40% 60 Minutes 60 Marks 12 Pages 8 Question What You Need To Know: Engineering Sectors Engineering Materials and their Properties Function of Components Engineering Processes Quality Control Techniques New Technology and their Impact Stages in Manufacturing a Product Created by Ahmed 1

2 Engineering Sectors 1 Engineering Materials 4 and their Properties Function of Components 5-7 Engineering Processes 8 Quality Control Techniques 9 Stages in Manufacturing 10 Advantages and Disadvantages 11 Of Modern Technology

The first part of the exam will ALWAYS be based around Engineering Sectors. For each individual sector, learn the components correlating with the sector. -You do not have to learn them all, as long as you have remembered a couple from each sector, you will be fine! Finished reading this page? Read it again. Your GCSE at the end of the day. 3

This slide will explain different ‘Engineering Materials’ and their properties. You will need to know the definitions of the following: Ferrous and Non-Ferrous Metals; Ferrous – A METAL that contains IRON. (There’s a reason for why METAL is in CAPS – If question is : “What is a Ferrous Metal?” then the answer will be: “A METAL which contain IRON.” If you do not write metal, you will not get a mark.) Non-Ferrous – A METAL which DOES NOT contain IRON. Polymers; A POLYMER is a large CHAIN-LIKE molecule made up of monomers. -An example of a Polymer would be the synthetic plastic, ‘Polystyrene’. -Synthetic means man-made; synthetic products are made in factories from artificial substances. Ceramics; A ‘Ceramic’ is an inorganic, non-metallic solid made up of either metal or non-metal compounds (e.g CLAY), that have been shaped and then hardened by heating in high temperatures. -Always remember to include that it is a solid that is hardened by heating. Examples of Ceramics include: Pottery, Pots, Earthenware, Tile, ETC. Composite Material; A ‘Composite’ material is a material made from two or more different materials with unique properties that, when combined, produces a material with characteristics different from the individual components. Lots of words on this page, my sincere apologies Well then, KEEP REVISING. 4

The exam questions regarding these components will often be asking to name the object and put it under the correct “Components” section. The only way to learn these is to see the exam questions for yourself! So here’s a few: Examples of Mechanical Components and their Functions: There are 3 examples of components – and their individual function - you NEED to know about. These 3 include: Mechanical Components Electrical/Electronic Components Pneumatic/Hydraulic Components Circlip This is the layout of a typical style exam question. Often there will be a question asking the “Function” of these components. “Example of Use:” The Circlip is used to stop things from moving along a shaft. The clips are put into grooves on each side of the object so that it can't move along. Nyloc/self-locking nut – Tightened onto a thread, the (nylon) insert stops it coming loose. Gears (train) – Used to transmit power and change speed/direction of rotation in a driven system. 3-port valve – Used in a pneumatic circuit to control the flow of air to a cylinder Cam – Changes rotary motion of the cam into linear motion of a follower; used to open valves on a car engine There are many different “Mechanical” components they could ask of, unfortunately I do not know every one. However, try to remember as many as you can and if in the exam there is a component you do not know of, TAKE AN EDUCATED GUESS. 5

Example of Electrical/Electronic Components Name: LDR – Light Dependent Resistor (You can just write LDR in the exam) Example of use: Used to make electronic circuits light sensitive. Can switch on light when its dark. Function: Gives off light when a small electric current flows through it. LDR Relay - Low voltage circuit energises an electro-magnet to close contacts for a higher voltage circuit. Basically, it allows low voltage control of higher voltage circuits. Fuse - Contains a thin wire that melts if too much current flows through it, this protects electrical/electronic circuits and components from damage. Resistor – Used to resist/control the flow of electricity in a circuit. Example of Pneumatic/Hydraulic Components Name: Pressure Gauge Use: Used to measure the pressure of air in a pneumatic circuit. Is usually fitted to a (pressure) regulator valve. More about Pneumatic/Hydraulic Components on the following page! 6

Cylinder/actuator - compressed air forces the piston out along the cylinder to move/operate a piece of equipment. A spring pushes the piston back when the air is turned off. Reservoir/air receiver – Used to store air in a pneumatic circuit so that the circuit operates smoothly. Some of these components names could be asked in different ways. You may not get an image of the component but just its name, and you may be asked to describe the function or use of the component. Here is an example of how the examiners could ask you about these components: Stay strong, And you’ll never be wrong! 7

