BGE - S1 Design and Manufacture by Musselburgh Grammar School

1 Craft Design Technology Working Safely

Those involved in the making of products have a responsibility to use safe working techniques in order to avoid harm to themselves or to others. Using tools and equipment • tools and equipment should be stored so that sharp edges and blades are protected • power tools should be isolated from electrical supply • operators should be fully trained in the use of tools and equipment • personal protective equipment should be used • all guards and other protective devices should be in place at all times when the equipment is in use Materials, chemicals, finishes and solvents • materials must be stored so that sharp edges and ends cannot cause harm • gloves should be used when handling materials with sharp edges • all chemicals, finishes and solvents should be stored correctly in accordance with the manufacturer's instructions • some materials may need special storage away from other substances Flammable and toxic substances • when using toxic or flammable substances, personal protective equipment should be used • care should be taken to avoid excess contact with toxic substances • turn off naked flames when flammable substances are used

1 Craft Design Technology Introduction To Woodworking - Storage Box

Aims of the storage box project • To learn about some of the more common materials and processes used in the School CDT workshops. • To learn to how to work in a safe orderly fashion in a workshop environment. • To learn how to prepare, mark out, cut and join wood. • To learn how to obtain a high quality finish on wooden surfaces.

Time Schedule 10-12 weeks

Success Criteria  You will successfully complete a test piece  Your lap joints will be marked out and cut accurately.  All pencil lines shall be removed before gluing.  Your box sides will be ‘square’.  Your inserts will fit correctly.  All surfaces will be smooth and free of blemishes.  Your lid will fit accurately.  The finish on your box will be of a high quality.  You will understand how to perform a ‘risk assessment’ on a sanding machine before using it safely.

1 Craft Design Technology Terminology

Craft Design Technology has its own language, just like French or German. During your time in CDT you will hear your teacher using certain words to describe tools or operations that they wish you to carry out. In order to help you, the following list contains the terms that you will have to learn during this unit of work. Adhesives.............. used to join materials together Band saw................ a machine for cutting curved lines Bench vice............. a device for holding wood securely Bevel edge chisel.. used to cut out wood joints Clamp..................... a portable device for holding wood securely Glass paper ........... used to remove marks and smooth wood Hand plane �� used for removing small strips of wood to make the wood smooth Hardwood............... wood from trees with broad leaves (deciduous) Isometric �� a form of pictorial drawing showing three sides of an object Laminating �� the process of sticking together layers of wood Lap joint.................. a strong L shape joint for wood Marking gauge �� a marking out tool used for marking lines parallel to an edge PVA glue................. an adhesive used to wood together Rendering �� a technique of adding colour to a sketch to make appear more realistic Softwood................ wood from trees with needles (coniferous) Steel rule................ used to measure when marking out wood Tenon saw.............. a back saw used to make straight cuts on wood Try square �� a marking out tool used for marking lines at 90 degrees to an edge Varnish................... a clear protective finish for wood Wooden mallet �� used in woodwork to prevent damage being caused to tools or the wood being worked

1 Craft Design Technology Trees The living cycle within a tree

The structure of Wood

1 Craft Design Technology Materials

You will be making your project out of natural wood with a manmade board base. There are two main types of natural wood; hardwood and softwood. You will be working mainly with softwood called pine although you will also receive a small strip of hardwood to form the design on your lid.

Man-made board comes in many different forms. The base of your project will be constructed using plywood. Plywood is made by slicing wood into thin layers and then re-gluing all the layers back together like a sandwich. This technique is called laminating and makes the man-made board very strong and suitable for forming large flat surfaces.

1 Craft Design Technology Characteristics of Pine and how to identify it

Look around your house and try to identify and list five objects that are made out of pine or include some pine in them. 1.____________________________ 2.____________________________ 3.____________________________ 4.____________________________ 5.____________________________

Characteristics of Mahogany and how to identify it Look around your house and try to identify and list five objects that are made out of Mahogany or include some mahogany in them. 1.____________________________ 2.____________________________ 3.____________________________ 4.____________________________ 5.____________________________

1 Craft Design Technology

The Environment â&#x20AC;&#x201C; Using Resources

Thinking about the environment when designing products is becoming more and more important. The storage receptacle is made out of timber, which is what we call a renewable resource. Using the internet, family or friends or books from the school library, find out the following. What is a renewable resource and why are these better for the environment? ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Give an example of a renewable resource. ___________________________________________________________________ What is a finite (non-renewable) resource? ___________________________________________________________________

Give an example of a finite resource. ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________

1 Craft Design Technology Adhesives

Adhesives are used to join materials by glueing. Different types of adhesives are used for different materials - for example, if a product is going to be used outside, then a waterproof adhesive should be used. The main types of adhesive are PVA (polyvinyl acetate), synthetic resin, epoxy resin, contact adhesive and acrylic cement. Uses of adhesives Adhesive Uses PVA (polyvinyl acetate) General purpose woodwork glue. Some PVA adhesives are water resistant. Synthetic resin

A strong water-resistant glue for woodwork. It needs to be mixed up immediately before use.

