Structures
Fundamentals of Manufacture
and Assembly Techniques
(Intermediate 2)
5821
DET: Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2)
September 1999
HIGHER STILL
Structures
Fundamentals of Manufacture
and Assembly Techniques
(Intermediate 2)
Support Materials
DET: Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2)
Contents
PART 1
Lecturer and Teacher Information and Support Materials
Outcomes
Delivery
Advice on starting levels
Assessment
Resource Materials
Sources of Information and Learning Materials
Acknowledgements
PART 2
Information and Support Materials for use with Candidates
Integrative Learning Approaches
Evidencing Superior Performance
Casework Solutions
Tutorial Examples
DET: Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2)
DET: Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2)
STRUCTURES: FUNDAMENTALS OF MANUFACTURE
AND ASSEMBLY TECHNIQUES
(INTERMEDIATE 2)
PART ONE
Teacher/Lecturer Materials
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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LECTURER’S/TEACHER’S INFORMATION AND SUPPORT MATERIAL
Outcomes
The outcomes and PCs are listed in sequence for the unit. After each PC a note is
included to indicate the extent of knowledge, understanding and application required.
Outcome 1
Describe the characteristics of simple component manufacturing processes and
assembly or structural fabrication methods.
Performance Criteria
a) The processes used to make a range of simple products or structural fabrications
are correctly identified.
All the commonly used, well established, processes associated with:
Measurement
Marking out
Shape creation
Joining
Finishing.
Should be familiar to candidates either for the manufacture and assembly of
components or for structural fabrication. A brief knowledge of what these processes
involve and how they help to convert raw materials into the finished product should
be gradually learned by the candidate and eventually retained as a data base.
b) Processes achieving the same requirements are critically compared for two
situations.
Once a reasonable number of processes are familiar to the candidate it will become
clear that often the same transformation can be achieved to produce the desired effect
on a piece of raw material by employing different techniques. In one or two instances
for each process area listed in performance criteria a) two or more techniques can be
compared which achieve the same transformation and the suitability of these
techniques compared for that instance.
For Example:
Measurement
The diameter of a turned component requires to be checked to a requirement of 25
mm
+0.000/-0.500
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Alternative techniques to be considered are:Direct measurement using a Vernier caliper.
Direct measurement using a go/no go gap gauge.
Comparison using a dial test indicator and stand, vee block, surface plate, gauge
blocks.
Comparison of Techniques
Vernier – suitable for accuracy required, some degree of skill required to operate,
readily available, portable.
Micrometer – suitable for a greater accuracy than that required, some degree of skill
required to operate, should be available, portable.
Go/no go gap gauge – suitable for a greater accuracy than that required, very little
skill required, may have to be set prior to use, may not be available, portable.
Dial Test Indicator Set Up – suitable for a greater accuracy than that required,
considerable skill required, requires to be set prior to use, must be used on a surface
plate.
Marking Out
Three hole centres require to be marked out to +/- 0.2 mm from perpendicular datum
edges and relative to each other on the flat surface of a component measuring 200
mm x 100 mm.
Alternative techniques to be considered are:Surface table, Angle plate, Vernier height gauge. Two dimensional Indexing table.
Comparison of Techniques
Surface table – just suitable for the accuracy required, skilled operation, all
equipment should be readily available.
Indexing table – suitable for the degree of accuracy required, little skill required, may
not be available when required.
Shape Creation
A small stepped block has to be created from an oversize blank cut from bright stock
material.
Alternative techniques to be considered are:Shaping machine
Vertical milling machine.
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Comparison of Techniques
Shaper – suitable to generate the shape required, skilled operation, available, takes
longer than the mill.
Mill – suitable to generate the shape required, semi-skilled operation, available, takes
less time than the shaper.
Joining
An enlarged end has to be joined to a 12 mm diameter x 80 mm long steel pin to act
as a head.
Alternative techniques to be considered are:
Force fitting of head to pin.
Inserting pin to head, welding and dressing weld.
Comparison of Techniques
Force fit – Requires accurate turning of pin end and accurate boring of head and
possibly the use of a mandrill press, skilled operations throughout.
Welding – does not require as accurate machining on the two component parts,
welding could be done by a semi-skilled operator. Possibly will take longer than
force fitting due to the weld dressing requirement.
Finishing
A simple go-no go gap gauge has been produced from an alloy steel, hardened and
the functional faces ground to size. The non functional surfaces now require to be
finished.
Alternative techniques to be considered are:
Shot blast and paint
Hand finish with energy cloth and plastic dip.
Comparison of Techniques
Shot blast and paint – area required to allow paint to dry.
Hand finish and dip – takes longer to complete and may not be as durable.
c) Processes are classified into general groupings in accordance with established
practice.
Classification of processes may be done as the processes are considered or as an
exercise from time to time when a number of processes have been looked at. The
typical general groupings used are:
Primary forming
Material preparation
Assembly
Finishing
for example:for example:for example:for example:-
casting, forging
cutting off, turning
fabrication, fitting
polishing, painting
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d) General and Specific safe working practices are stated correctly in terms of
current legislation.
Safety should be considered as an integrated part of each process considered.
Generally used in this context it is intended to mean practices which continuously
apply across all processes, such as footwear and overalls, while specific is intended
to apply to particular classification categories of processes or the processes
themselves, such as skin protection, where sharp edges or swarf is encountered or
cutter guards used for all power tool applications.
Outcome 2
Select component manufacturing and assembly or structural fabrication
methods for given applications
Performance Criteria
a) Given the form of supply to be used, appropriate techniques are selected to
manufacture a simple part.
Techniques such as measurement, marking out and quality control will require to be
selected for most situations concerned while hand shaping, machining or moulding
methods chosen will depend on the requirements of a particular application. Parts
should be very simple, involving only a few processes requiring not more than 3
operations for each process.
For example, for a small cold chisel the operations required are:





Measure length from bar stock and cut off
Mark out section to be drawn down
Forge
File cutting edge, deburr, tidy up
Harden and temper (Hardness Test)
Polish and sharpen (try out)
The techniques involved are:Measure, mark out, (quality control), hand shape
b) Given the components available, appropriate techniques are selected in order to
assemble a device or structure.
Techniques such as measurement, marking out and trial testing will require to be
selected for most situations while fitting (in its widest sense), joining and finishing
techniques chosen will depend on the requirements of a particular application.
Assemblies chosen should be very simple involving only a few processes requiring not
more than 3 operations for each process.
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For example, for a replacement driving chain to be made the operating required are:



Measure and count the links required from the original chain
Check the pitch, count the links and cut off the new chain using the appropriate
tool
Insert the joining link and join either permanently by riveting or temporarily by a
spring clip
Check length against the original chain
The techniques involved are:Measure, trial test, fitting, joining.
c) Specific safe working practices are correctly stated for each technique.
During the selection of appropriate techniques in PC’s a) and b) consideration should
be given to specific safe working practices and these should be recorded beside the
operations chosen, for example, when selecting the operations for producing the cold
chisel
Cutting off requires goggles and gloves
Forging requires a leather apron in addition to the above
Hardening and tempering requires the addition of suitable tongs
Sharpening only requires goggles and gloves.
And when selecting the operations for producing a driving chain.
If a spring clip is used the open end must always be fitted opposite to the direction of
driving motion of the chain.
Outcome 3
Plan the manufacture and assembly procedures for a product or structural
fabrication.
Performance Criteria
a) the order of operations selected is logical for the manufacture and assembly of a
given product or structural assembly
The work done in Outcome 2 can be extended to produce actual planning documents
such as route cards and planning sheets. Examples should not be complex containing
no more than four simple parts in the product which require to be manufactured and
a few purchased parts if required.
b) Appropriate consideration is given to methods of work holding, capacity of
equipment and tools available.
