Flashcards
Product Design Theory
Cards in this deck (176)
- 1Physical Properties of MaterialsHow a material behaves under a specific condition
- 2AbsorbencyA material’s ability to soak up and retain liquid
- 3Resistance to moistureA material’s ability to prevent liquid and moisture permeating its surface
- 4DensityA material’s mass per unit volume
- 5Electrical ConductivityHow easily electrical energy can pass through a material
- 6Thermal ConductivityHow easily heat energy can pass through a material
- 7StrengthThe ability of a material to withstand a constant force without breaking.
- 8TensionPulling material apart
- 9CompressionPushing material together
- 10ShearMoving one part of the material in one direction and another part in the opposite direction
- 11TorsionTwisting material
- 12BendingCompressing one side of the material while putting the other side on tension
- 13HardnessThe ability of a material to withstand scratching, cutting and abrasion
- 14ToughnessA material’s ability to withstand impact from a dynamic force
- 15MalleabilityA material’s ability to be permanently deformed or shaped by impact, rolling or pressing without breaking
- 16DuctilityA material’s ability to be drawn or pulled in to a long length or wire without breaking
- 17ElasticityA material’s ability to stretch under force and return to its original shape without deformation when the force is removed
- 18What are paper and boards made of?Wood pulp (cellulose and water)
Sometimes hemp, flax, bamboo, sugarcane & staw - 19Bleed proof paperWhite paper that is coated and used for marker pens with final designs
- 20Cartridge paperThick white paper that is 120-150 gsm and is completely opaque for pencil and ink sketching
- 21Grid paperWhite paper with a printed pattern that is 80 gsm and is used for scientific or mathematical diagrams
- 22Layout paperOff-white medium opacity paper that is semi-transparent for sketches and ideas
- 23Tracing paperoff-white, low opacity paper that is used for tracing an image.
- 24Corrugated cardboardNatural brown board that is strong and lightweight for packaging, boxes and impact protection
- 25Duplex boardTwo layers of card bonded together that is stiff and lightweight with layers and is used for food and drink containers
- 26Foil lined boardWhite card coated with aluminium foil to reflect heat for takeaway containers and to retain heat
- 27Foam core boardSmooth board with an inner foam core that is lightweight and rigid to hold pressure for models and prototyping
- 28Inkjet cardWhite card treated with a smooth finish for high-quality photographic images
- 29Solid white boardHigh-quality card with a white finish that is used for cards and packaging
- 30Classification of SoftwoodConiferous trees
(Evergreen, needles)
- Quick growing
- Seeds housed in cones
- Used in joinery
- Less expensive
- Poor resistance to decay - 31Name some types of softwoodLarch
Pine
Spruce - 32Classification of HardwoodDeciduous trees
(loose leaves in winter, broad leaves)
- Clow growing
- Seeds housed in fruit
- More expensive
- Good resistance to decay - 33Name some types of hardwoodOak
Beech
Mahogany - 34Manufactured timberLaminated boards or compressed boards
- 35Advantages of manufactured timberAvailable in large sheets, consistent properties and can be recycled from bad timber. They also are suited to CNC machining
- 36Name some types of manufactured timberPlywood
MDF (Medium-density fibreboard)
Chipboard - 37Ferrous metalIn Earth's crust is a rock called hematite (iron ore)
Contains iron (magnetic)
Will rust - 38Name some examples of ferrous metalCast iron: Hard surface, brittle core
Low carbon steel: Good tensile strength, malleable, corrosive
High Carbon Steel: Harder than LCS but brittle - 39Non-ferrous metalIn Earth's crust in a rock called ore
No iron (not magnetic)
Will not rust - 40Name some examples of non-ferrous metalAluminium: Lightweight, soft, ductile and malleable
Copper: Ductile, malleable, excellent conductor
Zinc: Highly corrosion resistant, low melting point, weak
Tin: Highly corrosion resistant, low melting point, weak - 41AlloyMixture of two or more metals combined to improve properties
- 42Name a ferrous alloyStainless Steel - Mixture of steel, chromium, nickel and magnesium. Hard, corrosion-resistant
- 43Name some non-ferrous alloysBrass - Mixture of copper and zinc. Corrosion-resistant, strong, ductile, malleable
Duralumin - Mixture of aluminium, copper, magnesium and manganese. Lightweight, soft, ductile, malleable - 44Thermoforming materialCan be softened with the use of heat and moulded into shape
- 45Thermosetting materialOnce moulded into shape, cannot be remoulded with the use of heat
- 46Acrylic (PMMA)Hard, shiny and flat surface that can scratch easily. Can be transparent, translucent or opaque.
