ) . Use this information to help you sketch five different design ideas for a computer gam-ing storage unit. Marks will be awarded for creativity. ( 5 x 3 marks )

Question 3 is about developing the design.

You are advised to spend about 25 minutes on this question. Choose your best idea from Question 2. Use notes and sketches to show how you would develop the design features of your chosen computer gaming storage unit. Your developed design should include details of materials and finishes, method of con-struction and design features. You should include three important dimensions. Marks will be awarded for:

details of materials and finishes ( 3 marks) method of construction ( 3 marks) design features and sizes. ( 3 marks)

Question 4 is about evaluation.

You are advised to spend about 3 minutes on this question. Evaluate your developed de-sign (Question 3).

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The starter activity is about health and safety. You are advised to spend about 10 minutes on this question.

Complete the sentences below by adding the key words from the following list Dust mask ear defenders gauntlets apron goggles safety boots When using a pillar drill to drill wood you should ensure that you are wearing

……………………………………to protect your feet. ……………………………………to protect your eyes. ……………………………………to protect your breathing. ……………………………………to protect your hearing. ( 4 marks) Complete the table below by giving the meaning of each sign.

State an example of a situation where you would see these signs.

Sign

Meaning

Example

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Wood Equipment Name What does it do? How to use it?

Wood L......

Mortiser

Belt S.........

Circular saw

Planer Thicknesser

Forstner Bit



Woods and Boards There are two main types of wood - hardwoods and softwoods. Hard woods Hard woods come from broad leaved trees. These trees have flowers and produce seeds such as nuts and fruit) . Examples are oak, beech and mahogany. Hardwoods are denser than softwoods and are stronger and more durable too. They are used for furniture making. Beech is often used for making toys. Hardwoods are much more expensive than softwoods. Soft woods Soft woods come from cone bearing trees. Examples are pine, redwood and fir. Soft-woods can be used for furniture and doors but are mostly used in construction for roof trusses and stud partitions. Manufactured boards Manufactured boards are processed timber. They have new and useful properties. MDF ( medium density fibreboard ) is now widely used. Plywood made up from alternating layers of thin sheets of wood is strong in all directions. Chipboard made from softwood chips and sawdust is cheap but only attractive when coated with melamine – used for kitchen cupboards ( c arcases ) . Not all hardwoods are actually hard and not all softwoods are soft. GCSE Exam Practice Questions Describe, in as much detail as you can, the properties of beech

Give two uses for ash 1. 2. Match the use A, B, C and D with the woods 1-4 in the table, Enter the appropriate num-ber in the box A An Outdoor table

B A child ’ s toy

C A hockey tick

D An indoor dining table

1. Ash 2. Mahogany 3. Teak 4. Beech



Across 2. This type of tree have do not have a fruit or nut. 3. This hardwood grows a nut which is called an acorn 5. The layers in this board are bonded together in odd numbers, in a criss cross pattern. 8. This machine is used to drill holes in wood 11. This wood is chips bonded together with glue or resin. Down 1. This saw is used to cut straight lines in wood. 4. This wood is stable and wont warp 5. This hammer is used to knock pins into wood 6. Wood This a hard wood but is very soft 7. This wood is a softwood and is often used to make cheaper products 9. This saw is used to cut curves of narrow pieces of wood 10. These types of tree lose their leafs in winter. 12. This hardwood has antibacterial properties



Name of Joint Describe the tools Required






Machine presentation- Make a presentation about workshop machine you have used. Your presentation should contain the following information ( 2 0 minutes)

Name of machine

Picture of machine

Materials you can use on it

Specific processes where the machine might be used

Health and safety precautions required with the machine

Sketch and Name Materials Processes



The starter activity is about health and safety. You are advised to spend about 10 minutes on this question. Complete the sentences below by adding the key words from the following list.. Dust mask ear defenders gauntlets apron goggles safety mask When using a brazing hearth to join metals you should ensure that you are wearing

……………………………………to protect your hands. ……………………………………to protect your clothing. ……………………………………to protect your face. ……………………………………to protect your hearing. ( 4 marks) Complete the table below by giving the meaning of each sign. State an example of a

situation where you would see these signs.

