You can take your own notes into the exam'

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You can take your own notes into the exam. Use
the following notes to help you with your
research. More detailed information can be found
in your textbook GCSE ENGINEERING by Godfrey and
Wallis
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EXAM HINTS

• Read ALL the questions first and note which
  questions carry the most marks and which
  questions you are most confident in answering.
  With this in mind, attack these first making sure
  that you plan your time correctly to earn all the
  marks on offer.
• Read the question carefully - a common mistake is
  that a question may ask about CONTROL TECHNOLOGY
  and the students answer is about CAD. CAD is an
  example of ICT, not control technology. Control
  technology switches things on and off, alters
  speed,checks levels etc..
• When you read the question UNDERLINE or highlight
  KEY WORDS. Ie Describe three advantages of
  control technology used when making a gas
  barbecue.
• If the question asks about a specific product
  make sure your answer refers to that product. Try
  not to get side-tracked into discussing other
  examples.
• Dont rush, use all of your time to ensure you
  answer all parts of the question fully and to the
  best of your ability.
• Think carefully about answering the question
  before you put pen to paper. Look at your notes
  and use them as a prompt to answer the set
  question. Dont panic and answer the wrong
  question.
• Read your answer carefully and check that you
  have answered the key points that you have
  underlined when you first read the question.
• Check you have given a full answer that will earn
  all of the available marks.
• Write neatly and carefully, check your spelling
  and grammar.
• Sketch in pencil and put notes around the drawing
  to explain each feature.

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ANALYSIS OF BARBEQUE
The Top cover is hinged so that it can be lowered
to keep in the heat. It covers the cooking area
which is a metal grill situated above the gas
burner. Some barbecues use LAVA ROCK above the
burner. The gas bottle is stored in the cupboard.
The metal frame structure gives the unit strength
and stability. The side shelves are for storage
and must be easy to keep clean. The wheels make
it easy to move the unit. The top cover will get
very hot so all handles must be made from
materials that are poor conductors of heat. Hot
parts are usually coloured red to indicate
danger.
PARTS LIST PART FUNCTION MATERIAL Frame To
support all parts Steel or aluminium Doors To
give access to gas Sheet steel Door handles To
provide a grip, heat Plastic resistant Front
cover To cover grill, look good Sheet steel Side
panels Cover large area , Sheet steel Back
panel As sides Floor To support gas bottle Sheet
steel Top cover To cover grill, keep in heat
Pressed steel Side shelves Hardwood for easy
to clean Beach Handles Heat resistant, to move
the Steel tube unit Wheels To move the
unit Injection moulded plastic Castors To
steer the unit Polymer
Top cover
Handles
Side shelves
Frame
Door handles
Front cover
Doors
Wheels
Castors
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Study and understand the design and manufacture
of a range of mass produced products belonging to
and used in the Engineering Fabrication sector.
These products are generally made out of metal
and are joined by welding, riveting or nuts and
bolts. Modern materials like reinforced plastics
are replacing metals.
Filing cabinets Door handles Climbing
frame Weight lifting bench Gas barbecue Bike
frame Motor bike frame Metal frame table Metal
frame chair Metal tool box
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Name components and explain their use. You must
be able to recognise pictures of each component.
Add other components to this list.
COMPONENT USE SKETCH Nut Crown
nut Bolt Washer Locking pins Rivet (Type of
head) Pop rivet Bearing Wheel Cotter
pin Compression spring Hinges Self tapping
screw Split pins
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Q3 Might ask you to name a product from the
fabrication sector and explain what it does and
any special features it might have. (You could
use your clock as an example). You will be
expected to name the modern materials used in its
production and say why the material was suitable.
You will also be expected to say how CONTROL
TECHNOLOGY could be used in its production at the
DESIGN
MARKETING
PRODUCTION PLANNING
MATERIAL SUPPLY AND CONTROL
PROCASSING/ PRODUCTION
ASSEMBLY AND FINISH
PACKAGING AND DISPATCH
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Understand the use and benefits of information
and communications technology (ICT), including CAM
CAD generally refers to the software packages
that are used to produce high quality drawings
and computer generated models. You have used
prodesktop in designing your clock.