(Thermoforming) - 47High Impact Polystyrene (HIPS)Tough, easily moulded and durable
(Thermoforming) - 48High Density Polythene (HDPE)Hard, stiff and resistant to chemicals
(Thermoforming) - 49Polypropylene (PP)Tough, durable, good heat and chemical resistance
(Thermoforming) - 50Polyvinyl Chloride (PVC)Hard, tough, good chemical and weather resistance. Low cost due to high volume production
(Thermoforming) - 51Polyethylene terephthalate (PET)Tough, durable, food-safe, easily moulded
(Thermoforming) - 52Epoxy resinEasily moulded. Two-part liquid. When mixed, the resin sets hard and is good at insulating
(Thermosetting) - 53Melamine formaldehydeStiff and hard-wearing with good resistance to heat and staining
(Thermosetting) - 54Phenol formaldehydeHard, good electrical and heat insulator
(Thermosetting) - 55Polyester resinEasily moulded, from a two-part liquid. Sets hard and brittle
(Thermosetting) - 56Urea-formaldehyde (UF)Stiff, hard and excellent electrical insulator
(Thermosetting) - 57PlasticisersMake polymers soft and pliable
- 58PigmentsAdded to polymers to change their colour
- 59StabilisersAdded to polymers to help them withstand degradation from UV light
- 60FillersAdded to polymers to increase their bulk, which improves their resistance to impact
- 61FibresFine, hair-like threads. Can be natural or synthetic
- 62Name some natural fibresCoton
Wool
Silk - 63Name some synthetic fibresPolyester
Polyamide (nylon)
Elastane - 64Mixed/blended fibreMade by spinning fibres together to make yarn
(Most modern fabrics have multiple types of fibre) - 65Features of blended fibresReduce cost
Make stronger
Make easier to care
More crease-resistant
Allow fabrics to be heat-set - 66Name some blended fibresPolyester/cotton
Lycra
Wool + Nylon - 67Woven fabricsProduced by interlacing two sets of yarn at right angles on the loom
Warp yarns run the length
Weft yarns run the width
At the edge, yarn turns round. Finished edge called selvedge
Warp yarns called straight grain (strongest)
Weft yarns unfinished edge called the raw edge
Interlacing makes it stronger and stable as do not stretch. Still stretch diagonally. Called the bias of the fabric - 68Why are plain weave fabrics good?Simplest and cheapest to produce
Strong and hard-wearing
Look same from both sides
Smooth and plain - 69What are the two non-woven fabricsBonded fabrics
Felted fabrics - 70Bonded fabricsMade from webs bonded by adhesive, thermal bonding or stitching
Cheap
Easy to sew
Doesn’t fray
Not as strong as woven fabrics
Used for interlacing and disposable items - 71Felted fabricsNatural felting ability of wool cause fibres to bond using heat, mechanical action and moisture
Warm and soft
Doesn’t fray
Not as strong as woven fabrics
Expensive - 72Knitted fabricsYarns looped together to make more flexible fabrics
- 73Weft KnitsStretchy, soft, doesn’t crease, warm, ladders easily
For socks, t-shirts, jumpers etc. - 74Warp KnitsFirm and doesn’t ladder
For swimwear, underwear, net curtains - 75GrapheneDeveloped in 2004. Difficult to manufacture
Super capacitive
Electroconductive
Biodegradable
200x stronger than steel
Takes any shape
Ultra-lightweight - 76Metal FoamsDeveloped in 2011. Sponge-like. Made by passing gas through the liquid metal
Strong
Lightweight
Thermally conductive
Very porous
Good sound absorption
Excellent energy absorption - 77TitaniumVersatile base metal. Alloyed with other metals to enhance its properties
Pure titanium used orthopaedic implants because doesn’t react with the human body
Easily polish
High strength-to-weight ratio
Easily formed and welded
Hypo-allergenic
Used for expensive items - 78Coated MetalsAnodised aluminium: Thick oxide layer which can be coloured
Nickel-plated steel: Uses electrolysis to add a nickel to cheap material. For corrosion resistance or aesthetics.
