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2 Craft Design Technology Working with Metal and Wood
Aims of the Tea Light Holder 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. • To learn how to work in conjunction with others • To learn how to communicate using technical jargon Time Schedule 10 -12 hours Success Criteria Your steel holders will be cut out accurately. All the edges will be smooth. Your supports will be filed and drilled neatly before being bent to the correct shape. All parts of this project will be fitted together correctly. Your will successfully laminate the Oak base to the aluminium sheet Your base will be finished smoothly and accurately to a high standard You will successfully coat the project with two different colours of plastic. You will understand how to perform ‘risk assessments’ on all necessary machinery before using them safely.
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2 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. Adhesive ��������������� Used for bonding materials together 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 ����������� Covering metal with a plastic coating Emery Cloth........... An abrasive cloth used to finish metals to give a clean surface 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. Lamination ������������ Joining two pieces, or more, of disimilar materials using adhesive 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.
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2 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.
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2 Craft Design Technology
Health and Safety Risk Assessment – 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. ______________________________________________________________ ______________________________________________________________
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2 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. ______________________________________________________________
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2 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.
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2 Craft Design Technology Metalworking Test Piece
Centre punch and drill through Diameter 3.5mm 40
.5
5
12.5
25
R12
10
Countersink to 1mm depth
25
Plan
3
75
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.
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2 Craft Design Technology
Tea-Light Holder Manufacture - Marking Out/Drilling
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2 Craft Design Technology Tea-Light Holder Manufacture - Bending
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2 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.
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2 Craft Design Technology Project Evaluation
1.
Describe four things that you have learnt during this project.
a.
____________________________________________________________ _
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).
_____________________________________________________________ ____________________________________________________________
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2 Craft Design Technology Candle Holder Assessment
Name:
Class:
Mark achieved for this project
Target mark for next project
Teacher’s comment on overall manufacturing skills shown on the completion of this project.
Teacher’s comment on conduct and attitude throughout this unit of work.
Your targets for future improvement. 1. _________________________________________________
2. __________________________________________________ ______________________________________________________
Parent/Guardian Signature
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