Mr Hore's Year 12

Wednesday, 18 March 2015

Unit 22 P6

Look at this unit Pass 6 in relation to the work we are doing with the Greenpower car . Consider the methods of construction and the jointing methods we will be using . Comment on this and how if we were to make if from aluminium the construction would differ

Monday, 15 September 2014

P1 task

Task 1 P1 Identify the health and safety legislation, regulations and safe working practices

applicable in a fabrication workshop, with learners being asked to produce a written report. Evidence presented for P1 must be specific to fabrication processes. There is a huge amount of generic material which learners will have access to. Care should be taken to ensure that what you present is referenced properly and not directly copied from the internet or any other source.

Monday, 9 December 2013

P8

P8 identify the appropriate heat treatment processes, secondary, finishing and assembly techniques needed to manufacture four given components.

Given components are
Upright for the front suspension on the Green power racer. Anodise it .

A garden gate, hot galvanised

Waterpump shaft
Use this for the Water pump Grind the main shaft as the finishing technique
Lathe and surface hardening should come into play!

http://fuelpumps.tpub.com/TM-5-4320-258-34/TM-5-4320-258-340026.htm

an engine block rough cast to finished surfaces. Milling machine.

Friday, 15 November 2013

None traditional machining techniques

Know how a range of non-traditional techniques are used

Electro discharge: machines eg spark erosion, wire erosion; features of the workpiece eg holes, faces (such as flat, square, parallel, angular), forms (such as concave, convex, profile, square/rectangular), other features (such as threads, engraving, cavities, radii/arcs, slots)

Broaching: machines eg horizontal, vertical; features of the workpiece eg keyways, holes (such as flat sided, square, hexagonal, octagonal), splines, serrations, other special forms

Honing and lapping: machines eg honing (such as horizontal, vertical), lapping (such as rotary disc, reciprocating); features of the workpiece eg holes (such as through, blind, tapered), faces (such as flat, parallel, angular)

Friday, 25 October 2013

Spec for homework to help you

1 Understand how a range of secondary machining techniques are used

Turning: machine eg centre lathe, turret; features of the workpiece eg flat faces, diameters (such as parallel, stepped, tapered), holes (such as drilled, bored, reamed), profile forms, threads (such as internal, external), eccentric features, parting off, chamfers, knurls or special finishes, grooves, undercuts

Milling: machine eg horizontal, vertical, universal, planer/gantry; up-cut; down-cut; features of the workpiece eg faces (such as flat, square, parallel, angular), steps/shoulders, slots (such as open ended, enclosed/recesses, tee), holes (such as drilled, bored), profile forms (such as vee, concave, convex, gear), serrations, indexed or rotated forms, special forms

Boring: machine eg horizontal, vertical; features of the workpiece eg bored holes (such as through workpiece, to a depth, tapered), holes (such as drilled to depth, drilled through workpiece, reamed, threaded), external diameters, grooves/recesses, chamfers/radii, faces (such as flat, square, parallel, angular, milled), slots, forms (such as indexed, rotated), external tapers

Grinding: machine eg surface (such as horizontal, vertical), cylindrical (such as external, internal), centreless, universal, thread, profile; features of the workpiece eg faces (such as flat, vertical, parallel, square to each other, shoulders and faces), slots, diameters (such as parallel, tapered), bores (such as counterbores, tapered, parallel), profiles forms, thread forms (such as vee, right hand, single start, multi-start, internal, external), angular faces

Presswork: machines eg single action, multiple action; features of the workpiece eg blanking, notching, piercing, joggling, cropping/shearing, bending/forming, coiling/rolling, planishing/flattening, first draw, second draw, compound operations, cupping, embossing, coining

Health and safety: appropriate legislation and regulations eg Health and Safety at Work Act 1974, Fire Precautions Act 1971, manual handling, Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) 1995, Provision and Use of Work Equipment Regulations (PUWER) 1998, Health and Safety (First Aid) Regulations 1981; use of personal protective equipment (PPE)

Materials: eg ferrous, non-ferrous, non-metallic, stainless, special alloys, deep drawing steels

Kinematics: machine tool design; generation and forming of shapes; six degrees of freedom

Gomework to be handed in by 1st Tueasday back from 1/2 term

P1 explain how five different secondary machining techniques are used safely on a range of materials

P2 explain kinematics in secondary machining techniques

Friday, 20 September 2013

Monocoque Design

Looking at the lesson you need to research monocoque race car design. Look at the work of Colin Chapman from the 1960's as he was the father of the design revolution which overtook formula 1 design.