Polymer-coated aluminium: dip coating or powder coating aluminium. Polythene used as a coat for grip or stop scratches. - 79Liquid Crystal Display (LCD)Made of laminated material of two layers
When power, lets light through
Low power consumption - 80NanomaterialsLess than 100 nanometers wide
Exist on an atomic or molecular scale
Used in sports equipment to add strength
Used in clothing - 81Smart MaterialsReacts to external input. Changes look or function dependent on the environment
React to stimuli such as heat, pressure or moisture - 82Thermochromic PigmentsReact to change in temperature
When the temperature reached, changes in colour
Pigment in material
Often for babies’ feeding spoons to indicate if too hot - 83Photochromic PigmentsReact to UV rays and change colour
Usually in colour changing nail varnish, T-shirts
Particles such as silver halides found in sunglasses and darken clear glass when exposed to UV light - 84Shape Memory AlloysMost materials have memory and spring back to original shape
Nitinol - Alloy of nickel and titanium. Used in braces. Also used in surgical stents to expand blood vessels. Responds to electrical current and causes it to contract - 85How are composite materials formed?Two or more different materials combined together to make a new material with improved properties
- 86How is Glass-Reinforced Plastic (GRP) & Carbon Reinforced Plastic (CRP) made?1. Stainless steel mould coated with the resin layer
2. Glass fibre or carbon fibre matting laid on top
3. Another coat of resin applied
4. Repeated until the thickness and strength of material created - 87Glass Reinforced PlasticCovered with smooth plastic resin which sets hard and glossy
Easy to manufacture complex-shaped
Lightweight, corrosion-resistant and chemical resistant
Labour-intensive to produce
Used to make boat hulls, car body parts, storage tanks, seatings, helmets - 88Carbon Fibre Reinforced PlasticForm a cloth woven from strands
Vinyl decals added for decoration
Good strength to weight ratio
High tensile strength
Very expensive
Labour intensive
Used in supercars and sports cars - 89Technical TextilesTextiles that are manufactured for their technical and performance properties rather than their aesthetic characteristics
- 90Conductive FabricsConductive fibres are woven
Conductive powers impregnated in them
Often called electronic textiles or e-textiles - 91Fire-resistant FabricsNomex fire-resistant for fire fighters’ suites. Thickens when heated to protect the wearer
Flexible
Lightweight
Flame-resistant
Breathable
Durable
Used by law in children’s nightwear - 92KevlarLight polymer with high tensile strength
Doesn’t melt.
Resistant from many chemicals - 93What are the uses of kevlarBullet-proof vests
Helmets
Face masks
Sports equipment - 94MicrofibresVery thin synthetic fibres
- 95Micro-encapsulationFibres hold chemicals in tiny capsules which slowly break, releasing chemicals like perfume, insecticides or antiseptics
- 96Features of modern factoriesAccess to transport (road, rail and sea) to get raw materials in, and transport products out.
Large warehouses with manufacturing machinery.
Assembly-line production. - 97Advantages of roboticsProduces high-quality products
low product cost
Produce products quickly
CNC machines are adaptable, and can often carry out a range of tasks - 98Disadvantages of roboticsVery expensive to set up
Requires a specialist workforce
Costly if the system breaks down. - 99CrowdfundingRaising money using the internet to get people to contribute money.
- 100Virtual marketingUsing social media and websites to increase brand awareness, by getting websites or users to pass on marketing messages to other websites and users.
- 101ShowroomingShoppers visit shops to look at a product before buying it online at a lower price
- 102Co-operativeBusiness owned and self-managed by its workers
- 103FairtradeMovement created to help producers in developing countries
- 104Technology PushWhere new technology or materials are developed, and designers take this as an opportunity to design new products
- 105Market PullWhere users want a product to be improved or redeveloped to meet their needs
- 106CultureThe values, beliefs, customs and behaviours used by groups and societies to interact with each other and the world.
Designers must adapt to these needs - 107SustainabilityMeeting present-day needs without compromising the needs of future generations
- 108Finite resourcesA resource that does not renew itself quickly enough to meet the needs of future generations.
Once gone, there is no natural way to renew them.
eg. Coal, oil, metal ores, natural gas, minerals - 109Non-finite resourcesA resource that renews itself quickly enough to meet the needs of future generations.