Epoxy resin

For joining metals and plastics. It is waterproof but must be mixed up immediately before use.

Contact adhesive

For joining polystyrene and fabrics. Also useful for fixing plastic laminates to a wooden base.

Acrylic cement For the joining of acrylic and some other types of plastics. The adhesive "melts" the surface of the plastic and fuses it together

1 Craft Design Technology

Health and Safety Risk Assessment â&#x20AC;&#x201C; Sanding machine

All students are instructed in the safe use of the sanding machine before they are allowed to use it. You must sign to say that you know how to use the sanding machine.

Guard

Sanding belt

On/Off Switches

Table Motor

You have been shown how to use a Belt Sander correctly and safely. State 2 risk assessments that you must carry out before using a Belt Sander machine. 1. ________________________________________________________________________ 2. ________________________________________________________________________

1 Craft Design Technology Woodworking Test Piece

1 Craft Design Technology Step by Step guide - How to cut a lap joint

Measure the width of the lap joint.

Use the Try Square and a pencil to mark the width of the lap joint.

Use the Try Square and a pencil to continue the line around the material.

4. Set the Marking Gauge to half the thickness of the material, hold the material in a bench vice and score a line with the Marking Gauge across the end grain of the material. Repeat this process on the two sides. 5.

Pencil along the scored lines to make them easier to see.

Clamp the material to the bench, as shown, so that the line to be cut is visible.

Using the clamped material as a guide cut to the correct depth with a Tenon Saw.

8. Use a Wooden Mallet and a Bevel Edged Chisel to remove the waste wood. Hint: Remember to have the bevelled edge of the chisel facing the floor for this operation. 9. Use the flat side of the chisel to clean up the joint carefully.

10. Your lap joint should now fit together as shown.

1 Craft Design Technology Sequence of Operations

1 Craft Design Technology Preparation before applying a Finish

Glue Spots Glue spots are not easy to see in raw wood. The easiest way to spot them is to wet the wood. Because wet wood looks different, usually darker, and because glue forms a liquid barrier preventing the wood beneath it from wetting, the glue spots should show up a lighter color. Remove the glue by scraping, cutting, sanding. Rewet the surface afterward to make sure you removed all the glue, then let the wood dry completely. Sanding Sand diagonally to the grain. Start with a rough sandpaper and work down to a fine sandpaper. With each new size, reverse direction and sand in the opposite diagonal from before. By switching direction, the wood will tell you when it is time to stop; as soon as scratches in the former direction are all gone, you are ready to move to the next grit. Repeat until all pencil lines are removed and the wood is smooth to touch.

Raising the Grain In order to achieve a smooth finish you must firstly raise the grain on the woods surface. After sanding, wet the wood thoroughly with clean water, The wood surface will be saturated but there should be no standing water or puddles left. Let it dry. When the wood is completely dry, it will feel furry. That's because sanding leaves the ends of wood fibers shredded, and water makes them stand up. Cut back the raised grain fibers by sanding lightly with fine grit paper. Sand only enough to smooth the raised fibers. You are now ready to apply a finish.

1 Craft Design Technology Applying a Finish - Varnishing

Good brush handling technique is essentially the same for all finishes. Solvent and waterbased finishes should be applied quickly in one direction with one or two swipes per row, then left alone. Four steps to achieving a good finish.

1. Start the brush stroke just off the end of the board to prevent drips on the adjacent side.

2. As the stroke continues, deflect the bristles more so they continue to feed finish onto the wood.

3. Lift up and end the stroke gently to avoid flicking finish on nearby pieces.

4. Now go back and pick up the area you missed at the start of the stroke, brushing lightly in the other direction.

Cleaning the brush As soon as you are done, unload the brush by scraping it across the edge of the container, then immediately wash it thoroughly in warm water and soap. Rinse well until all the soap is out.

1 Craft Design Technology

Tools used during the manufacturing of your project

Why is accurate marking out necessary when making things? _______________________________________________________________

Label each of the tools shown below with there correct name (hint: the glossary of terms might help you). State what material they are used on and exactly what they are used for.