Sign

Meaning

Precaution

6 x 1 mark



You are advised to spend about 20 minutes on this ques on. Study the wooden lamp shown below. Stem

Switch Base

Use notes and sketches to show clearly how you would make a batch of ten lamps in a school workshop. At each stage, name all the tools, equipment or so ware you would use.

Stage 1. Marking out or CAD (Computer Aided Design)

Stage 2. Cutting or shaping CAM (computer Aided Manufacture)

(4 marks)

(4 marks)



Stage 3: Show how the base could be joined to the stem

Stage 4: Show how the wires could be secured to the back of the switch



The activity is about materials.


Study the products shown below. Name one suitable, specific material which has been used to make each product. Give one reason for each choice. Give the original source of the material.

Material……………………………………

(2 marks)

Reason……………………………………. ……………………………………………… ………………………………………………

(1 mark)

Original source of the material

……………………………………………..

(1 mark)

Toy Digger

Material……………………………………

(2 marks)

Reason……………………………………. ……………………………………………… ………………………………………………

(1 mark)

Original source of the material

……………………………………………..

(1 mark)

Kitchen Stool



Work sheet on man made boards



This activity is about plastics.

Use your text book to help you answer the following questions (10 Minutes)

Where does plastic come from and explain how it is made

…………………………………………………………………………………...……………..

Explain what a thermoplastic is

…………………………………………………………………………………..…………......

Give 4 examples of thermoplastics

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Explain what a thermosetting plastic is

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Give 2 examples of thermosetting plastics

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Danny wants to stick together 2 pieces of acrylic, what glue could he use?

…………………………………………………………………………………..…………......

He now wants to finish the pieces of acrylic to a high standard, what could he do?

…………………………………………………………………………………..……………..

Tennis Racket

Nest of Tables

Food Storage Containers



Diagram or sketch Description of Process Example of Products

Press Moulding

Vacuum Forming

Blow moulding

Die Casting

Injection Moulding

Extrusion



This question is about sustainability.


Quality of Written Communication will be assessed in your answer.

Explain what is meant by the term ‘sustainability’. Give examples of products where sus-

tainability has been considered during their design, manufacture or use.

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(10 marks)



Thermo setting plastics Once 'set' these plastics cannot be reheated to soften, shape and mould. The mole-cules of these plastics are cross linked in three dimensions and this is why they cannot be reshaped or recycled. The bond between the molecules is very strong. Many adhesives (glues) are thermosetting plastics. A good example is ‘Araldite’ which is an epoxy resin that hardens when a second chemical is added (a catalyst). It will bond most materials including woods and metals as well as some plastics. Many adhesives (glues) are thermosetting plastics. Thermo plastics These plastics can be re-heated and therefore shaped in various ways. They be-come mouldable after reheating as they do not undergo significant chemical change. Re-heating and shaping can be repeated. The bond between the molecules is weak and be-come weaker when reheated, allowing reshaping. Thermoplastics tend to be composed of 'long chain monomers'. These types of plastics can be recycled.

Polyurethane

Melamine Formaldehyde

Urea Formaldehyde (UF)

Polyester resins

This forms the basis of many paints and varnishes because it is very tough and has water resistant qualities.

Used in the production of plastic laminates because of its smooth surface and hygienic qualities. It is also used in elec-trical plugs and sockets because it can be cast and it is an excellent insulator.

Urea Formaldehyde has physical properties of high hardness and high toughness, making it suitable for strong, knock-resistant electrical fittings. It is also scratch resistant and a very good electrical insulator, making electrical fittings manu-factured from this polymer safe to use.

If resins are combined with a material such as fibre glass the result is a very tough material that can resist impact. This type of material is known as a glass reinforced plastic (GRP) and is used in car body repairs, sailing boats, corrugated sheet because of its lightness, toughness and resistance to water.



This question is about sustainability and maintenance.

You are advised to spend about 15 minutes on this question. Study the mountain bike

shown below.

Identify three components found on the mountain bike that require maintenance. For

each component, describe the maintenance operation that should be carried out.

Explain why a designer should consider the importance of maintenance when designing

products.

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(8 marks)

Component Maintenance Operation

(1mark)

(2 marks)



Date Topic Covered in Lesson My confidence in

this topic JKL

revision & course booklet, ks3 & ks4 - the bicester...

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