There is a natural way to renew them.
eg. Water, plant life, wind power, solar power, geothermal power - 110Global WarmingBurning fossil fuels releases pollutants
- Smoke causes soot deposits
- Carbon monoxide is a poisonous gas
- Carbon dioxide contributes to global warming
Global warming is the gradual increase in global temperature - 111The 6 RsReduce
Refuse
Recycle
Rethink
Reuse
Repair - 112Three ways of disposing wasteLandfill
Resource recovery
Energy recovery - 113LandfillDisposing of waste material by burying it
- It pollutes soil & water
- Emits methane gas
- It smells
- Negative impact on wildlife
- Cause noise pollution - 114Resource recoveryRecovering disposed of materials for specific uses. For example, recycling or composting
- 115Energy recoveryRecovering disposed of materials for energy generation
- 116Planned ObsolescenceWhen a manufacturer plans or designs a product to have a short useful life
- 117RecycleA material is re-processed so that it can be used again
- 118BiodegradableA material that breaks down naturally without causing harm
- 119Computer-Aided Design (CAD)Using computer software to draw, design and model on a screen
- 120Computer-Aided Manufacturing (CAM)Manufacturing products designed by CAD
- 121Flexible Manufacturing System (FMS)A system in which production is organized into cells of machines performing different tasks
- 122Computer Numerically Controlled (CNC)Machine tools that are controlled by a computer
- 123Just in Time (JiT)Materials and components arrive when needed
- 124Lean ManufacturingFocusing on the reduction of waste when manufacturing
- 125Design for maintenanceDesigning it in such a way that makes maintenance easy
- Easily changeable batteries
- Good access into the product to be repaired
- Creating easily changeable modules - 126Disposal & the environmentRecycle rather than landfill
Reuse bottles, containers and bags to stop waste
Create biodegradable products that break down - 127Manufacturing ethicsTo keep prices low, companies cut costs in the workforce and manufacturing their products in countries with low labour costs. As well, their working conditions are poor and pollution is higher as there is a bigger transport cost.
- 128How is power generated from fossil fuels?30% from Natural gas power stations
22% from Coal-fired power stations
<1% from oil-fired power stations - 129How is electricity made from fossil fuels?Coal (Chemical energy)
Energy transferred as heat
Water & Steam (Heat energy)
Energy transferred as movement
Turbine
Energy transferred as movement
Generator
Energy transferred as electricity - 130Coal-fired power station (Diagram)
- 131Gas-fired power station (Diagram)
- 132Oil-fired power station (Diagram)
- 133Where does coal come from?Formed over 300 million years ago
Dead plants die, forming peat which over time turns to coal - 134Where do oil and gas come from?Remains of animals and plants from millions of years ago
Found under the sea
Heat and pressure from core turns them into oil and gas
Oil and gas were trapped between layers of impermeable rocks - 135Advantages of fossil fuelsGenerate large amounts of energy for cheap
As technology Improves, can get to more reserves
Finding the location of fossil fuels quite easy
Oil and gas can be transferred over long distances through pipelines
We can already extract fossil fuels - 136Disadvantages of fossil fuelsRelease carbon dioxide
Contribute to global warming
Mining causes scars on the landscape
Mining can be dangerous
Oil spills cause environmental damage
Supplies running out
Prices are set by other countries - 137Nuclear Power Station (Diagram)
- 138Advantages of nuclear powerClean and efficient energy
Provides 10% world's energy
Very little pollution
Lots of investment is being put into it - 139Disadvantages of nuclear powerVery expensive to build
radioactive waste is produced and needs to be stored for many thousands of years
Links to the development of nuclear weapons
Risk of nuclear accidents which have a large impact - 140Human effects of the Fukushima Daiichi disasterNatural earthquake broke the power plant
Radioactive radiation spread across nearby areas
Many towns had to evacuate
It will take 30 years to finish cleaning up the surrounding areas - 141Environmental effects of the Fukushima Daiichi disasterThe earthquake triggered a tsunami which resulted in radioactive waste sweeping across a large area
The waste has been absorbed into plants and animals
Rising levels of mutation
High levels of radiation in freshwater fish - 142How power is generated from the windHas been used for many years
Moved from windmills to turbines
Turbines are often grouped (Wind Farm)
Technology quite simple
Best place where wind reliable
Small scale sometimes seen on caravans - 143How power is generated from solar powerCaptured by a photovoltaic cell and converted into electricity
Solar farms common in countryside
Many houses have solar panels
There is more solar energy coming to Earth than fossil fuel available