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Suitable planning sheets can have a column dedicated to equipment and tooling
requirements but additional information such as feeds and speeds are not necessary
for this unit.
c) Special safety requirements and consequent precautions are correctly identified.
Again the work started during Outcome 2 should be continued and included in the
planning documentation either as part of the detailed operation or in another column.
An elementary consideration of the impact on the number requirement of the product
should be introduced towards the end of the unit allowing the elementary
consideration of flow production techniques, the use of jigs and fixtures, Automatic
and CNC methods to occur.
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DELIVERY
It is likely that some students will have an elementary experience of manufacture
from Engineering Craft Skills. In general delivery should encourage the student to
develop the skills of qualitative synthesis, organisation of information storage and
optimisation.
The requirements of Outcome 1 are basically to develop an awareness of a wide range
of component manufacturing and assembly processes or structural fabrication
methods, to compare these processes as to their suitability for a particular
manufacturing requirement and to collate processes into particular classifications.
Towards the end of this section of the work the student should have developed a
database, probably paper based which, under the classification headings contains brief
information for perhaps as many as 10 processes or techniques under each heading.
The information for each process should simply say what it achieves, briefly how it
works, any limitations (for example, wood cannot be welded) and including specific
safety requirements.
Initially this looks like a massive task but it must be remembered that only very
simple products will be considered and these will generally be considered to be small
in number and to be produced in a small general purpose work place.
The temptation to present the student with many pages of information on, for example
shape creation under the sub heading of material removal ranging from the shaping
machine to the 3 axis CNC machining centre, should be avoided. At this stage in the
student’s development a simple video presentation or workshop demonstration of one
or two shape creation processes followed by a brief discussion of the intended range
of such processes to be used as an information source by the student.
Perhaps one side of A4 size paper could be laid out as a template and the student
could fill in the relevant information for perhaps five such processes. Extra sheets
could be made available for students to write up say two processes each from their
own experience.
A selection of all the processes detailed can be put together as the database
contribution for this classification of processes and the other classifications
undertaken in much the same way.
Using this type of approach a simple database of processes and techniques can be
built up, the particular processes included should of course reflect the requirements of
the products to be introduced during the other outcomes.
Students can be encouraged to continue adding to their individual database as the unit
progresses.
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The requirements of Outcome 2 and 3 should follow naturally from the knowledge
and understanding developed in Outcome 1. The degree to which an integrated
approach is followed depends on how the presenter visualises the way in which final
planning documentation is evolved.
Several products can be considered working backwards from the final assembly to the
details of how each individual component is produced and the associated paperwork
development at appropriate stages.
Alternatively simple part and assembly drawings can be used to decide which
processes could be used for particular parts, operational sequences decided and
planning sheets produced for part manufacture. The assembly procedures can then be
documented in the same way.
Examples of simple products to use as learning vehicles and suggested paperwork
approaches are given later in this pack.
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ADVICE ON STARTING POINTS
It is likely that all candidates will have a fairly wide knowledge of how particular
parts and devices are produced and the challenge will be to record this information
simply but comprehensively so that it can be used effectively when overcoming the
requirements of Outcome 2 and 3.
The tendency can often be to jump to the end of the planning process without a valid
consideration of alternative processes to logically reach an optimum solution. Ideally
a logical approach to matching the requirements of the task with the methods of
production available with due regard to safety, degree of skill required and suitability
of commonly available equipment should be followed throughout the delivery. Equal
emphasis should be given to group work and individual effort at least in the earlier
exercises.
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ASSESSMENT
Assessment packs for this unit are available from the National Assessment Bank and
should be used in conjunction with the Structures Arrangement Document and
Subject Guide.
Assessment packs suggest how and when assessment tasks should be administered,
the duration of each assessment and the conditions under which assessment should
take place.
Part of Sectional – “Organisation and Conditions for Assessment” from one
assessment pack has been reproduced here.
Using instrument(s) of assessment
There are two assessments in this unit, each one can be administered as an end of
topic test. The first test covers outcome one. However the assessment for the second
and third learning outcomes is designed to combine these outcomes into a single
piece of work.
INSTRUMENT
OF
ASSESSMENT
OUTCOMES AND
PCs
1
TYPE OF ASSESSMENT INSTRUMENT
Four Short Questions
1c
1.
Classify processes
1d
2.
Relate safe working requirements
1 a,b
3.
Compare processes to complete the same component
manufacturing operation
4.
Compare processes to complete the same assembly
operation
1 a,b
2
One long structured Question
2a
a)
select techniques for component manufacture
2a
b) select techniques for assembly
2 c, 3 a,b,c
c)
complete planning documents including safety
references
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The Timing and duration of assessments
The forty hours should be broken into approximately two equal parts and the tests are
administered at the end of outcome one, and towards the end of the unit. The first test
should last approximately one hour and given after approximately 10 hours of study.
The second piece of work requires that an assembly with 4 manufactured components
and two purchased components is completely planned, considering the operational
sequence, equipment and safety requirements. Planning documentation is also
required to be completed using prepared sheets. The time required for this
comprehensive assessment would be approximately 2 hours and it would be given
towards the end of the unit.
Reassessment
Time is allowed within units for assessment and reassessment of outcomes. Where a
candidate has not attained the standard necessary to pass a particular outcome or
outcomes, they should have the opportunity to be reassessed. Reassessment should
focus on the outcome(s) concerned and, as a general rule, should be offered on a
maximum of two occasions following further work on areas of difficulty. Evidence
from the original unit assessment should assist teachers and lecturers to identify why
an individual candidate has failed to achieve a particular outcome and to plan focused
support for learning.
The reassessments could take the form of similar question to those already shown
with different numbers, information etc. The reassessment process should not be
restrictive and could simply be evidence in verbal, written or graphical form giving
an addition of information or clarification of statements already presented by the
candidate.
The conditions under which assessment takes place
Arrangement documents refer to assessment being carried out under controlled
conditions to ensure reliability and credibility. For the purposes of internal
assessment, this means that assessment evidence should be compiled under
supervision to ensure that it is the candidates own work. Supervision may be carried
out by a teacher, lecturer, invigilator or any other responsible person for example, a
workplace provider.
Data sheets should be available to students during all tests.
Non programmable calculators may be used.
The two instruments of assessment should be unseen and of the closed book type.
Using internal assessment evidence to contribute to course estimates.
Unit assessments are designed exclusively for internal assessment. However, the
requirement in the second assessment for candidates to make qualified choices and
apply knowledge and understanding to specific applications may be used to contribute
to course estimates.
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The evidence of superior performance gathered from the candidates response to the
second assessment along with similar evidence from the other unit, Statics:
Equilibrium in Frameworks and Simple Stress, Outcome 3 when selecting materials,
could be used along with other evidence produced by the candidate when attempting
similar, but perhaps more extended work, during the additional 40 hours to predict the
grade of pass achieved by the candidate for the course. However, the integrated
nature of the external assessment for the course, which reaches across outcomes in the
same unit and across units, would suggest that a more reliable estimate of candidate
performance would be determined by using a "prelim exam" type of instrument.
Preparatory work and presentation of this prelim could be completed as an important
part of the additional 40 hours section of the 160 hour course.
Basically, Two assessment instruments are recommended
Assessment Instrument 1 - 4 Questions
Recommended duration - 1 hour
Presented under controlled, supervised conditions to ensure the completed attempt is
the candidates own work.
The first question requires the candidate to classify 20 given processes under four
headings.
In the process of completing this question the candidate demonstrates that they can:Identify the type of process
Classify the processes into general groupings
The second question requires the candidate to state one general and one specific
safety requirement for one process under each classification.
In the process of completing this question the candidate demonstrates that they can:State general and specific safe working practices.
The third question requires the candidate to describe and compare two techniques
which could be used to produce one feature of a component.
The component drawing is given and two components are to be produced.
