Unit 22 P6

Look at this unit Pass 6  in relation to the work we are doing with the Greenpower car . Consider the methods of construction and the jointing methods we will be using . Comment on this and how if we were to make if from aluminium the construction would differ

P1 task

Task 1 P1   Identify the health and safety legislation, regulations and safe working practices

applicable in a fabrication workshop, with learners being asked to produce a written report. Evidence presented for P1 must be specific to fabrication processes. There is a huge amount of generic material which learners will have access to. Care should be taken to ensure that what you present is referenced properly and not directly copied from the internet or any other source. 

P8

P8 identify the appropriate heat treatment processes, secondary, finishing and assembly techniques needed to manufacture four given components.

Given components are 
Upright for the front suspension on the Green power  racer. Anodise it . 

A garden gate, hot galvanised 


Waterpump shaft
Use this for the Water pump Grind the main shaft as the finishing technique
Lathe and surface hardening should come into play!

http://fuelpumps.tpub.com/TM-5-4320-258-34/TM-5-4320-258-340026.htm

an engine block rough cast to finished surfaces. Milling machine.

None traditional machining techniques

Know how a range of non-traditional techniques are used

Electro discharge: machines eg spark erosion, wire erosion; features of the workpiece eg holes, faces (such as flat, square, parallel, angular), forms (such as concave, convex, profile, square/rectangular), other features (such as threads, engraving, cavities, radii/arcs, slots)

Broaching: machines eg horizontal, vertical; features of the workpiece eg keyways, holes (such as flat sided, square, hexagonal, octagonal), splines, serrations, other special forms

Honing and lapping: machines eg honing (such as horizontal, vertical), lapping (such as rotary disc, reciprocating); features of the workpiece eg holes (such as through, blind, tapered), faces (such as flat, parallel, angular) 

Spec for homework to help you

1 Understand how a range of secondary machining techniques are used

Turning: machine eg centre lathe, turret; features of the workpiece eg flat faces, diameters (such as parallel, stepped, tapered), holes (such as drilled, bored, reamed), profile forms, threads (such as internal, external), eccentric features, parting off, chamfers, knurls or special finishes, grooves, undercuts

Milling: machine eg horizontal, vertical, universal, planer/gantry; up-cut; down-cut; features of the workpiece eg faces (such as flat, square, parallel, angular), steps/shoulders, slots (such as open ended, enclosed/recesses, tee), holes (such as drilled, bored), profile forms (such as vee, concave, convex, gear), serrations, indexed or rotated forms, special forms

Boring: machine eg horizontal, vertical; features of the workpiece eg bored holes (such as through workpiece, to a depth, tapered), holes (such as drilled to depth, drilled through workpiece, reamed, threaded), external diameters, grooves/recesses, chamfers/radii, faces (such as flat, square, parallel, angular, milled), slots, forms (such as indexed, rotated), external tapers

Grinding: machine eg surface (such as horizontal, vertical), cylindrical (such as external, internal), centreless, universal, thread, profile; features of the workpiece eg faces (such as flat, vertical, parallel, square to each other, shoulders and faces), slots, diameters (such as parallel, tapered), bores (such as counterbores, tapered, parallel), profiles forms, thread forms (such as vee, right hand, single start, multi-start, internal, external), angular faces

Presswork: machines eg single action, multiple action; features of the workpiece eg blanking, notching, piercing, joggling, cropping/shearing, bending/forming, coiling/rolling, planishing/flattening, first draw, second draw, compound operations, cupping, embossing, coining

Health and safety: appropriate legislation and regulations eg Health and Safety at Work Act 1974, Fire Precautions Act 1971, manual handling, Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) 1995, Provision and Use of Work Equipment Regulations (PUWER) 1998, Health and Safety (First Aid) Regulations 1981; use of personal protective equipment (PPE)

Materials: eg ferrous, non-ferrous, non-metallic, stainless, special alloys, deep drawing steels

Kinematics: machine tool design; generation and forming of shapes; six degrees of freedom 

Gomework to be handed in by 1st Tueasday back from 1/2 term

P1 explain how five different secondary machining techniques are used safely on a range of materials

P2 explain kinematics in secondary machining techniques

Monocoque Design

Looking at the lesson you need to research monocoque race car design. Look at the work of Colin Chapman from the 1960's as he was the father of the design revolution which overtook formula 1 design.