Resistant Materials Paper Three

What material? – Aluminium – Why? Lightweight Non-ferrous metal, so corrosion resistant Good strength to weight ratio Low density

Safety Checks – Coping Saw Handle tight Pins in line Blade facing correct way (towards handle) Wood held securely Blade tight Blade not damaged Blade sharp

Types of plane – can you see the difference between the two? Jack Plane Preparation of material, quick removal of waste material Smoothing Plane Smoothing short pieces of wood

Cutting Metal Guillotine / Bench shears Tin snips Hack saw Abrafile

Shaping by Wasting ProcessWoodMetalPlastics Cutting straight linesTenon saw (dovetail saw for fine work) Hacksaw (junior hacksaw for small work) Cutting curved linesCoping saw (fret saw for fine work)Abra saw (piercing saw for fine work). Tin snips can be used on thin sheet metal Abra saw (piercing saw for fine work). A coping saw can also be used Trimming cut edges to a straight line Jack plane or smoothing planeFlat or hand file Trimming cut edges to a curved line Spokeshave or raspRound or half round file Cutting grooves and slotsTenon saw to cut sides, then wood chisel or coping saw Drill holes at ends, then use abra saw Drill holes at ends, then use abra saw or piercing saw Guillotine / Bench shearCutting thin metal / small sections of metal

Draft angles for moulds Moulds for vacuum forming need a draft angle of 5-7 degrees otherwise they cannot be removed

Fluting adds strength

Anthropometrics Anthropometry is the branch of human sciences concerned with body measurements such as body size, shape and strength. This is used by ergonomists to ensure that products, such as seats, fit and suit as many users as possible. If you are designing a seat, you need to take the following measurements into account. Anthropometric estimates for British adults aged years (in mm, from Pheasant) Dimension5th %ile50th %ile95th %ile A Sitting height B Sitting shoulder height C Shoulder breadth D Hip breadth E Buttock-popliteal length F Popliteal height MALEFEMALE

Marking out Metals ProcessMetal LinesScriber Lines at right angles to an edge Engineer's try square Lines parallel to an edgeOdd-leg calipers Marking for a mortiseN/A Marking a circleDividers Marking the centre of a holeCentre punch Marking an irregular shapeTemplate

Marking out Wood ProcessWood LinesPencil Lines at right angles to an edgeCarpenter's try square Lines parallel to an edgeMarking gauge Marking for a mortiseMortise gauge Marking a circlePair of compasses Marking the centre of a holePencil Marking an irregular shapeTemplate

Marking out Plastics ProcessPlastics LinesFelt-tip pen Lines at right angles to an edgeEngineer's try square Lines parallel to an edgeOdd-leg calipers Marking for a mortiseN/A Marking a circleDividers Marking the centre of a holeFelt-tip pen Marking an irregular shapeTemplate a waxy pencil used to write on china, glass, or other hard surfaces Chinagraph Pencil

Folding bars

Joining Metals - Soft soldering Quick method of joining copper, brass and tinplate when little strength is required in the joint. Also for fixing electronic components

Weather resistance Durable More easily moved around Comfortable armrests Will not rust Easier to clean Stronger (must be qualified) Polypropylene has good resistance to work fatigue

Suitable joint for corner A Mortise & Tenon Halving Bridle Dowell

Clamping (cramps) Sash Clamps These clamps are for big tasks such as sash windows, table tops, doors etc. Usually several such clamps are required

Clamping G Clamp

Checks when Clamping Are pieces in correct position (square, flat) Joints pulled together Excess glue removed Use scrap glue to spread pressure and avoid damage Clamps not over tightened Clamps tight / secure

Drilling at an angle Table of bench drill rotated to provide angle. Work piece clamped in place Table

Drilling at an angle With table of bench drill horizontal, a wedge to provide the angle is placed under the work piece Work piece securely clamped Table

Bending Rods of Metal Watch the short video clip to understand how to bend metal rods. Note: the retention method; the jig; the method of force

Advantages of a cutting gauge instead of pencil and try-square Quicker More accurate Cuts fibres of wood Cannot be rubbed off

ProcessTools / equipment used Mark outPencil, rule, sliding bevel, marking knife, mitre square Saw off wasteTenon saw, coping saw, machine saws Make sawn edges smooth Sanding disc, file, chisel, plane, sand paper

Type of nails ROUND WIRE NAIL - This is used for general work. It is not attractive in shape and it can split wood when hammered in position OVAL WIRE NAIL - This is a long nail and care must be taken when it is hammered into the wood. It is unlikely to split the wood. LOST HEAD NAIL - This is ideal if it is necessary to hide the head of the nail as a punch can be used to hammer the head beneath the surface level. PANEL PIN - A very popular way of joining woods although glue is usually included as part of the join. TACK - Can be used for fixing textile materials to wood for example, fixing upholstery to furniture. ANNULAR NAIL - The teeth of this nail hold it in place firmly. Therefore, it is used for fixing plywood and other materials. HARDBOARD PIN - The diamond shaped head is hidden when used in materials like hardboard

After reading the PPP and taking notes you should retake Paper 3. You should answer all questions except 11f, 12c(ii), 12f, 12g and 13e. Attempt all questions without referring to the notes you made. If you get stuck, leave it until you've answered all the questions you can. Then look at your notes to help you answer those questions you were stuck on. You might have to do some further research to answer some of question 13