In the process of completing this question the candidate demonstrates that they can:Describe manufacturing processes
Critically compare manufacturing processes
The fourth question requires the candidate to describe and compare two techniques
which could be used to assemble the parts of a simple device which contains 12 parts
but in effect only 4 different components are used.
Sketches of the parts are given and 100 components are to be produced.
In the process of completing this question the candidate demonstrates that they can:Describe assembly processes
Critically compare assembly processes
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Assessment Instrument 2 - One long structured question
Recommended duration - 2 hours
Presented under controlled, supervised conditions to ensure the completed attempt is
the candidate’s own work.
The question requires the candidate to extract information from a bill of material
showing the forms of material supply available for all component parts, the equipment
and tools available.
The candidate uses this information to select and describe suitable techniques to
perform various joining and assembly operations and to produce planning sheets on
prepared worksheets.
In the process of completing this question the candidate demonstrates that they can:Select appropriate techniques to manufacture a structural fabrication
Select appropriate techniques to assemble a structural fabrication
Select operations sequentially to manufacture and assemble a structural fabrication
Consider work holding, capacity of tools and equipment
Consider any specific safe working practices and special safety requirements which
are necessary.
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RESOURCE MATERIALS
Video presentation of process applications and development planning are available
from sources such as the BBC.
Interactive CD roms are available for candidates to use in conjunction with a PC from
The Technology Enhancement Programme. Information which may have been used
in the past for modules such as Design and Make may also be useful.
Examples of outline descriptors of processes, forms of supply and typical planning
documents are given later in this pack.
Sources of Information and Learning Materials
This unit, although written to satisfy the requirements of an Intermediate 2 Structures
course, contains many elements which have already been covered by earlier SQA
Modules. Materials already developed for these earlier modules can provide a useful
source of examples and applications.
The Subject Guide Engineering 2: Structures at Intermediate 2 – Appendix 4 maps the
content of this unit with
69703 Engineering Manufacturing Processes 1
The main sources of information used to develop this pack were the Higher Still
Development Unit publications
Arrangements – Structures Intermediate 2 May 1997
Subject Guide – Structures at Intermediate 2 1997
NABS – Fundamentals of Manufacture and Assembly Techniques January 1999
The learning materials contained in this pack were developed from first principles but
similar material is available from
Equipment Manufacturers Catalogues such as Buck and Hickman or any textbook on
Manufacturing Technology produced since 1980.
Examples of outline notes of process characteristics
A simple component can be used as a vehicle to introduce the steps in the general
manufacturing process from specification through considering possible techniques to
deciding optimum techniques to produce the component.
A customer or designer will produce a specification (detailed description) which
outlines the requirements of the desired component. In the general engineering and
structural fabrication areas all this information is often contained in a part drawing.
The part drawing will show shape, dimensions, tolerances, surface finish and material
to be used.
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The part drawing is usually the initial source of information on the product
requirements. In conjunction with the drawing an overall knowledge of the processes
available for manufacture is used to logically decide the sequence of techniques to be
used.
Consider that a shouldered component is required as drawn below.
1.6
E
R
A
U
Q
S
52
51
2x 45O
59.95
60.05
3.2 OVERALL
80
MATERIAL:- MEDIUM CARBON STEEL
Depending on:
 Material
 Size and shape
 Accuracy
 Quantity required (perhaps introduced later).
The various primary forming/material preparation which could be used are:
 Machine all over from 25 mm bright square bar
 Forged followed by machining
 Fabricated and welded from two prepared pieces
 Force fitted or shrunk fitted from two more accurately prepared pieces.
This approach will clarify that the candidate requires a knowledge of a range of
processes composed of a brief description of what the process does and how it works,
the equipment and tools commonly used, safe working practices, degree of skill
required and practical limitations.
The requirements of Outcome 1 can now be overtaken.
Perhaps two general processes under each of the four classifications could be
considered at this stage using workshop demonstrations, industrial visits, suitable
videos or candidate’s previous experience in order to start the necessary database
which can continue to be enlarged as the other outcomes are overtaken.
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Examples
Primary Forming
Material Preparation
Assembly
Finishing
casting, forging
machining, cutting off
Joining, fitting
Surface cleaning, Heat treatment
Following on from initial considerations brief details can be entered on prepared
sheets and collated by the candidates.
Examples
Classification:
General Process:
Description:
Can be:
Primary Forming
Casting
The form of supply of the raw material
ingots, usually between 5 and 100 kg for metals,
power or granules for plastics.
The charge of material now requires to be melted either in a furnace such as a cupola
for cast iron or in a closed chamber for thermoplastic materials just before it is poured
into a previously prepared mould. Once solidified the casting is removed from the
mould and any material necessary for the process, but not part of the final casting, is
removed.
List of Specific Processes:
FOR METALS
NON-METALS
SandCasting
Cold casting – glass fibre, concrete
Shell Moulding
Injection Moulding - thermoplastics
Die Casting
Compression Moulding – thermosetting plastics
General Safety Requirements:
Protective clothing
eye, body, hands and feet require to be protected from
extremely hot surfaces.
Ventilation
chemical agents and other dangerous or irritant fumes
require to be extracted from the air surrounding the
processes.
Lifting and Handling
training must be given for manual and mechanical
methods of lifting and transporting materials and
components.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Classification:
General Process:
Specific Process:
Description:
Primary Forming
Casting
Sand Casting
Commonly used for metals such as cast iron,
cast steel, brass, aluminium.
A pattern made of wood, plastic or metal has sand rammed round it in a metal box
called a moulding box. The moulding box can be split and the pattern withdrawn
leaving a cavity into which the molten metal is poured once the two halves of the box
have been re-assembled and secured. Complex castings can be produced using sand
cores to form holes and other internal cavities in the component.
The process is relatively cheap to operate for a small number of components but
dimensional accuracy is not as good as the more advance processes and surface finish
is poor. The rate of cooling of the metal often causes a course grain structure which
can result in a brittle structure.
Common equipment and tooling:
Pattern, moulding box, melting furnace, transfer ladle, moulding sand, external
weights to contain pressure, sand transferring equipment, core boxes, fettling
equipment. Moulding tools include formers to produce runners and raisers, ramming
tools, smoothing trowels, breaking out tools such as crowbar and hammer.
Specific Safety Requirements:
All specified protective clothing must be used.
Safety glasses.
Fire precautions must be practised regularly.
Casting and furnace areas must be well ventilated.
In this way a record of the knowledge and understanding associated with a broad
range of manufacturing processes can be started and time allowed, when appropriate,
for students to enlarge and order this information as the presentation of the unit
continues.
The products considered in conjunction with the processes to develop the students
knowledge need not be extensive since the intention is to allow the candidate to match
up requirements of the finished product with the techniques at hand. Perhaps an
integrated approach could be achieved by considering one very simple assembly
containing a few manufactured components and purchased components covering two
metal and two non metallic materials.
An example of this approach has been included in Part 2 of this pack.
There is some advantage in using pre-prepared or template sheets for use throughout
the presentation of the unit. Examples of such a sheet is included overleaf for use
with developing a record of processes.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Classification
General Process:
Specific Process:
Description:
List of common operations:
Common Equipment and tooling:
Specific Safety Requirements:
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Example of an Operation Sheet or Route Card
Route Card
Drg No
Product:
Material
Part:
Op No
Operation:
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Teacher/Lecturer
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Example of an operational planning document
Planning Sheet
OPERATION
NUMBER
DESCRIPTION
EQUIPMENT
AND TOOLS
SAFETY
REQUIREMENTS
010
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ACKNOWLEDGEMENTS
The support and assistance provided by colleagues at the Scottish Advanced
Manufacturing Centre in Livingston and the collaboration with staff at Banff and
Buchan College in Fraserburgh is acknowledged.
