Manufacturing

Metal Turning
Metal turning is carried out on metalwork lathes as
shown in the picture opposite. It is quite a slow process
compared to mass production.

The lathe speed is sometimes changed for the following

reasons:

• For a better quality finish

• For special processes like ‘knurling’
• For different materials (soft aluminium can be cut
faster than hard steel)

Processes

The stainless steel dart and unfinished handle below have had a few metal turning
operations carried out:

Facing Off
Taper Turning
(flat face)
(a slope)

Chamfering
Knurling (45 degree angle) Parallel Turning
(grip) (long, flat edge)

Working with Acrylic

Acrylic is a thermoplastic that can be heated and shaped. Some examples of its use are
below:

Acrylic leaflet holder Acrylic headlamp cover Acrylic necklace (beads

and sign)

Name ……………………………………………………………… Class ………. National 5 Design and Manufacture

 Manufacturing
Cutting
Here are the three basic tools for cutting:

Junior Hacksaw to cut Coping Saw to cut curves Drill (forstner bit) to make
straight lines holes

Four stages in edge finishing

1. File 2. Wet and Dry 3. Emery Cloth 4. Steel Wool

Paper

Line Bending

This can be done with a strip heater to form products bent along a line.

Strip Heater to heat acrylic Line bending in photo Line bending in letter rack
frame

Name ……………………………………………………………… Class ………. National 5 Design and Manufacture

 Manufacturing
Forming Curves

Acrylic can be heated in an oven then held into shape to form curved objects. Here is an
example for an acrylic handle:

Heat in oven Check acrylic is hot Clamp in a wooden Finished handle

and flexible former and leave to cool

Woodwork Joints

Three versions of a butt joint are shown below. These are joined using PVA glue only and
tend to be weak.

Butt Joints

Dovetail joints and finger joints are good for corners because they are very strong. They are
specially shaped then joined with PVA glue.

Finger Joint
Dovetail Joint

Name ……………………………………………………………… Class ………. National 5 Design and Manufacture

 Manufacturing

Sash Cramps

These can be used to help hold woodworking joints together while gluing.

Left jaw on screw

thread

Right jaw locked in

place with metal pin
Questions

1. The CAD model for a toy car designed by a secondary school pupil is shown below.

Windscreen (4mm
Thermoplastic)
Headlamp

(a) (i) State the name of a suitable thermoplastic for the windscreen.

__________________________________________________________________________
1

(ii) Having sawn the thermoplastic screen to size it was necessary to tidy up the rough marks
on the edges before bending. List four stages to finish the edges of the thermoplastic.

1__________________________________________________________________________

2__________________________________________________________________________

3__________________________________________________________________________

4__________________________________________________________________________ 4
Name ……………………………………………………………… Class ………. National 5 Design and Manufacture
 Manufacturing

(iii) In order to bend the piece of thermoplastic to shape a strip heater was used. State the
name given to this forming process.

__________________________________________________________________________ 1
(iv) State the name of another piece of equipment that can be used to heat thermoplastic
sheet and form curves.
1

2. One of the headlamps for the car is shown below.

(a) (i) An easily shaped, light and non ferrous metal was used to make the headlamp. State the
name of a suitable material.

___________________________________________________________________________ 1

(ii) A metalwork lathe was used to manufacture the headlamps

Process B
Process A

Process C

State the names of the processes used to produce the features at A, B and C (3):

Process A ________________________________________________________________

Process B ________________________________________________________________

Process C ________________________________________________________________
3

Name ……………………………………………………………… Class ………. National 5 Design and Manufacture

 Manufacturing
(b) When creating the shape of the headlamp the speed of the lathe was increased to improve the
surface finish.

(i) Describe two other reasons for changing the speed of the lathe

___________________________________________________________________________

(ii) State a disadvantage of metal turning when creating components

___________________________________________________________________________
1

3. (a) State the names of the three joints shown below

__________________ __________________ __________________ 3

(b) Which of the three joints is the weakest?

______________________________________________________________ 1

(c) The picture shows a sash cramp. Describe two adjustments that can be made on the sash
cramp.

________________________________________________________________ 2

__
20

Name ……………………………………………………………… Class ………. National 5 Design and Manufacture