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.

BTEC

Produce a list of components  you think you will need to do in order to build the car.  Look at techniques for its construction. Welding machining GRP etc.

Cambridge Uni solar car.

Try this as an idea for getting your ideas flowing .

http://www.cam.ac.uk/research/news/new-and-under-the-sun

Deadline date

Hi we need to finish off the unit by the second last week of term. Unit 307. If you fail to complete by then there is no extension!
Best regards

Unit 305 LOL1

Hi Chaps here is the mark scheme for LOL1 to help you check you are on the right lines 

Guidance for allocating marks

This section provides further guidance for the assessor on how to award marks within each mark

band in an objective way.

Marking grid A

Assessment focus LO.1.1

Mark Band 1–3

(0–9 marks)

There are typically up to 2 marks for each of the two descriptions, but could

go to 3 marks if either the consequences of failure or the effect on

production is answered well and above that required for this mark band but

up to a maximum of 4 marks.

Up to 2 marks can be awarded for the explanation of the effects and should

be based on the how well it shows the effects are appropriate to customer

expectation and corporate image and 1 mark can be awarded for linking

image and customer expectation within the explanation.

Up to 2 marks could be awarded for indicate why consequences affect

corporate image; this could be in the form of advantages and limitations.

Unit 305 Snow work

Dear All


If you can look at Unit 5 as we have just started this unit. . I recommend you look at the mark scheme as we have been doing in class as this will assist in getting the marks clearly allocated for Learning Objective LOL1  
You will have downloaded this into your area already.

You need to clearly identify 2 areas. of maintenance.  Suggest areas of  System failure, such as the case study  on the Bombadeir undercarriage, Rail signal failure  

Mark Band 1–3
(0–9 marks)
There are typically up to 2 marks for each of the two descriptions, but could
go to 3 marks if either the consequences of failure or the effect on
production is answered well and above that required for this mark band but
up to a maximum of 4 marks.
Up to 2 marks can be awarded for the explanation of the effects and should
be based on the how well it shows the effects are appropriate to customer
expectation and corporate image and 1 mark can be awarded for linking
image and customer expectation within the explanation.
Up to 2 marks could be awarded for indicate why consequences affect
corporate image; this could be in the form of advantages and limitations.

New Unit 305

Hi chaps
Pleased with the exam and your feedback from it. Looks like you should have done well and you appeared to have got the majority of the marks in the feedback session.   Well done


We have now started Unit 5 and this is the maintenance unit . Following the lesson ensure you have downloaded all the unit documentation into your area.. I need you to research
Plant   equipment and system with a view to maintanence so you have a clear view tto this before next lesson. That way we can start unit 5 LO1.1 and have an idea as to covering 2 areas

See if you cxn find some examples of these failures, Plane rail crashes etc.


Mark Band 1–3
(0–9 marks)
There are typically up to 2 marks for each of the two descriptions, but could
go to 3 marks if either the consequences of failure or the effect on
production is answered well and above that required for this mark band but
up to a maximum of 4 marks.
Up to 2 marks can be awarded for the explanation of the effects and should
be based on the how well it shows the effects are appropriate to customer
expectation and corporate image and 1 mark can be awarded for linking
image and customer expectation within the explanation.
Up to 2 marks could be awarded for indicate why consequences affect
corporate image; this could be in the form of advantages and limitations.