Level 2 Engineering Design and Product Investigation BTEC

This subject is broken down into 43 topics in 6 modules:

  1. Engineering Design 8 topics
  2. Product Investigation, Analysis and Disassembly 8 topics
  3. Materials Science and Testing 6 topics
  4. Manufacturing Techniques and Practices 7 topics
  5. Health and Safety in Engineering 7 topics
  6. Engineering Maintenance Procedures and Techniques 7 topics
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  • 6
    modules
  • 43
    topics
  • 16,181
    words of revision content
  • 2+
    hours of audio lessons

This page was last modified on 28 September 2024.

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Engineering Design and Product Investigation

Engineering Design

The design process

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The design process

The Design Process

Identifying the Need

  • Successful design starts with identifying a need or problem that needs to be solved.
  • This involves conducting market research to understand the target audience and recognise the competition.
  • It's important to have a clear understanding of the client's requirements and the application of the intended design.

Concept Development

  • Concept development involves brainstorming and sketching to generate ideas.
  • Research and analysis of various potential designs helps narrow down the possibilities.
  • Using CAD (Computer-Aided Design) software, preliminary designs are drafted and refined.
  • This stage often includes producing prototypes and models.

Detail Design and Optimisation

  • This stage focuses on finalising the design and ensuring it meets the requirements laid out in the identifying stage.
  • Optimisation ensures the design is not only capable of performing its function but does so in a cost effective and efficient manner.
  • Key tools used in this stage include Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to perform stress tests and optimise the product.
  • Detailed technical specifications and drawings are also produced, which clearly communicate how the product should be made.

Implementation

  • This is the stage in which the design is transferred into a tangible product.
  • Manufacturing processes are taken into account and chosen based on the design, budget, and desired output.
  • After production, the product goes through quality assurance and testing to reassure it works as intended.
  • Final efforts in this stage include launching the product and marketing to reach the target audience.

Evaluation

  • Post-launch, gathering user feedback and analyzing sales data can give valuable insight into the product's performance.
  • Identifying improvements and opportunities for further optimisation is a key aspect of this stage.
  • This iterative process is crucial for continuous improvement in product design.

Remember, the design process is not strictly linear. Iterative steps can often occur, looping back to earlier stages to refine and improve the design based on new information or requirements.

Course material for Engineering Design and Product Investigation, module Engineering Design, topic The design process

Engineering Design and Product Investigation

Manufacturing Techniques and Practices

Manufacturing processes: casting, forging, forming, and machining

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Manufacturing processes: casting, forging, forming, and machining

Manufacturing Processes: Casting, Forging, Forming, and Machining

Casting

  • Casting is a manufacturing process where a liquid material is poured into a mould, which contains a hollow cavity of the desired shape.
  • Once the liquid cools and solidifies, it is removed from the mould, resulting in the desired shape.
  • Casting can be used for mass producing complex shapes that would otherwise be difficult or costly to manufacture.
  • Common materials used in casting include: metals, plastics, glass, and concrete.

Forging

  • Forging is a manufacturing process where force is applied to a piece of metal to achieve the desired shape.
  • This process uses localised compressive forces, which can be generated by a hammer or a die.
  • Forging is known for creating strong, durable parts. It can also help in improving the microstructure of metals.
  • The process of forging often produces a fine "grain" structure in the metal, which makes the resulting product stronger.

Forming

  • Forming is a process where metal is manipulated to form a particular shape.
  • Forming can be done through many techniques including: bending, drawing and rolling.
  • This process often involves tooling to force the metal into the desired shape. It could be done under cold, warm or hot conditions.
  • The aim of forming is to modify the metal without removing any material, as opposed to processes like machining.

Machining

  • Machining is a process where a piece of material (often metal or plastic) is shaped by removing unwanted material from it.
  • The process usually involves cutting tools that progressively remove material from the workpiece to achieve the desired shape.
  • Common machining processes include: milling, turning, and drilling.
  • Machining is a versatile process, allowing for the creation of a wide variety of shapes and features.
  • This process produces waste material, which distinguishes it from other processes like forming and forging, which strive to change the shape without waste.

Remembering the unique characteristics of these various manufacturing processes will help in choosing the best method to use based on the characteristics of the material and the desired end product.

Course material for Engineering Design and Product Investigation, module Manufacturing Techniques and Practices, topic Manufacturing processes: casting, forging, forming, and machining

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