Question 1: Define the term 'shaping' in the context of manufacturing processes. Explain its importance in product design.

Answer: Shaping is a process used to form material into a specific shape by removing or deforming parts of it. It is important because it allows designers to create precise, functional, and aesthetically pleasing components.

Question 2: List three common shaping methods used in the manufacture of metal components.

Answer: Three common shaping methods are forging, casting, and machining.

Question 3: Describe how a 'press' is used in the shaping process of sheet metal. Include what kind of products it might produce.

Answer: A press applies a high force to deform sheet metal into a specific shape using dies. It can produce items like car panels, appliance casings, or metal containers.

Question 4: Explain the difference between 'forging' and 'casting' as shaping methods.

Answer: Forging involves shaping metal by compressive forces, usually while the metal is hot, resulting in a strong, durable part. Casting involves pouring liquid material into a mold and allowing it to solidify into a shape, which can produce complex designs but may be less strong.

Question 5: Design Brief: You need to create a lightweight, ergonomic handle for a handheld tool. Which shaping process would you choose and why?

Answer: A suitable process could be machining or forging, as both can produce strong, precise, and ergonomic shapes. Machining allows detailed shaping, while forging can produce a durable, lightweight handle with good grip.

Question 6: Sketch a simple design for an ergonomic handle intended for a screwdriver. The sketch should include the overall shape and any features that improve grip.

Answer: A correct sketch would show a handle with a curved, contoured shape that fits comfortably in the hand, with textured or ribbed sections to improve grip and possibly an enlarged end for better control.

Question 7: Identify two advantages and two disadvantages of using plastic casting in product manufacturing.

Answer: Advantages: 1) Can produce complex shapes with detailed features. 2) Relatively low cost for small production runs. Disadvantages: 1) Longer lead times compared to other methods. 2) Potential for defects like air bubbles or incomplete fills.

Question 8: A designer wants to create a decorative sculpture with intricate details. Which shaping method would be most suitable and why?

Answer: Casting would be most suitable because it allows the creation of complex, detailed shapes and fine surface features in the finished product.

Question 9: Draw a cross-sectional sketch of a simple mould used in casting. Label the key features, including the cavity, sprue, and riser.

Answer: A correct sketch would show a hollow mould with a cavity in the shape of the product, a funnel-like sprue for pouring material, and a riser to allow air escape and material flow. Labels should clearly identify each part.

Question 10: Explain how the choice of shaping process impacts the environmental sustainability of a product. Consider factors such as material waste and energy consumption.

Answer: The shaping process affects sustainability by influencing material waste—methods like casting can produce waste or scrap, whereas machining may generate chips. Energy consumption varies; forging and casting often use more energy than processes like machining or forming. Choosing efficient methods reduces environmental impact.