Thursday, 19 September 2013

BTEC

Produce a list of components you think you will need to do in order to build the car. Look at techniques for its construction. Welding machining GRP etc.

Wednesday, 4 September 2013

Cambridge Uni solar car.

Try this as an idea for getting your ideas flowing .

http://www.cam.ac.uk/research/news/new-and-under-the-sun

Tuesday, 11 June 2013

Deadline date

Hi we need to finish off the unit by the second last week of term. Unit 307. If you fail to complete by then there is no extension!
Best regards

Wednesday, 30 January 2013

Unit 305 LOL1

Hi Chaps here is the mark scheme for LOL1 to help you check you are on the right lines

Guidance for allocating marks

This section provides further guidance for the assessor on how to award marks within each mark

band in an objective way.

Marking grid A

Assessment focus LO.1.1

Mark Band 1–3

(0–9 marks)

There are typically up to 2 marks for each of the two descriptions, but could

go to 3 marks if either the consequences of failure or the effect on

production is answered well and above that required for this mark band but

up to a maximum of 4 marks.

Up to 2 marks can be awarded for the explanation of the effects and should

be based on the how well it shows the effects are appropriate to customer

expectation and corporate image and 1 mark can be awarded for linking

image and customer expectation within the explanation.

Up to 2 marks could be awarded for indicate why consequences affect

corporate image; this could be in the form of advantages and limitations.

Sunday, 20 January 2013

Unit 305 Snow work

Dear All

If you can look at Unit 5 as we have just started this unit. . I recommend you look at the mark scheme as we have been doing in class as this will assist in getting the marks clearly allocated for Learning Objective LOL1
You will have downloaded this into your area already.

You need to clearly identify 2 areas. of maintenance. Suggest areas of System failure, such as the case study on the Bombadeir undercarriage, Rail signal failure

Mark Band 1–3
(0–9 marks)
There are typically up to 2 marks for each of the two descriptions, but could
go to 3 marks if either the consequences of failure or the effect on
production is answered well and above that required for this mark band but
up to a maximum of 4 marks.
Up to 2 marks can be awarded for the explanation of the effects and should
be based on the how well it shows the effects are appropriate to customer
expectation and corporate image and 1 mark can be awarded for linking
image and customer expectation within the explanation.
Up to 2 marks could be awarded for indicate why consequences affect
corporate image; this could be in the form of advantages and limitations.

Wednesday, 16 January 2013

New Unit 305

Hi chaps
Pleased with the exam and your feedback from it. Looks like you should have done well and you appeared to have got the majority of the marks in the feedback session. Well done

We have now started Unit 5 and this is the maintenance unit . Following the lesson ensure you have downloaded all the unit documentation into your area.. I need you to research
Plant equipment and system with a view to maintanence so you have a clear view tto this before next lesson. That way we can start unit 5 LO1.1 and have an idea as to covering 2 areas

See if you cxn find some examples of these failures, Plane rail crashes etc.

Mark Band 1–3
(0–9 marks)
There are typically up to 2 marks for each of the two descriptions, but could
go to 3 marks if either the consequences of failure or the effect on
production is answered well and above that required for this mark band but
up to a maximum of 4 marks.
Up to 2 marks can be awarded for the explanation of the effects and should
be based on the how well it shows the effects are appropriate to customer
expectation and corporate image and 1 mark can be awarded for linking
image and customer expectation within the explanation.
Up to 2 marks could be awarded for indicate why consequences affect
corporate image; this could be in the form of advantages and limitations.

Friday, 30 November 2012

Health and Safety at work Act 1974 Powerpoint

lThis topic explores the impact of health and safety legislation on the way that manufacturing operations are carried out in engineering business.

lHealth and Safety at work Act 1974

lFactories Act 1961

lPUWER 1998

lCOSHH 2002

lRIDDOR 1995

lConstruction (Design and Management)2007.

Control Measures

Wednesday, 28 November 2012

H&S questions

9 According to the Working Time Regulations 1998 guidance, workers cannot be

required to do more than how many hours, on average, each week?

A 38

B 44

C 48

D 54

(Total for Question 9 = 1 mark)

14 Which of the following engineering premises are not covered by the Factories Act

1961?