1 Craft Design Technology Project Evaluation

Describe four things that you have learnt during this project.

____________________________________________________________ _

b. _____________________________________________________________ c. _____________________________________________________________ d. _____________________________________________________________ 3. If you could make this project again, what alterations would you make and why? _____________________________________________________________ _____________________________________________________________ 4. Which part of this project did you have the most difficulty with? _____________________________________________________________ _____________________________________________________________ 5. Explain, in some detail, whether or not you enjoyed working on this project. _____________________________________________________________ _____________________________________________________________ 5.

If you were to change the way in which you worked what would you change (e.g. behaviour, concentration, care etc).

_____________________________________________________________ ____________________________________________________________

1 Craft Design Technology Storage Box Assessment

Name:

Class:

Mark achieved for this project

Target mark for next project

Teacherâ&#x20AC;&#x2122;s comment on overall manufacturing skills shown on the completion of this project.

Teacherâ&#x20AC;&#x2122;s comment on conduct and attitude throughout this unit of work.

Your targets for future improvement. ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ Parent/Guardian Signature

1 Craft Design Technology Introduction to Metalwork

Aims of the coat-hook project • To learn about some of the more common metals used in the School CDT workshops. • To learn how to work in a safe and orderly fashion in a workshop environment. • To learn how to prepare, mark out, cut and finish metal. • To learn how to create a high quality finish on metal surfaces. Time Schedule 10 -12 hours Success Criteria  Your Aluminium and Plywood backplate will be cut out accurately.  The edges of your backplate will be smooth.  Your coat-hook will be filed and drilled neatly before being bent to the correct shape.  Both parts of this project will be fitted together correctly.  You will successfully coat the project with plastic.  You will understand how to perform a ‘risk assessment’ on a pillar drill before using it safely.

1 Craft Design Technology Terminology

Craft Design Technology has its own language, just like French or German. During your time in CDT you will hear your teacher using certain words to describe tools or operations that they wish you to carry out. In order to help you, the following list contains the terms that you will have to learn during this unit of work. Annealing �� Method of heating up metal to a certain temperature to make it easier to bend. Ball pein hammer � A heavy hammer with one end rounded to help form the head of a rivet. Centre punch �� Used to mark the centre of a hole before drilling. Countersink drill �� Used to form a 45 degree sloping surface on metal or plastic Dip coating �� Coating metal with a plastic finish Emery Cloth �� An abrasive cloth used to finish metals to give a smooth finish Engineers square Used to draw lines at 90 degrees (right angles) on metal. Engineers vice �� A method of holding metal whilst you work on it. Always mounted onto a bench. Ferrous metal ........ Metals that contain iron, they will rust. Non-Ferrous .......... Metals that do not contain iron. Forge �� Hot working area where gas powered torches are used to heat up metal. Hand file �� Used to shape material by cutting using series of parallel ridges or teeth. Machine vice �� Similar to an engineers vice except it is used to hold materials whilst working on a machine. Pillar drill �� Tool with rotating drill bit, used for making holes in a material. Rivets �� Used to join two pieces of material together Rivet set �� Use in conjunction with a rivet to help form the head of the rivet. Rule �� Used to measure accurately in millimetres. Scriber �� Used instead of a pencil to mark lines on metal. Twist drill �� The tool or bit that cuts the hole though the material, e.g. a 6mm diameter drill. Wet and Dry �� An abrasive paper which can be used wet or dry.

1 Craft Design Technology Health and Safety Risk Assessment â&#x20AC;&#x201C; Pillar Drill

All students are instructed in the safe use of the pillar drill before they are allowed to use. You must sign to say that you know how to use the pillar drill. On/Off Switch

Operating Handle

Chuck

Drill bit

Guard

Height Adjustment

Table

You have been shown how to use a pillar drill correctly and safely. State 3 risk assessments that you must carry out each time before using a pillar drill. 1. ______________________________________________________________ ______________________________________________________________ 2. ______________________________________________________________ ______________________________________________________________ 3. ______________________________________________________________ ______________________________________________________________

1 Craft Design Technology Health and Safety Risk Assessment - Forge

Mild steel is most easily bent and shaped when it is hot. The forge produces a very hot fire to bring steel to red hot. Due to the nature of the forge, protective gloves and goggles must be worn at all times. Once heated, a heavy ball-pein hammer is used to beat the hot steel into shape. Tongs hold the work securely in the forge and over the anvil. The anvil provides a solid, hard-wearing work surface. Forging is still a common process. Products such as wrought iron gates and hanging basket brackets are very popular. Extraction

Hearth Torch

On/Off Buttons

State three safety precautions before using the forge: 1. ______________________________________________________________

2. ______________________________________________________________ 3. ______________________________________________________________

1 Craft Design Technology Dip Coating

Dip coating is a process that is suitable for most metals. It is used for coating metal products such as hanging baskets, brackets, kitchen drainers, coat hooks and tool handles. The metal must first be thoroughly cleaned and degreased before being heated either in an oven or at a forge to 180oC. It must be heated to this temperature before being plunged into a bath of a fluidized powder. It should be left there for a few seconds while the powder sticks to the hot surface to form a thin coating. The object should then be either returned to the oven or the forge, allowing the plastic coat to fuse to leave a smooth glossy finish.