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STRUCTURES: FUNDAMENTALS OF MANUFACTURE
AND ASSEMBLY TECHNIQUES
(INTERMEDIATE 2)
PART TWO
Student Materials
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
1
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
2
INFORMATION AND SUPPORT MATERIALS FOR USE WITH STUDENTS
Integrative Learning Approaches
Once a reasonable number of processes have been considered in outline by the student
and some experience in matching manufacturing requirements to what processes can
achieve the requirements of Outcomes 2 and 3 can be overtaken in an integrative way,
perhaps working backwards from two or three graded examples of product assemblies
or structural fabrications.
During the additional 40 hours component of the structures course this work could be
further extended using similar techniques spanning across two or more of the three
units making up the course.
Three examples of this type of integrative learning vehicle written in the form of an
assignment are given below. These have been written in a form which enables them
to be used with candidates either individually or as a small group assignment.
Assignment 1 - Gate Valve
The gate valve shown below is to be made from brass. The rate of production is to be
200 per week for two years.
The taper is to be individually lapped with the valve body by the customer on
delivery.
Drawing Number 01
162
18
90
48
TAPPED HOLE
FOR SECURING
SCREW
56
18
26
FLOW HOLE
15
SQUARED END
TAPER TO BE
SEALING FIT
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
3
From the list of processes given:
a) order the processes into those suitable for shape creation of finishing
b) critically compare the two most appropriate, in terms of suitability for number
required, material used, size and shape, accuracy, safety requirements and skill
requirements to produce the outside shape of the component
c) select appropriate techniques to completely manufacture the component and order
these techniques into a logical sequence
d) complete a route card indicating the minimum information for each operation to
be completed and any equipment or tools necessary
Processes available
Sand Casting
Shell Moulding
Die Casting
Hand Forging
Closed Die Forging
CNC Lathe
Vertical Drilling Machine
Multi spindle Drilling Machine
Cylindrical Grinder
Heat Treatment Plant
Chromium Electroplating Plant
Metal surface cleaning plant
Spray Paining Plant
Plastic fluid dip bath
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Assignment 2 - Jib Crane
The essential elements for the construction of a simple jib crane are shown below.
The beam B is to be permanently joined to the square bar S.
Strengthening web G is to be permanently joined to beam B and square bar S.
Column C is a hollow square section and at its upper end plates P and Q are to be
permanently joined to allow another contractor to fit a pivot pin through square bar S.
Finally a base plate A is to be permanently fixed to the lower end of column C.
Material for all parts has been agreed as weldable structural steel to BS4 and cut off to
the required dimensions.
3500
A
B
S
C
G
6000
Q
130
15
240
15
200
SQUARE
SECTION OF BEAM B
A
Initially 60 are to be made and further orders are a possibility. Your task is to:
a) Decide if joining should be completed as one assembly or as two or more sub
assemblies – give reasons for your choice.
b) Decide if one or more fixtures would be appropriate and if so give rough sketches
showing how location and clamping would be achieved.
c) State which welding process would be appropriate to use for all joining
requirements.
d) Complete the planning sheet for one sub assembly giving as much detail as
possible regarding equipment and tools used, where quality checks should be done
and any safety requirements or safe working practices to be used.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Assignment 3 - Bird Feeder
A prototype is to be made for a bird feeder, at this stage only one is to be produced.
The 5 parts of the feeder and an assembly are shown as a design sketch indicating all
functional dimensions and any special requirements. Your task is:
a) For each part to be manufactured complete a standard planning sheet.
b) Complete a standard planning sheet for the assembly of the product.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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HOLES A ON ONE PART &
HOLES B ON OTHER
HOLES A:
2 OFF 3 DIA x 6 DEEP
30
25 DIA HOLE
DRILLED THRO’
ONE PART ONLY
130
HOLES B:
2 OFF M4 x10 DEEP
25
HOLES B ON ONE PART &
HOLES A ON OTHER
2
35
8
SIDES:
2 OFF REQUIRED
MATERIAL - YELLOW PLASTIC
SHEET x 8 THICK
O
8
4
45
20
50
20
HOLES A:
4 OFF x 3 DIA x 5 DEEP
4
15
15
20
HOLES B
4
50
25
15
HOLES A
HOLES B:
2 OFF x 2 DIA x 6 DEEP
AT HALF THICKNESS
50
TOP:
1 OFF REQUIRED
MATERIAL: BLUE PLASTIC x 8 THICK
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20
HOLES A:
4 OFF x 4.5 DIA
C/BORED 7 DIA
ON UNDER SIDE
4
15
25 HOLE x 6 DEEP
FLAT BOTTOMED
20
60
20
15
HOLES A
4
30
60
130
129
BASE:
1 OFF REQUIRED
MATERIAL: ALUMINIUM x 10 THICK
56
FRONT:
1 OFF REQUIRED
MATERIAL: PERSPEX x 2 THICK
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10
40
25.05
25.15
7
PLUG:
1 OFF REQUIRED
MATERIAL: BLACK PLASTIC
x 40 DIA
50
10
35
INTERNAL DIA 10
HANDLE:
1 OFF REQUIRED
MATERIAL: BRIGHT BRASS WIRE
2 DIA x 255 LONG
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Evidencing Superior Performance
The information reproduced earlier in Part 1 from the National Assessment Bank pack
for this unit indicated that the second assessment would allow candidates to make
qualified choices and apply knowledge and understanding to specific applications at a
level above that for a C pass in the subject. The integrative and extended nature of the
work required by candidates, mainly when attempting assignments 2 and 3, could
provide a source of evidencing superior performance. Any evidence produced to
support superior performance would have to be retained for each candidate to back up
the lecturer’s/teacher’s prediction of this performance or to be used as part of an
appeals procedure.
Examples of where to look for evidence indicating superior performance are given for
each assignment.
For Assignment 1 - Gate Valve
a) This requires the candidate to order a series of 14 given processes into two
categories which in turn requires the candidate to recall knowledge or otherwise
link each process name with its characteristics. Superior performance could not
easily be demonstrated.
b) This requires the candidate to interpret a drawing to deduce the requirements of
the external shape of the component, select two shape creation processes from the
6 given and compare the merits of these two processes within the criteria given.
To indicate superior performance selection would be closed die forging and CNC
Lathe mainly on a basis of number of components and component materials. The
Comparison should indicate comparison of accuracy of processes, skill
requirement and safe working practice as the main areas of comparison.
c) The selection of closed die forging followed by two drilling operations (drill and
tap axial hole then drill 15 mm dia hole using a drill Jig) would indicate superior
performance and other combinations are also worthy of consideration.
d) the preparation of a standard route care would not easily allow superior
performance to be evidenced any further than that already shown in parts b) and c)
For Assignment 2 - Jib Crane
a) On a number required basis choice would be for two sub assemblies (B, G, S and
P, C, Q, A) this would allow the two sub assemblies to be completed
simultaneously with less days required to complete the product. This approach
would indicate superior performance.
b) One simple fixture described for each sub assembly showing location pins and
quick release clamping could indicate superior performance.
c) Perhaps three methods could be given in the question if the lecturer does not want
more wide ranging open ended responses. Almost any method of electric arc
welding would be suitable – superior performance is not easily evidenced.
d) Possibly the simpler sub-assembly to plan would be BSG. A standard planning
sheet would be completed starting with checking the size of the three component
parts and finishing with chipping or dressing the welds if required.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Using a Jig, mentioning more than 70% of tools, equipment and safety requirements
would indicate superior performance.