Premises where components or

articles are made

A dry dock where ships are

broken up

Any premises used for the

storage of gas in a large

gasholder

Premises used for the purpose of

housing railway locomotives

(Total for Question 14 = 1 mark)

20 The Control of Substances Hazardous to Health Regulations (COSHH) 2002 state a

number of methods to control exposure to harmful substances.

Which of the following is not one of those control methods?

The use of processes which

minimise the amount of

material used or produced,

or equipment which totally

encloses the process

The controlled exposure of

substances at source which

reduces the level and amount

of risk

The use of alternative forms of

substances which are equally

hazardous, using PPE as a

primary control method

The provision of PPE, but only

as a last resort and never as a

replacement for other controls

which are required

(Total for Question 20 = 1 mark)

27 Discuss the roles and responsibilities of employees under the Health and Safety at

Work Act 1974.

(6)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Total for Question 27 = 6 marks)

Jan 2011

5 Which one of the following is a requirement of employers under The Management of

Health and Safety atWork Regulations (1999)?

A Set out arrangements needed to reduce

hazards

B Follow given emergency procedures

C Employ only fully qualified staff

D Display the website address of the Health

and Safety Executive

(Total for Question 5 = 1 mark)

9 Which one of the following is not subject to the Confined Spaces Regulations (1997)?

A Mine

B Chamber

C Vat

D Trench

(Total for Question 9 = 1 mark)

16 According to RIDDOR (1998), which one of the following does not need to be

reported?

A Injury resulting from an electric shock

leading to unconsciousness

Failure of industrial radiography or

irradiation equipment to de-energise after

the intended exposure period

Unintended collapse of a building or

structure under construction where 10

tonnes of material falls

D The sudden release of 50kg of flammable

liquids inside a building

(Total for Question 16 = 1 mark)

17 Which one of the following gives the lower and upper action levels for noise control

introduced by The Noise atWork Regulations (2005)?

A 60 – 65 dB (A)

B 70 - 75 dB (A)

C 80 - 85 dB (A)

D 90 - 95 dB (A)

(Total for Question 17 = 1 mark)

18 A supplier has responsibilities under the Supply of Machinery (Safety) Regulations

(2005).

Which one of the following is not covered by the regulation?

A Ensuring equipment is fit for purpose

B Declaring country of origin of parts

C Operation to conform to current

standards

D Providing risk assessments for equipment

use

(Total for Question 18 = 1 mark)

(b) Identify three key features of the Employment Act (2002).

(3)

1 ..........................................................................................................................................................................................................................................................................

2 ..........................................................................................................................................................................................................................................................................

3 ..........................................................................................................................................................................................................................................................................

27 There are a number of considerations which should be taken into account before

opening a new engineering plant.

(a) Describe why designing out potential health and safety issues ensures a safe

workplace.

(5)

Jan 2012

5 According to the Factories Act 1961, a workroom floor should be cleaned by washing

at least every:

A day

B week

C month

D year

(Total for Question 5 = 1 mark)

14 Soldering is an activity performed in the electronic engineering sector.

Which one of the following is not a risk associated with soldering?

A Burning skin

B Inhaling fumes

C Eye irritation

D Impaired hearing

(Total for Question 14 = 1 mark)

17 The HSE guidance for producing risk assessments states there are five different stages.

These stages (not in order) are:

A. Review your assessment and update if necessary

B. Record your findings and implement them

C. Decide who might be harmed and how

D. Evaluate the risks and decide on precautions

E. Identify the hazards

Which order should these stages be completed in?

A E, D, B, A, C

B A, C, D, E, B

C E, C, D, B, A

D D, B, E, A, C

(Total for Question 17 = 1 mark)

18 The Fire Precautions Act 1971 sets out a structure for fines if regulations are broken.

Currently, the maximum fine is:

A £1 000

B £5 000

C £10 000

D £50 000

(Total for Question 18 = 1 mark)

27 Discuss how the Reporting of Injuries, Diseases and Dangerous Occurrences

Regulations (RIDDOR) 1995 can influence the operation of an engineering business.

(Total for Question 27 = 8 marks)

June 2010

4 According to the Personal Protective Equipment at Work Regulations (2002), which of

the following would be suitable for use where there is the hazard of falling objects?

