Year 10 Industrial Products - The Casting Project



Year 10 Engineering- Casting and Pattern Making

The Task
To design and make a door number and plaque. The number will be open cast from aluminium using a m.d.f pattern, which the pupils will make.

Setting The Task
As part of the course students need to examine methods of industrial manufacturing. We will use this project as a vehicle to examine sand casting. It will also bee used to examine mass production.


Main Aims
· For pupils to design and make a m.d.f pattern.
· To learn how to make a pattern which will work successfully and give good definition.
· For pupils to use the process of open top sand casting to make a flat back casting.
· For pupils to appreciate the importance of Health and Safety in the workshop and in industry.
· For pupils to understand the other types of casting techniques.

 

Values
· To understand what batch production is as opposed to mass production.
· To understand the principles behind sand casting.
· To learn how to use the casting equipment in the engineering room.
· To use a variety of materials and to understand the properties and suitability of certain materials
· To understand the importance of a quality finish in relation to patterns and mouldings.
· To further they're designing skills.

 

The Nature Of The Product
· Each pupil will design and make a card template.
· Each pupil will make a m.d.f pattern in a number of pieces.
· Each pupil will open top cast the pattern.
· Each pupil will learn the following terms: -Flat back moulding, drag and cope, sprue pins, riser and runner, strickling off, gates and channels.
· Pupils will also learn about casting with expanded polystyrene, lost wax casting, pressure die-casting and gravity casting.


Technical Knowledge and Understanding

· Each pupil will learn the following terms: -Flat back moulding, drag and cope, sprue pins, riser and runner, strickling off, gates and channels.
Pupils will also learn about casting with expanded polystyrene, lost wax casting, pressure die-casting and gravity casting.
· Health and Safety issues involved.

Tools and Equipment Needed

· M.D.F for pattern making. Gloves.
· Hegner. Mask.
· Sanding Belt. Leather aprons.
· P.V.A glue. Foundry Boots.
· Glass paper. Heating Unit.
· Aluminium scraps. Rammer.
· Purifying tablet. Card.
· Drags and copes.
· Sprue pins
· Parting powder.


Using Mathematics

· Measuring and scaling up.

Using I.T
· CAD package to design the pattern.

Using Science
· Properties of materials.
· How we can alter the state of materials.

Using Other Subjects

Using Economic And Industrial Understanding

· Mass production and Batch Production.
· History of Industrialisation.

Useful Resource Tasks

· Design and Technology John Cave


Programmes Of Study References

1. Pupils should be given the opportunity to develop their design and technology capability through:
1a Assignments in which they design and make products. Taken together these assignments should require activity related to industrial practices and the application of systems and control;
1b Focused practical tasks in which they develop and practise particular skills and knowledge;
3a To develop and use design briefs and detailed specifications;
3c To design for manufacturing in quantity;
3d To recognise that moral, economic, social, cultural and environmental issues makee conflicting demands when designing;
3e To consider an increasing range of users;
3f To determine the degree of accuracy required for the product to function as planned, taking account of critical dimensions and tolerances in determining methods of manufacture;
3h How graphic techniques, I.T equipment and software can be used in a variety of ways to model aspects of design proposals and assist in making decisions;
4a To match materials and components with tools, equipment and processes;
4b To use tools and equipment accurately and efficiently to achieve an appropriate fit and finish and reliable functioning in products that match the specification;
4c A range of industrial applications for a variety of familiar materials and processes;
4e How products are manufactured in quantity, including the application of quality control and assurance techniques;
4g To simulate production and assembly lines;
5d About a variety of self-finishing and applied finishing processes, and to appreciate their importance
For aesthetics and functional reasons;
5e That to achieve the optimum use of materials and components, account needs to be taken of the complex interrelations between material, form and intended manufacturing processes;
Health and Safety
Pupils should be taught further knowledge and understanding of health and safety as designers, producers and consumers, including;
9a Taking responsibility for recognising hazards in the products, activities, including the unfamiliar;
9b Using information sources to asses the risk of the unfamiliar;
9c Managing their environment and justifying the action taken to control the risk.