For Assignment 3 - Bird Feeder
No attempt has been made in the information given in the question to limit the
processes to be used, if desired this could be done using very simple machinery and
equipment since only one assembly is to be produced.
a) For each part in turn the candidate could possibly start with a simple sequential
list of processes and a brief description of operations before starting the
individual part planning sheets. Consistently selecting the optimum process,
minimising the number of operations, selection of the correct equipment and
tooling and highlighting safe working practice would indicate superior
performance.
b) Adopting a single operator approach to assembly, deducing a reasonable
sequence of operations and stating the main tooling and equipment requirements
would cover the necessary ground in the planning sheet. Safe working practice
does not have a high profile in this particular part of the assignment. Superior
performance would not be easily evidenced in this part of the assignment.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Assignment Solutions
Assignment 1 - Gate Valve
a)
SHAPE CREATION
Sand Casting
Shell Moulding
Die Casting
Hand Forging
Closed Die Forging
CNC Lathe
Vertical Drilling Machine
Multi spindle Drilling Machine
FINISHING
Cylindrical Grinder
Heat Treatment Plant
Chromium Electroplating Plant
Metal Surface Cleaning Plant
Spray Painting Plant
Plastic fluid dip bath
b) Outside shape could be produced by any of the casting, forging or by the CNC
lathe.
Considering the required accuracy for the taper then Die Casting, closed
die forging or CNC turning would be best.
Considering the number required i.e. 200 per week for 2 years making a total of
10,000 components the same choice would remain so a direct comparison
between any two would be acceptable.
Leaving out Die Casting because brass is not often used in this process due to its
relatively high melting temperature the comparison should be made between
Closed Die Forging and CNC machining.(This depth of consideration to decide
the two processes to be compared would indicate superior performance).
FACTOR CONSIDERED
Number required
Material used
Size and shape
Accuracy
Safety
Skill
CLOSED DIE FORGING
Very suitable
Very suitable
Possible in one operation
Including square end and
Flats but not tapped hole
Or 15 mm dia hole
Within the requirement
Implication with transferring hot
metal slugs, guarding, removing
hot finished part
Operator or semi-skilled
occupation
Quicker than CNC lathe
CNC MACHINING
Suitable
Very suitable
Possible in one operation
including tapped hole but not 15
mm dia hole flats or square end
Capable of more accurate work
Implication with transporting
heavy bar material, high swarf
production rate and use of
coolant.
Often a skilled occupation
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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c) Closed Die forge shape
Drill and tap, drill 15 mm hole
Visually check form
d)
Route Card
Drg No
01
Material
Brass
Op No
010
Product:- Gate Valve
020
Heat billets in suitable batch numbers
Muffle furnace
030
Drop forge
Closed die forge with specially made dies
040
Remove flash and dress
050
Drill and tap, drill 15 mm hole
Specially made jig, multi spindle drilling machine, tapping attachment, suitable taps and drills
060
Deburr and visually check
Part:- Gate Valve
Operation
Cut billet off to length.
Tools – Mechanical saw with stop set
Note: if the processes selected at c) were different e.g. CNC machining chosen for the
main shaping process then the operations would of course be different and the flats
and square end would have to be produced, possibly by milling. In effect, as many as
4 of the 6 operations listed could be different but if the degree of detail was similar
and the sequence was comprehensive and logical the answer would be equally valid.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Assignment 2
a) Considering that 60 fabrications are to be made then a sub-assemblies approach
would simplify manufacture.
Two sub-assemblies would be appropriate:Sub Assembly 1 – consisting of beam B, Square bar S and Strengthening web G
Sub Assembly 2 – consisting of upper plate P, column C, lower plate Q and base
Plate A
Reasons for using sub assemblies
 Each sub-assembly will be less complex than the complete job
 Sub-assemblies can be overtaken simultaneously so reducing substantially the
number of days to complete the work
 Even if planned as a single assembly the work would essentially be
Completed as two sub assemblies
b) For Sub-assembly 1 - The Beam
One fixture would be appropriate
5 OFF
LOCATING PINS
2 OFF QUICK RELEASE CLAMPS
(BASE OF ONE CLAMP ACTS AS
A SETTING BLOCK FOR WEB G)
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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For Sub assembly 2 - The Column
Two fixtures would be appropriate
One for the top end and one for the bottom end
7 OFF
LOCATING PINS
4 OFF
HEIGHT SETTING
BLOCKS
1 OFF QUICK
RELEASE CLAMP
TOP FIXTURE
2 OFF
HEIGHT SETTING
BLOCKS
1 OFF QUICK
RELEASE CLAMP
4 OFF
LOCATING PINS
1 OFF
WEDGE CLAMP
BOTTOM FIXTURE
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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c) the following welding processes would be suitable:
Metal Arc
Gas shielded Arc
Submerged Arc
d) Planning Sheet for Sub-assembly 1 - The Beam
OPERATION
NUMBER
DESCRIPTION
EQUIPMENT AND
TOOLS
SAFETY
REQUIREMENTS
010
Visually check parts B, G and S
Dress if required
Flat file
Gloves, safety shoes to be
worn
020
Place fixture on welding table
and insert parts B and S. Locate
and clamp
Special fixture
As above
030
Tack weld parts B & S together.
Check position and full weld
corner where part G will be
fitted.
Chosen welding plant,
chipping tool, square
As above plus eye
protection from arc
As above except square
As above
As above
As above
Chipping tool, portable
grinder
Gloves, safety shoes, eye
protection from chips
040
Hold part G in place and tack
weld in position.
050
Remove from Jig and full weld
all three parts together
060
Remove all slag and dress weld
if appropriate to the welding
process
Note: In addition to the remarks made earlier concerning evidencing superior
performance, at operation 030 the full welding of the corner before part G is fitted
indicates a depth of consideration above that for competence.)
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Assignment 3 - Bird Feeder
a) Looking at each part in turn starting with Side – 2 required, only one has the 25
mm
dia hole. Material used is 8 mm thick yellow plastic sheet.

Material requires to be cut from the sheet material. Marking out, followed by
cutting out using a band saw or hand saw.
 Considering this is a prototype then the profile could be hand finished using a file,
milled or shaped.
 The 2 mm wide x 3 mm deep slot and the 8 mm wide x 8 mm deep bevel now
require to be cut, used a horizontal milling machine.
 Holes now require to be (marked off), drilled and tapped where required (the fit of
the top and bottom will require that the hole position must be accurately held).
The required degree of accuracy could be achieved using a vertical milling
machine or by making a simple drill jig to use on the top, bottom and sides in
conjunction with a pillar or vertical drilling machine.
Planning Sheet for: SIDE
OPERATION
DESCRIPTION
EQUIPMENT AND TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Mark out and cut off
48 x 132
Square, scriber, 150 mm rule,
Bandsaw
Wear goggles, use a
push bar
020
Mill profile, two ends
together to 46 x 130
Horizontal mill, side and face
cutter, parallels, m/c vice, 150
mm rule, mallet
Wear goggles, gloves,
safety glasses. Use
properly adjusted
cutter guard
As above
030
Mill Bevel
040
Mill slot
050
Drill in both parts
2 – 3 mm dia holes x 6
mm deep
2 – tapping holes for M4
thread
Mark off and drill in one
part 20 mm pilot hole
then 25 mm dia hole
Note:- care must be
taken with which edge
the different holes go on
each side.
As above except side and face
cutter is changed to a 2 mm
thick slitting saw
As above
Vertical drilling m/c, machine
vice, Jacobs Chuck and key
3 mm drill
3.3 mm drill
M4 taps (tap by hand)
10 mm drill
25 mm drill
specially made drill jig
As above
As above
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Front – 1 required
Material used is clear plastic, 2mm thick
No planning sheet is required, the material is marked off 130 x 56 using a marking
point, rule and square, then cut off using straight snips.
Top – 1 required
Material used is 8 mm thick blue plastic sheet
 Material requires to be cut from the sheet material. Marking out, followed by
cutting out using a band saw or hand saw
 Profile to be hand finished, milled or shaped
 Holes require to be drilled (in order to pin to the two sides to the top the holes
require to match up accurately) use a drilling machine and a specially made drill
jig The two 2 mm holes in the side of the Top do not require a jig.