A thermoplastic material, usually polythene, in a powder form is made to act like a liquid by blowing air through it. This is known as fluidization.

1 Craft Design Technology Information Sheet - Metal

Metals are classified as either FERROUS or NON-FERROUS. Ferrous metals are all those based on IRON e.g. mild steel and cast iron. Non-ferrous metals are not based on iron and include for example aluminium copper and silver. Two or more metals can be mixed together to form ALLOYS. Brass is an alloy of Zinc and copper. Metals are alloyed together to give properties that pure metals cannot provide; stainless steel for example, is an alloy of iron that resists the formation of rust. Aluminium is the most common non-ferrous metal used in schools. It is supplied in a variety of forms; round rod, rectangular and hexagonal bar, angles ‘I’ section and ‘T’ section. Aluminium is also readily available as a sheet material.

Properties of Aluminium Aluminium has a light grey surface that becomes shiny silvery grey when it is worked. Aluminium is lightweight and fairly strong. Aluminium is difficult to solder and weld so it is often joined by mechanical means i.e. riveting.

1 Craft Design Technology Metalworking Test Piece

Centre punch and drill through Diameter 3.5mm 40

12.5

R12

Countersink to 1mm depth

Plan

Elevation All dimensions in mm

Stages of Manufacture

Finished Test Piece ( 1 : 1 )

a. Mark out your test piece b. Following the correct safety procedures drill the 3.5mm diameter holes c. Countersink the hole at the end of the test piece d. File the two sloping surfaces down to the marked-out line e. File the curved end down to the marked-out line. f. Using a hacksaw cut along the marked line. g. Collect the required tools and rivet your pieces together h. Take your finished item to the teacher for assessment.

1 Craft Design Technology Hook Manufacture Centre punch and drill through Diameter 3.5mm

Countersink to 1mm depth

150

All dimensions in mm Stages of Manufacture a. Mark out your hook b. Following the correct safety procedures drill the 3.5mm diameter holes c. Countersink both holes d. File each corner to the marked-out line e. Follow the instructions below to correctly bend your hook Part 1 Grip metal in engineers vice with the fold line level with the top of the vice. Check that the material is sitting at right angles with an engineers square. Hammer over with a ball pein hammer. Part 2 Using the same technique described in the completion of Part 1 complete the two bends in the order shown on the diagram Both bends are at 45째.

Completed Hook

Backplate Manufacture

Centre punch and drill through Diameter 3.5mm

R10

Countersink to 1mm depth

1 Craft Design Technology

Centre punch and drill through Diameter 6mm

27.5

All dimensions in mm

Completed Coathook

Completed Backplate Stages of Manufacture a. Mark out your backplate b. Following the correct safety procedures drill the 3.5mm diameter holes c. Following the correct safety procedures drill the 6mm diameter holes d. Countersink both the 6mm holes e. File each corner to the marked-out line f. Clean up both pieces of your coathook using a File and Emery Cloth g. Collect the required tools and rivet your pieces together h. Take your finished item to the teacher for dip coating and assessment

1 Craft Design Technology Tools used in manufacture

Label each of the tools shown below with there correct name (hint: the glossary of terms might help you). State what material they are used on and exactly what they are used for.

1 Craft Design Technology Project Evaluation

Describe four things that you have learnt during this project.

____________________________________________________________ _

If you were to change the way in which you worked what would you change (e.g. behaviour, concentration, care etc).

_____________________________________________________________ ____________________________________________________________

1 Craft Design Technology Coat Hook Assessment

Name:

Class:

Mark achieved for this project

Target mark for next project

Teacherâ&#x20AC;&#x2122;s comment on overall manufacturing skills shown on the completion of this project.

Teacherâ&#x20AC;&#x2122;s comment on conduct and attitude throughout this unit of work.

Your targets for future improvement. 1. _________________________________________________

2. __________________________________________________ ______________________________________________________

Parent/Guardian Signature