The issue is harnessing the energy and storing it when it is not sunny - 144How power is generated from tidesMovement of water through turbines
20% energy needed could be generated through tidal power
Main issue is the environment to work in
Advantage is that there will always be tides - 145How power is generated from hydroelectric sourcesVery reliable source of renewable energy
High set-up costs
Large areas have to be flooded
Houses, farms and/or villages have to be relocated - 146How power is generated from biomassBiomass crops produce either oil or starch
Biomass is burnt to generate electricity
Oilseed rape can be processed into biodiesel for cars
Burning biomass produces some pollution
Crops can be grown quickly
Takes up a lot of land - 147Kinetic pumped energy storage systemWater is stored at the top and has the potential of providing kinetic energy. When water moves down, it converts the kinetic energy into electricity
- 148Alkaline batteriesBatteries store electricity
electro-chemicals inside, react to produce electricity
Typically produce 1.5 volts of energy
Alkaline batteries are single-use
Chemicals inside are dangerous to humans and wildlife - 149Re-chargeable batteriesCan be used several times
Typically produce 1.2 volts of energy
Used in products such as cars and phones
Need to be disposed of carefully - 150SystemsInput
Process
Output - 151InputsElectrical or mechanical sensors that use signals from the environment and convert them into signals
eg. Light-dependent resistor (LDR), Thermistor (termerature sensor), Switches - 152OutputsPart of an electronic system that people are most aware of. The output can be, for example, light, sound or movement
eg. Lamp, LED, Buzzer, Loudspeaker - 153MicrocontrollersSmall computers within a single integrated circuit that contains a processor core, memory and programmable input and output capability
- 154PIC Chip (Peripheral Interface Controller)Common form of microcontroller that uses flash memory to be reprogrammed
- 155Example of products that use microcontrollers- Car engine control systems
- remote controls
- washing machines
- mobile phones
- office devices
- medical devices
- toys - 156MechanismA device that changes an input motion into a different output motion.
Normally changes the amount of movement or direction of movement.
eg. Levers, linkages, cams, gear trains, pulley and belts - 157Linear MotionMovement in a straight line
- 158Reciprocating MotionMovement backwards and forwards in a straight line
- 159Rotary MotionMovement around in a circle
- 160Oscillating MotionMovement swinging from side to side
- 161LeverChanges an input movement and force into an output movement and force
Moves around a fixed point called a pivot or fulcrum - 162LoadObject to be moved
- 163EffortForce applied to move the load
- 164First-order levelFulcrum between the effort and the load
If fulcrum closer to the load, less effort needed
- 165Second-order leverLever has the load and effort on the same side of the fulcrum
Load is nearer to the fulcrum, less effort required. To make effort smaller, distance lever moves is greater
- 166Third-order leverLever has the load and effort on the same side of the fulcrum
Load is further from the fulcrum, so the effort required is greater than the load
- 167LinkagesIn mechanisms to transfer force. Change the direction of movement
Closer the pivot is to the output end of the lever, larger the force is at the output - 168BellcrankDirection of motion turned 90 degrees.
The magnitude of the output force is greater than that of the input force when the fixed pivot is closer to the output lever - 169Push/Pull (Parallel motion linkage)Direction of motion and magnitude of the forces are the same but are used when the force cannot be transferred directly in a straight line
- 170Cams & FollowersThree parts - cam, slide, follower
When the cam rotates, follower moves up and down in reciprocating motion
A follower can rise, fall, and dwell
Cams come in different shapes to create different combinations of rise, fall and dwell - 171Gear TrainsMechanism for transmitting rotary motion and torque.
Gears have teeth that interlock to transmit the rotary motion
Different sized gears connected together increase or decrease the speed of rotation and torque transmitted - 172Velocity Rationum teeth on driven / num teeth on driver
- 173Rack & PinionTurns rotary motion to linear motion
(Most use steel because it is hardworking) - 174Crank & SliderTurns rotary linear motion to rotary motion
By rotating a cran, a slider is made to move back and forwards along a cylinder or track - 175Chain & SprocketTransfers rotary motion to rotary motion elsewhere
Sprocket is a toothed wheel
A chain links that pivot and goes over the teeth on a sprocket - 176Pulleys & BeltsTransmit rotary motion to rotary motion. A pulley is a wheel with a groove in its rim. More pulleys, more rotary motion and torque
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- Flashcards on Product Design Theory, created by Ilya Sullivan on 11/09/2020.
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