Planning Sheet for TOP
OPERATION
DESCRIPTION
EQUIPMENT AND
TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Mark out and cut off
51 x 51
150 mm rule
square
scriber
Band saw
Wear goggles
Use a push bar
020
Hand finish profile
File, rule, square, vice
Wear gloves
030
Drill
4 – 3 mm dia x 5 mm deep
holes
Mark off and drill
2 – 2 mm dia x 5 mm deep
holes
Drill Jig
Vertical drilling m/c
Jacob’s chuck & key
3 mm dia drill
Machine vice
2 mm dia drill
Wear goggles and
gloves.
Use properly adjusted
chuck guard.
Bottom – 1 required
Material used is 10 mm thick x 60 mm wide aluminium bar
 Material requires to be cut from flat bar using a mechanical or hand saw
 Ends have to be finished using a mill or shaper
 Holes require to be drilled (again the same simple drill jig could be used to
achieve the necessary accuracy with the 4.5 mm dia holes). The 25 mm dia flat
bottomed hole does not require a jig but will have to be marked off
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Planning Sheet for BOTTOM
OPERATION
DESCRIPTION
EQUIPMENT AND TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Cut off 65 long
150 mm rule, scriber,
mechanical saw
Wear gloves, safety
glasses
020
Mill to length 60
Vertical milling m/c,
12 mm dia end mill, Autolock
collet, machine vice, mallet
As above and use
properly adjusted cutter
guard
030
Deburr
200 mm smooth flat file
As op 010
040
Drill
4 - 4.5 mm dia through
c/bore 7 mm dia x
4 mm deep
Mark off and drill
1 – 25 mm dia x 7 mm
deep
Drill jig
Vertical drilling m/c
Jacobs chuck and key
mm drill
7 mm drill
Machine vice
25 mm flat bottom drill
As op 020
Plug – 1 required
Material used 40 mm dia ABS plastic bar
Material requires to be cut from round bar using a mechanical or hand saw
Part has to be machined using a centre lathe
Planning Sheet for PLUG
OPERATION
DESCRIPTION
EQUIPMENT AND TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Cut off 15 long
150 mm rule
Mechanical saw
Wear gloves, safety
glasses
020
Place in 3 jaw chuck with
10 mm projecting
Turn 25 mm dia, one
roughing and one finish
cut, face to 7 mm length
chamfer
Centre lathe with 3 jaw chuck,
turning tool, chamfering tool,
25 – 50 external micrometer
150 mm rule
As above
030
Reverse in chuck face to
length chamfer
as op 020
As above
Handle – 1 required
Material used 2 mm dia brass wire 255 mm long
No planning sheet required, the material us cut off to size from bar, then bent to shape
using a 10 mm dia piece of scrap bar and a vice.
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b) Assembly
Remembering that this is a prototype, one-off assembly.
The complete assembly would be done without the distinction of sub assemblies
or flow techniques.
- Check all parts visually
- Fit pins to TOP
- Fit SIDES to TOP
- Fit FRONT to Slot in SIDES
- Fit BOTTOM to SIDES using cap screws
- Fit PLUG to hole in side
- Fit HANDLE to TOP
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Planning Sheet for ASSEMBLY
OPERATION
DESCRIPTION
EQUIPMENT AND
TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Visually check all parts and
deburr if required
200 mm smooth flat
file
020
Fit 4 off 3 mm dia pins to
underside of TOP using
super glue. Leave 5 mm
length of pins protruding
Hammer
Square
Super glue
Read instruction on super
glue tube and carefully follow
the instructions
030
Fit TOP to SIDES keeping
the side with the 25 mm dia
hole to the back. Glue pins
to sides using super glue
Hammer,
Small hardwood
block,
Super glue
As above
040
Carefully enter FRONT in
2 mm wide slots and slide
down to touch top
050
Fit BOTTOM to sides using
4 off M4 cap screws
Suitable hexagon
wrench
060
Fit 25 mm dia PLUG to hole
in side to achieve a tight
push fit
Half round scraper
070
Fit HANDLE to TOP
A group exercise could be attempted at the end of this assignment starting from the
premise that the BIRD FEEDER design has been tested and approved. An initial
product run of 500 is to be completed. The candidates are to consider the processes
which could now be used to manufacture the product either in an open ended way or
from a given list of available processes.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Tutorial Examples
The following tutorials are intended to be used directly after the concerned aspects
have been described and discussed. While attempting the tutorial questions the
candidates may require to be given, or to research, further information on processes
and techniques in order to maximise the benefit derived from developing solutions.
Outcome 1 - Tutorial
1. Complete a specific process sheet for the following processes including a
description
of the process, common equipment and tooling used as well as specific safety
requirements.
a) Classification:- Primary Forming
General Process:- Forging
Specific process:- Hand Forging
b) Classification:- Material Preparation
General Process:- Machining
Specific process:- Vertical Milling
c) Classification:- Assembly
General Process:- Fusion Welding
Specific process:- Metal Arc Welding
d) Classification:- Finishing
General Process:- Surface Cleaning
Specific process:- Shot Blasting
2. During the installation of overhead speakers as part of an intercommunication
system in the company office, it was decided that 8 – Aluminium brackets as
shown in the sketch below were required. After briefly describing the processes.
Compare, on a basis of accuracy, safe working practice, skill necessary and the
suitability of producing the keyhole feature by:
a) hand by drilling, sawing and finishing by filing
b) making a simple punching tool and using a fly press
10
6
3
Aluminium material is 2 mm thick and the keyhole dimensions are shown
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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3. Three standard spherical plastic knobs are to be attached to the end of clamp
levers on a fixture currently being made. The plastic knobs are 30 mm in diameter
and are supplied with a 20 mm dia hole, 20 mm deep. The clamp lever are all 12
mm dia for a length of 40 mm. After briefly describing the processes compare on
a basis of functional suitability, degree of complexity, appearance and safe
working practice the suitability of fitting the knobs to the levers by:
a) Threading both components to a suitable form and screwing together
b) Increasing the size of the knob holes to a suitable size and force fitting.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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Outcomes 2 and 3 Tutorial
1. The following list shows 5 factors associated with the product which should be
considered during process selection. Add two other factors to the list.
-
Material characteristics
Material form of supply
Size of components
Shape of components
Accuracy requirements of components
2. The following list shows 5 factors associated with a process which should be
considered during process selection. Add two other factors to the list.
-
Suitability of process for operation with the component material
Suitability of process for the component size
Suitability of process for the component shape
Suitability of process to produce the accuracy required
Suitability of process to produce the surface finish required.
3. List the principles most commonly applied in planning the manufacture of a
product. Starting with – Look at the final product and break it down into possible
sub assemblies and finish with – write the planning documents for individual
components and assembly procedures.
4. List any four important considerations when deciding possible processes for the
manufacture of a component.
5. A straight pipe connector shown below is required to be manufactured to join
together lengths of pipe of a non-standard outside diameter. Only 10 pipe
connectors are required.
a) Determine the most suitable shape creating process from:
machining
closed die forging
sand casting
b) After joint fact X has been produced determine the most suitable process for
producing the 42.5 mm dia holes from using
a pillar drilling machine
a vertical milling machine
a centre lathe.
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A
A
200
80
42.5
42.6
55
80
FACE X
SECTION ON A-A
MATERIAL: ALUMINIUM
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6. An order of 4 cast-iron brackets are to be machined as shown below using
standard machinery and equipment.
80
100
a) decide the sequence of operations to be used and briefly describe.
b) Complete a standard operation sheet for the machining of this part
indicating the minimum information for each operation to be completed and
any standard equipment or tools necessary.
FOUR HOLES
10
80
10
50
100
51.00
51.08
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7. One pivot support bracket is to be produced from mild steel as shown below.
Complete a standard planning sheet for the manufacture of this bracket assuming
the boss is a standard part which has already been made with a 20 mm dia spigot.
4 CORNERS
R17
BOSS 25 TO BE
LOCATED IN 20 HOLE
IN PLATE. DRILL & TAP
THRO’ M10.