• ADVANTAGES OF CAD
• Produce drawings to a high standard of accuracy
  that can be repeated and scaled easily.
• It can produce drawings more quickly than manual
  methods.
• Drawings can be represented in 2D and 3D
• User friendly and requires less manual skill to
  produce high quality drawings.
• Drawings are easy to save and modify.
• Drawings can be saved and e-mailed around the
  world as well as being printed as hard copy.
• Standard parts such as nuts and bolts can be
  saved in a file and imported into drawings as
  they are required, saving time.

CAM is Computer Aided Manufacture.
This allows computers to be used to design,
develop and manufacture products.CAD software
converts the drawing into a NUMERIC code that can
be understood by machines like lathes, laser
cutters and milling machines. This process is
called COMPUTER NUMERIC CONTROL (CNC)
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• State three advantages of using robotics on a
  production line.
• Carry out hazardous operations such as handling
  toxic and radioactive materials.
• Work with great accuracy.
• Can repeat the same task without getting tired.

• INDUSTRIAL ROBOTS are used for-
• Material handling
• Spot welding
• Machining
• Spray painting
• Automated assembly
• Laser cutting.

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How is the door made?
How are the wheels fitted?
How do the hinges work?
How is the finish applied?
The doors could be manufactured from sheet steel
that once bent to shape could be given a
protective coating to prevent corrosion. Protectiv
e coatings could include painting, galvanising,
enamelling or a ceramic finish.
The frame of the barbeque could be made from
tubular steel or aluminium to provide a strong
lightweight structure.
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Each part of the barbecue could be made in the
same factory but it is more likely that some
components like the wheels, castors nuts and
bolts, handles etc. would be manufactured by
companies specialising in making that product.
To make any part the general stages in
manufacture would be-
DESIGN
ORDERING MATERIALS
QUALITY CHECKS MUST BE CARRIED OUT AT EACH STAGE
OF PRODUCTION
SETTING UP TOOLS
Marking out
Dispatch
Cutting and drilling
Assembly
Bending and joining
Finishing
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COMPUTER AIDED ENGINEERING (CAE) is the term used
to cover all CAD, CAM and CNC processes.
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ICT including CAD, communications technology,
control technology
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Use and impact, advantages and disadvantages of
the following technologies on the design and
manufacture of this type of mass produced gas
barbecue
Modern/smart materials and components
including Metals and ceramic coatings
Name all materials used for each part of the
barbecue.
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Understand the use and benefits of modern and
smart materials, including polymers, alloys and
ceramics.
Smart materials are modern materials that have a
built in memory. Some metals change length and
shape when an electric current passes through
them. When the current is removed the metal
returns to its original size or shape. Smart wire
and SHAPE MEMORY ALLOYS are used to make parts
move in robotics. Thermochromatic ink changes
colour with heat. This could be used to warn
people when materials get hot. Thermochromatic
plastic is used in making kettles that change
colour when the water is boiling.
POLYMERS are plastic materials that can be
THERMOPLASTICS, THERMOSETTING PLASTICS OR
ELASTIMERS
An ALLOY is a mixture of metals. The metals can
be designed to have special properties.
CERAMICS are things like pottery and porcelain
but can also be used as coatings to protect
metal like enamelling. A hard glass like finish
that can be coloured.
Make a list of each of the following materials
Smart materials. Polymers Alloys
Ceramics Composites. Ferrous Metals Non
Ferrous
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Use and impact, advantages and disadvantages of
the following technologies on the design and
manufacture of this type of mass produced gas
barbecue
Systems and control technology including-
Automation, quality control.
Make notes on AUTOMATION and production methods.
Handling materials. Conveyors are used on an
assembly line
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Understand the impact, advantages and
disadvantages of the use of modern technologies.
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