8 The properties, characteristics and features of materials / Engineering Processes You will need to know how the properties, characteristics and features of materials can be changed and manipulated; including examples. Below is a couple exam questions based on this: Below are different examples for each engineering process: Material Removal: Milling Drilling Sawing Filing Routing Chiselling Grinding Laser cutting Shaping and Manipulation Forging Vacuum forming Line bending Injection moulding Casting Joining and Assembly Welding Soldering Riveting Soldering Glueing Brazing Heat and Chemical Treatment Case Hardening Plating Painting Galvanising Tempering Quenching Annealing Surface Finishing Plastic/Powder Coating Anodising; Electro-plating - E.g Chromium Plating Spray painting Remember some of these from each process, you could be asked simple 1 mark question based on this. Good luck.

9 Quality Control Techniques What is Quality Control? ‘A system of maintaining standards in manufactured products by testing a sample of the output against the specification.’ Basically; ‘Quality Control’ is all about the testing of a sample of manufactured products. There are many different techniques and many different machines (and tools) which test a product to see whether it has been manufactured correctly and to a high standard; and more importantly whether it follows the specification. In simple terms, it checks the quality of the product to see whether it abides the specification. Why do we need Quality Control? Quality control check are needed to make sure that the product is being manufactured properly and against the specification. Quality control checks can also tell you whether there is a problem or fault in the manufacturing or designing stage of the product. Without quality control checks, a badly manufactured product could end up being sold to a consumer. If the product does not function properly, the product could gain a bad reputation. There are many different tools used in “Quality Control”. Here are a few: Micrometer Digital/Vernier calliper Rule All these specific tools measure precise lengths and diameters of different components. These are used in quality control checks to confirm that the product is manufactured within certain lengths and diameters and at the right size. Other examples of quality control checks: Sampling - Used to check the quality of one product within a set number (e.g 1 in 50); this way it saves time. Sampling can help identify a faulty batch. CAD - Used to simulate production to check for faults. Visual inspection - To examine for faults in the product, perhaps the surface finishing is wrong or the diameter of the product is wrong.

1.Design 2.Marketing 3.Production planning 4.Material supply and control 5.Processing and production 6.Assembly and finishing 7.Packaging and dispatch 8.Disposal. 10 Stages in Manufacturing Here are the stages in manufacturing you need to know about: You need to remember these specific stages, IN THIS ORDER. Here is a description for each one: Design: In this stage design ideas of the product is produced and developed into a final design. Marketing: In this stage, the market of the product (who the product is going to be sold to and aimed at) is worked out. Production planning: In this stage all the materials and components are purchased, and the process of how the product is going to be manufactured is worked out. Material supply and control: This stage makes sure the material is supplied to the manufacturer at the correct time. Processing and production: In this stage different processes are used to produce a finished item or finished components for the final product. Assembly and finishing: In this stage all the different parts of the final product are assembled together to make the finished product. Packaging and dispatch: In this stage the final product is appropriately packed and dispatched to different countries and places to be sold. Disposal: This stage is about what happens to the product when it reaches the end of its life. Perhaps the materials from it (e.g Metals) can be recycled. It could also just end up being at a landfill – which makes it unsustainable.

11 Advantages and Disadvantages of Modern Technologies There have been many advantages and disadvantages of modern technology; this has impacted the society and the environment in numerous ways. Advantages: Robots and Computers are much more faster and efficient at manufacturing products than humans. There is No Human Error and can work all day – meaning they can produce a higher output then human workers. They are more efficient at using materials, they Produce Less Waste and so thus are more environmentally friendly as they consume less limited resources. They are More Profitable than humans, as they only need to be purchased once and can manufacture a large amount of products in a short time – compared to humans. They are Much More Accurate, each product will be identical to the other. Disadvantages: Workers will be replaced by machines – meaning there will be higher unemployment. Machines (like CNC) costs a lot of money to purchase – it is a big investment for a company. These machines also cost a lot of money to maintain and repair. They need engineers – which need to be paid – to maintain the machines. The machines require highly qualified engineers to operate – these engineers need salaries! The cost of running the machine (power consumption) could be huge. Unfortunately this is where the guide all ends. Very sad. KEEP READING this guide until you remember the information in here. PAST PAPERS are the BEST revision tool. YOUR exam will be VERY SIMILAR to recent past papers. You can find past exam papers (and mark schemes) on from-2012/ - Basically type in “ocr engineering unit a621 past exam papers” on Google and it’s the first link. This guide is not enough as your revision tool. Do past papers too! I wish you all the best in the exam. Good luck.