MATRIAL:- MS
(SUITABLE FOR WELDING)
R5
(TRUE PLANE)
R15
R5
4 HOLES 10
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8. The overall dimensions of a planer’s gauge are shown in the sketch below.
Only 4 are to be made.
The TOP (female member) is to be made from alloy steel, hardened and ground
all over. The BOTTOM (male member) is to be made from cast iron stock bar,
machined all over and hand scrapped on the bottom and top bearing face.
Three M5 hexagon socket set screws will be used to complete the assembly.
Complete standard planning sheets for the manufacture of the TOP, BOTTOM
and the fitting together of the two parts.
180
68 NOMINAL
O
15 + 2’
30
3 LOCKING SCREWS
Material available
40 x 120 Bright alloy steel bar
45 x 130 Black cast iron bar
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Solutions to the Tutorial Questions
The following solutions attempt to indicate how an average student would develop
their answers, the technique of writing explanatory notes for the particular approach
taken at appropriate points should be encouraged as a regular feature of student
responses.
Outcome 1 - Tutorial Solutions
1. a) Using a template for a specific process sheet from earlier in the pack.
Classification:
General Process:
Specific Process:
Primary Forming
Forging
Hand Forging
Description:
A billet of metal is heated in a forge to above its re-crystallisation temperature then
beaten to shape on an anvil, regular re-heating may be necessary. The metal is held in
an appropriate size and type of tongs. If other shaping tools require to be held then a
second operator will apply the hammer blows.
List of common operations:
Drawing down – making the material thinner
Upsetting – making the material fatter
swaging – shaping the outside of the material (e.g. round, square)
pierce – making holes
cut off – to cut using a chisel action
Common Equipment and tooling:
Anvil, series of hammers (usually about 4), swaging tools, flatters, piercing tools,
cutting tools, sets of tongs for various shapes and size of components.
Forge – usually gas fired
Specific Safety Requirements:
Feet, eye and hand protection is required from red hot metal.
Ventilation or air extraction equipment must be used.
Fire extinguisher of the correct type must be near by.
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1. b)
Classification:General Process:
Specific Process:
Material Preparation
Machining
Vertical Milling
Description:
The machine datum is a horizontal metal table capable of very accurate powered
movement in three axes. The work is held on this table. The cutter is held in a
vertical spindle above the table and can have its feed up and down,right or left and
speed preset. Coolant is available to prevent overheating while cutting. Most cutting
operations are generated by a combination of table and tool movement.
List of common operations:
Mill flat horizontal and vertical surfaces
Mill steps and grooves
Drill holes
Cut slots and keyways
Common Equipment and tooling:Collets for tool holding, cutters used as end mills, keyway cutters, drills, work
holding, by clamping directly on the table, by using a machine vice previously
mounted on the table or by a Jig or fixture previously mounted on the table.
Specific Safety Requirements:
Hand and eye protection from metal cuttings
Precautions against contact with coolant
Use of correctly adjusted cutter guard
Care in mounting sharp edged cutters.
Structures: Fundamentals of Manufacture and Assembly Techniques (Intermediate 2) Student Materials
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1. c)
Classification:General Process:
Specific Process:
Assembly
Fusion Welding
Metal Arc Welding
Description:
Sometimes called Electric Arc Welding. A consumable electrode is held using a
holder attached through a conducting cable to the electric arc welding plant. The
electric current flow rate is adjusted so that an arc is struck when the electrode tip is
placed near the area to be welded, molten metal from the electrode melts the parent
metal and this solidifies as the electrode is moved slowly onwards. The deposited
metal forms the weld and slag forms on the top as it cools.
List of common operations:
Weld can be tacks (intermittent), single run (one pass of the electrode) or multi-run
(several passes of the electrode) and can be laid down in prepared areas, such as a
Vee. Unsuitable for very thin sheet metal or for joining two dissimilar metals.
Common Equipment and tooling:
Welding plant.
Various sizes and compositions of flux coated electrodes.
Metal table acting as an electrical earth.
Various clamps and blocks.
Chipping hammer.
Specific Safety Requirements:
Hand and eye protection from heat and harmful arc glare and radiation.
Foot protection when large or heavy components are employed.
Usually leather aprons are also worn.
Fume extraction is also necessary.
Training in lifting and handling may be required.
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1. d)
Classification:General Process:
Specific Process:
Finishing
Surface Cleaning
Shot Blasting
Description:
Basically corrosion, dirt and scale are removed by blasting the surface with
compressed air containing abrasive particles. Usually this is completed in a closed
box, the front of which is provided with two armholes and a window. The front can
usually slide upwards to open. An adjustable nozzle situated inside the box delivers
the shot and this can be directed on the surface to be cleaned. The flow can be
controlled by a foot pedal.
List of Common operations:
Surface cleaning of metals before a further finishing process such as painting is done.
If required, degreasing must be done before blasting since grease can cause
contamination of the re-cycled abrasive material.
Common Equipment and tooling:
The whole process is usually done using a dedicated plant. Very long rubber gloves
are usually worn and care must be taken to avoid directing the jet of particles onto the
hands or arms.
General Safety Requirements:
Other than the special gloves which are usually considered as part of the equipment
the only requirement is training in lifting and handling in order to safely load and
unload components.
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2a) Possibly before the material was bent into shape the keyhole would be marked out
using a rule, draw point, centre punch and hammer. The 6 mm hole and three 3
mm holes drilled using a vertical drilling machine and Appropriate tools. The
keyhole would then be finished by hand sawing and filing.
b) At the same stage as a) the centreline and top of the 6 mm hole would be
marked out. If not available a suitable punching tool and bottom die would
require to be made in medium carbon steel. The fly press would require to be set
up with the punch and die. The keyhole would then be punched in one operation,
but some deburring or dressing may be necessary.
Comparison
By Hand
The required accuracy could be easily achieved and the complete job would possibly
be completed in about 2 hours. Safe working practice would involve using
appropriate guarding and protective items. The skill level required would be
appropriate to a craftsman.
By Punch
The required accuracy could be easily achieved and if a punch were available the
complete job would take less than an hour, but if a punch required to be made more
than one day would be necessary. Safe working practice would be much the same as
for the other method. The skill level would be appropriate at craftsman level if a
punch was required to be made or at operator level if a punch existed.
3.a) After consulting a suitable source of information, for example a ZEUS CHART
for ISO Metric Threads it can be established that an M12 thread requires a
tapping drill of 10.2 mm dia.The knobs could therefore be hand tapped for the
depth of the 10 mm dia hole.The levers could be hand threaded for a length of 18
mm.The knobs could then be screwed onto the levers.
b) After consulting a suitable source of information, for example BS4500 Data
Sheet 4500B – selected ISO Fits: Shaft basis. Help could be given with
extracting the following information.
Interference Fit h6/S7
The tolerance for the shaft (h6) is 12.000 to 11.991
The tolerance for the hole (S7) is 11.983 to 11.968
Since the knob holes are to be increased a suitable size would be 11.96 to 11.98,
as close a tolerance as this would require the use of an 11 mm drill, then a
specially modified reamer or to be bored in a centre lathe.
Comparison
Both approaches suit functional requirements and appearance equally well and both
require about the same degree of consideration for safety. Choice would therefore be
made on a basis of complexity. Boring out the knob holes would be a more complex
process than threading both parts, due to the requirement to modify a reamer or bore
on a lathe. On balance the threading method would be more suitable.
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Outcome 2 & 3 Tutorial – Solutions
1) Required (surface) finish of particular components.
Number of product required.
2) Skill required to operate the process.
Safety implications of using the process.
3) Break the product into suitable sub assemblies
Formulate a general method to complete each sub assembly and the final
assembly.
Note where special tooling or fixtures are required.
Consider each part in turn and formulate a general list of the processes necessary
including either/or situations like cast or forge.