A Boiler suit and gloves

B Hi-viz jacket and goggles

C Helmet and safety boots

D Bump cap and face shield

(Total for Question 4 = 1 mark)

16 According to the Employment Equality (Age) Regulations 2006, an employee should

expect to:

receive improved benefits,

training and promotion prospects

compared to other employees

not receive redundancy payments

once they have reached the age

of 65

be allowed to perform any job

no matter what their age is,

irrespective of any other law

be treated equally when setting

work objectives or measuring

levels of performance

(Total for Question 16 = 1 mark)

17 Which one of the following is a reason for not providing health and safety training in

an engineering workplace?

Young employees are more likely

to have accidents, so their training

should be a priority

All staff should understand the

health and safety policy and how

health and safety is managed

Everyone needs to know how to

work safely and without risks to

health

Experienced employees are able

to use all equipment without

further specific training

(Total for Question 17 = 1 mark)

20 Which one of the following is not required by The Provision and Use of Work

Equipment Regulations (PUWER) 1999?

Provide instruction and guidance

for the general public for the

use of compressed air supplies

on petrol station forecourts and

similar locations

Equipment is inspected by a

competent person to ensure that

it is safe for use. A record must be

kept until the next inspection

Provide suitable guards,

protection devices, emergency

stop buttons and personal

protective equipment

Ensure that where mobile work

equipment is used for carrying

people, it is suitable for this

purpose, and does not put people

at risk

(Total for Question 20 = 1 mark)

26 In an engineering workshop, there are often a number of fixed and portable electrical

tools.

According to the Electricity at Work Regulations (1992), there are a number of control

measures which can be used to reduce the risk of injury from electrical equipment.

Describe, for both portable and fixed equipment, how the risk of injury can be

reduced.

Portable Equipment

Fixed Equipment

(Total for Question 26 = 6 marks)

June 2011

5 Which one of the following is solely the responsibility of an employer when

considering health and safety in a workplace?

A Maintaining a risk free workplace

B Providing instruction and training

C Upholding legal requirements of the law

D Caring for the safety of all employees

(Total for Question 5 = 1 mark)

12 Which one of the following is not within the span of authority of the Health and

Safety Executive?

A Road haulage

B Schools and colleges

C Quarries

D Railways

(Total for Question 12 = 1 mark)

13 With regard to the Supply of Machinery (Safety) Regulations (2005), who is not

regarded as a ‘responsible person’ for demonstrating the safety of a newly available

piece of machinery?

A The manufacturer of the equipment

B The retailer or distributor of the equipment

C The end user of the equipment

D The authorised representative of the manufacturer

(Total for Question 13 = 1 mark)

14 The emergency action code on a hazard board carried by a vehicle transporting

substances which should be controlled includes which of the following sets of

information?

• Contact telephone number

• If there is a potential hazard to the public

• PPE requirements

• The type of fire extinguisher to be used

• If there is a potential hazard to the public

• PPE requirements

• The type of fire extinguisher to be used

• If there is a potential hazard to the public

• Symbol to represent hazards

• Method of firefighting

• Contact telephone number

• Symbol to represent hazards

(Total for Question 14 = 1 mark)

19 The Lifting Operations and Lifting Equipment Regulations (1998) does not apply to:

A suspended cradles used by window cleaners

B forklift trucks used in warehouses

C lifts provided for use by the general public

D four post hoists used to inspect under vehicles

(Total for Question 19 = 1 mark)

20 According to the recommendations of the Health and Safety (First Aid) Regulations

(1981), which one of the following would be a suitable contents list for a first aid box?

• Box of sterile plasters

• Triangular bandages

• Safety pins

• Large sterile, unmedicated dressings

• Individually wrapped moist cleansing wipes

• Box of sterile plasters

• Triangular bandages

• Safety pins

• Large sterile, unmedicated dressings

• Packet of six paracetamol tablets

• Box of sterile plasters

• Triangular bandages

• Sterile latex gloves

• Large sterile, unmedicated dressings

• Inhaler and nebuliser

• Roll of self-adhesive dressing

• Triangular bandages

• Latex gloves

• Safety pins

• Sterile eye wash

(Total for Question 20 = 1 mark)

27 (a) Compare the different responsibilities for employers and employees under the

Health and Safety at Work Act (1974).

(5)

(b) Explain the hazards and methods of control which would be appropriate for the

use of a lathe in an engineering workshop.

(5)

(Total for Question 27 = 10 marks)