Year 10 School Engineering: Workshop Safety & Metal Fabrication

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Questions and Answers

What do YELLOW signs indicate in a workplace?

Danger is present but precautions have been taken to minimize the risk (correct)

First aid equipment is available

Emergency escape is available

Danger is present and immediate action is required

What is the primary advantage of stainless steel over regular steel?

Increased shininess

Increased strength and corrosion resistance (correct)

Increased hardness and decreased strength

Decreased cost and increased durability

What is the process of creating a 3D printed part called?

Multiplicative layer manufacturing

Subtractive layer manufacturing

Divisive layer manufacturing

Additive layer manufacturing (correct)

What is the primary purpose of using jigs in metal fabrication?

To ensure fabrication repeatability Signup and view all the answers

What is the process of making inside threads in holes using taps?

Tapping Signup and view all the answers

What is the purpose of a CAD drawing in 3D printing?

To design and visualize the part before printing Signup and view all the answers

What is the primary use of soldering in metal fabrication?

To join electrical devices and copper wires Signup and view all the answers

What is the primary advantage of 3D printed parts?

They are less expensive and faster to produce Signup and view all the answers

What is the characteristic of solder that makes it suitable for joining electrical devices?

Its low melting point Signup and view all the answers

What is the alloy composed of iron and carbon?

Steel Signup and view all the answers

What is the purpose of a YouTube link in the text?

It is not relevant to the text and is merely a distraction Signup and view all the answers

What do GREEN signs indicate in a workplace?

Help is available during dangerous situations Signup and view all the answers

What is the purpose of RED signs in a workshop?

To indicate high risk or death danger, prohibition, or fire equipment Signup and view all the answers

What does PPE stand for in the context of workshop safety?

Personal Protective Equipment Signup and view all the answers

What is the purpose of CAM in engineering?

Computer Aided Manufacturing Signup and view all the answers

What is the primary application of the 555 TIMER in engineering?

Timing and oscillation circuits Signup and view all the answers

Which type of joint is used to connect two wooden pieces at a 90-degree angle?

Half corner block Signup and view all the answers

What is the term for the process of shaping metal by heating and pouring it into a mold?

Sand Casting Signup and view all the answers

What is the purpose of a cam lock in a knock joint?

To allow the pin head to enter between the cam grooves and tighten the joints Signup and view all the answers

What is the primary advantage of a truss structure?

It can withstand a heavier load due to its triangular shape Signup and view all the answers

What is the main function of a tie in a truss structure?

To tie two beams together to prevent them from moving apart Signup and view all the answers

What is the main difference between metal and wooden beams?

Metal beams are more popular than wooden beams Signup and view all the answers

What is the purpose of a captive barrel nut and bolt in a knock joint?

To screw the two pieces of wood together using a long screw Signup and view all the answers

What is the primary consideration when selecting a beam for a structure?

The shape and size of the beam Signup and view all the answers

What type of follower is suitable for high load applications?

Roller follower Signup and view all the answers

What is the main function of gears in a mechanical system?

To transmit motion Signup and view all the answers

In a bicycle gear system, what is the role of the pedal gear?

Driver gear Signup and view all the answers

What is the purpose of an idler gear in a gear system?

To connect two gears that rotate in the same direction Signup and view all the answers

How do the pedal gear and back wheel gear rotate in a bicycle?

In the same direction, at the same speed Signup and view all the answers

What happens to the shaft of an idler gear when it rotates?

It remains stationary Signup and view all the answers

Study Notes

Workshop Safety

Safety signs are categorized into three colors:
- Yellow signs indicate danger, but precautions have been taken to minimize the risk.
- Green signs show help during dangerous situations, such as emergency escape, first aid, and fire exit.
- Red signs indicate high risk or death danger, and prohibit certain actions.
Personal Protective Equipment (PPE) is essential for workshop safety.

Metal Fabrication Processes

Deforming: bending by hand using jigs to ensure fabrication repeatability.
Threading and tapping: making outside threads on a shaft using thread making dies, and making inside threads in holes using taps.
Joining metals using heat: soldering, which involves melting solder at a low temperature (300°C) to join metals.

Metallic Alloys

An alloy is a combination of a pure metal and another metal or non-metal to upgrade its properties.
Examples of alloys include:
- Bronze (Copper + Tin): increased hardness and strength.
- Brass (Copper + Zinc): increased hardness and yellowish color.
- Steel (Iron + Carbon): increased hardness, strength, and corrosion resistance.
- Stainless Steel (Iron + Carbon + Nickel + Chromium): increased strength, corrosion resistance, and shininess.

Plastics

3D printing: creating objects by layering fused plastic, using CAD drawings and 3D printer files.
3D printing is used in various industries, including medical implants and aircraft parts.

Composites

Not mentioned in the provided text.

Textiles

Not mentioned in the provided text.

Wood

Knock-down joints: Half corner block, Cam lock, Captive barrel nut and bolt, and Corner plates.
These joints are used to connect wood pieces together.

Properties of Materials

Not mentioned in the provided text.

Structures

To build structures, a builder needs to consider two things:
- Material type (e.g., metal or wood)
- Shape/Geometry (e.g., trusses, which adopt the natural strength of the triangular shape)
Trusses are used in bridges, roofs, and other structures to distribute weight along their span.
Ties are tension beams used in trusses to tie two beams together.

CAMs

A roller follower rotates on a cam, providing low friction and heat, and withstanding high load.
Not very accurate on sharp profiles.

Gears

Gears are used to transmit motion.
A driver gear is connected to a power source, and a driven gear is connected to the output.
Gears can be connected by chains or directly.
Idler gears are used to change the direction of rotation between two gears.

Logic Gates

Not mentioned in the provided text.

CAD-CAM

CAD stands for Computer-Aided Design.
CAM stands for Computer-Aided Manufacture.

Design Process

Not mentioned in the provided text.

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Description

Test your knowledge on workshop safety, metal fabrication processes, and materials used in engineering. Covers safety signs, PPE, metal deformation, joining, and protection, as well as plastics, textiles, and wood. For year 10 students.