Make a sequential list of the operations required to produce each part.
Finally write the planning documents.
4) Shape, size, form and finish of the component.
Material and its form of supply.
Processes available from which a selection can be made.
Any specific safety considerations or requirements.
5) a) Machining from solid bar would require work on more than one machine,
possibly with several operations on each. Closed die forging would produce
the component shape with one or two operations, but a complex set of dies
would have to be made. Sand casting would require a simple wooden pattern
to be made and possibly a core box to allow the long hole to be cast. Casting
would give the most suitable process considering the number being produced.
b) A pillar drilling machine could be set up fairly easily using Face X as a datum
clamped to an angle plate which in turn could be clamped to the machine
table, a hole could be drilled, but an adjustable reamer would have to be set
to finish the hole. Difficulty would be encountered when reversing the
component to drill and ream the other hole in order to achieve concentricity
of the two holes.
A vertical milling machine would be set up in the same way as the pillar drill
but by using an indexing head concentricity would not be a problem. A boring
tool could be used instead of a reamer.
A Lathe using a 4 Jaw Chuck could be used with a drill and boring tool,
concentricity when the component was reversed is easier to achieve than with
the pillar drill.
For a length of hole of 80 mm the lathe would be less likely to run off when
drilling.
On balance, the choice is between the mill and the lathe, with the lathe being
easier to set up so the most suitable process would be the lathe.
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6. a) Due to the close tolerance on the 50 mm dia hole, the bracket would require to
be machined on a lathe.
The sequence of operations is:
 centralise in a four jaw chuck, grip on the round surface
 Bore cast hole to size and face square end
 Reverse in chuck (changed to 3 Jaw), grip internally on 50 mm bored
hole
[This could be considered as superior performance, alternatively
keeping the four jaw chuck, grip on outside dia and true up to the bore
would be acceptable]
 Face to Length.
b) Route Card
Drg No
Material
Op No
010
Product:- Cast Iron bracket
Part:- Bracket
Operation
Bore and Face square end
Equipment & Tools:- Centre lathe, 4 Jaw Chuck, Turning Tool, Boring tool, 150 mm rule,
inside calipers, 50-75 Inside micrometer, height gauge
020
Face round end to length
Equipment & Tools:- Centre lathe, 3 Jaw Chuck, Turning tool, Outside calipers, rule.
7. Before starting the planning sheet some consideration would have to be given to
Selecting the processes required:
 Only one is required
 Because of the uncertainty of metal expansion during bending the holes
should be drilled after the bending operation
 A 20 mm dia service hole is required to be drilled in the plate to locate the
boss
A likely sequence of operations would be:
 Cut out the plate
 Mark for bending
 Bend to shape
 Check bent profile and cut to final length
 Mark holes and radii
 Radius corners
 Drill holes
 Weld Boss in position
 Deburr
 Mark tapped hole in boss
 Drill and tap boss.
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Planning Sheet
OPERATION
DESCRIPTION
EQUIPMENT AND TOOLS
NUMBER
SAFETY
REQUIREMENTS
010
Calculate length of plate
required for longest edge
and cut off
300 mm rule, scriber, square,
straight snips or guillotine
Wear gloves. Use
properly adjusted
guard if guillotine is
employed
020
Mark out for bending
300 mm rule, scriber, square
030
Bend to shape
Vice and hammer, 10 mm dia
bending bar, 30 mm dia
bending bar
Wear gloves
040
Check and adjust bends as
required and cut to final
height
As for Op 030 plus protractor,
5 mm & 15 mm radius gauges,
snips or guillotine
As Op 010
050
Mark out holes and radii
300 mm rule, scriber, height
gauge, dividers, Angle block,
surface table
060
Radius corners
Snips and 200 mm smooth file
Wear gloves
070
Drill
4 - 10 mm dia holes
1 – 20 mm dia hole
Vertical drill
Machine vice
Jacobs Chuck drills
Wear gloves. Use
properly adjusted
chuck guard
080
Hold boss in position, tack
weld, check and full weld
Electric arc
Welding plant, welding table,
chipping hammer
Wear gloves and
suitable eye protection
090
Duburr all over
200 mm smooth flat file
wear gloves
100
Mark position of tapped hole
in boss
surface table, scriber, square,
300 mm rule, height gauge,
angle block
110
Drill and tap boss tapping
drill size 8.5 mm dia
N10 taps, Topping drill,
vertical drilling machine,
machine vice, square
Wear gloves. Use
properly adjusted
chuck guard
8. Before starting the planning sheets, some consideration would have to be given to
Selecting the processes required:
 Four are required and the bar stock available could be cut in such a way that
two parts could be claimed from the width for both the TOP and the
BOTTOM
 Due to the accuracy of the dovetail, milling would be required so this cold be
used as the main shape creation process
 The TOP would be finished by hardening and grinding on a surface grinding
machine
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 The BOTTOM would be finished by hand-scrapping in conjunction with the TOP,
possibly as part of the assembly procedure
Note: Some research by the candidates into the less common aspects, like
Hardening and surface grinding may be required at this stage.
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Planning Sheet TOP
OPERATION
NUMBER
DESCRIPTION
EQUIPMENT AND
TOOLS
SAFETY
REQUIREMENTS
010
Mark length to be cut
from black bar stock at
185 mm, cut off
300 mm rule, suitable cut
of machine or hacksaw
Wear gloves, safety shoes,
eye protection, use properly
adjusted cutter guard if a
machine is used
020
Mill ends to a length of
180 mm. Set at 15
degrees to machine axis
horizontally in vice and
cut into two parts. Mill
all over except dovetail
Horizontal mill, slab
milling cutter, slitting
saw, machine vice, 300
mm rule, protractor
Wear gloves, eye protection,
use cutter guard
030
Set material to cut angle
face then female dovetail
suing a vertical mill and
machine vice. Leave
0.5mm grinding
allowance.
Vertical milling machine,
machine vice, 50mm dia
end mill, dovetail cutter,
Autolock collet, mallet,
protractor.
As above
040
Mark,. drill and hand tap
3 off locking screw holes
Vertical drill, suitable
drills and taps. Jacobs
chuck
As above except for coolant
050
Harden by heating to 800
degree C and quenching
in oil
Muffle furnace, oil bath
Use suitable tongs
060
Surface grind all over
Surface grinding
machine.
Use suitable guard properly
adjusted on grind wheel and
on the table side
Straight grinding wheel.
Dish grinding wheel for
dovetail
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Planning Sheet BOTTOM
OPERATION
NUMBER
DESCRIPTION
EQUIPMENT AND
TOOLS
SAFETY
REQUIREMENTS
010
Mark length to be cut
from black bar stock at
185 mm, cut off
300 mm rule, suitable cut
of machine or hacksaw
Wear gloves, safety shoes,
eye protection, use properly
adjusted cutter guard if a
machine is used
020
Mill ends to a length of
180 mm. Set at 15
degrees to machine axis
horizontally in vice and
cut into two parts. Mill
all over except dovetail
Horizontal mill, slab
milling cutter, slitting
saw, machine vice, 300
mm rule, protractor
Wear gloves, eye protection,
use cutter guard
030
Set in machine vice to
cut dovetail and cut
Vertical mill, dovetail
cutter, Autolock collet,
mallet, protractor
As above
Planning Sheet ASSEMBLY
OPERATION
NUMBER
DESCRIPTION
EQUIPMENT AND
TOOLS
010
Clean out tapped holes
and insert locking screws
Plug tap, suitable Hex
socket wrench
020
Offer TOP to BOTTOM
and scrape bottom until
all over contact is
achieved for dovetail
base
Bearing blue, flat
scraper, vice
030
Check parallel between
base and top, scrape
bottom until top reads
+0.01 mm over whole
length
DTI and stand, surface
table, hand scraper, vice
SAFETY
REQUIREMENTS
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