BOOK
BTEC Level 1/Level 2 Tech Award Engineering Student Book
Steve Singleton | Simon Goulden
(2018)
Additional Information
Book Details
Abstract
Written by an expert author team of BTEC teachers and professionals, this Student Book includes:
- full coverage of all three components, structured to match the spec
- content broken down into 1 hour lessons to help with your planning and delivery
- plenty of case studies and examples that students can relate to
- additional features including key terms, 'did you know' sections and plenty of assessment practice
Table of Contents
| Section Title | Page | Action | Price |
|---|---|---|---|
| Front Cover | Front Cover | ||
| Contents | iii | ||
| About this book | v | ||
| How to use this book | vi | ||
| Component 1: Exploring Engineering Sectors and Design Applications | 2 | ||
| What is engineering? | 4 | ||
| Engineering disciplines | 4 | ||
| Engineering achievements | 5 | ||
| The need for engineers | 6 | ||
| Types of engineer | 6 | ||
| Engineering interconnections | 6 | ||
| Why are more engineers needed? | 7 | ||
| The safe application of technical and practical knowledge | 8 | ||
| Designing for safety | 8 | ||
| Safety in practical working areas | 9 | ||
| Responsibilities for safety | 9 | ||
| Engineering sectors | 10 | ||
| Aerospace | 10 | ||
| Automotive | 10 | ||
| Communications | 10 | ||
| Electrical/electronics | 10 | ||
| Mechanical | 10 | ||
| Environmental | 11 | ||
| Transport | 11 | ||
| Rail | 11 | ||
| Marine | 11 | ||
| Engineered products | 12 | ||
| Engineered products from different sectors | 12 | ||
| Engineered products from combinations of sectors | 12 | ||
| Engineering organisations: large | 14 | ||
| Large global enterprises | 14 | ||
| Engineering organisations: SMEs and small jobbing companies | 16 | ||
| Small to medium-sized enterprises (SMEs) | 16 | ||
| Small jobbing companies | 16 | ||
| Large company vs SME | 17 | ||
| Engineering organisations: specialist functions | 18 | ||
| Research and development (R&D) organisations | 18 | ||
| Manufacturing organisations | 18 | ||
| Service organisations | 19 | ||
| Specialist organisations in sectors | 20 | ||
| Aircraft manufacturers | 20 | ||
| Manufacturers of hydraulic and pneumatic systems | 21 | ||
| Functions in engineering organisations | 22 | ||
| Research and development (R&D) | 22 | ||
| Design | 23 | ||
| Planning | 23 | ||
| Making | 23 | ||
| Functions in engineering organisations | 24 | ||
| Quality | 24 | ||
| Marketing | 24 | ||
| Selling | 24 | ||
| Customer service | 25 | ||
| Installation | 25 | ||
| Engineering job roles 1 | 26 | ||
| Maintenance technician | 26 | ||
| Machine operator | 26 | ||
| Aircraft fi tter | 26 | ||
| Design engineer | 27 | ||
| Engineering job roles 2 | 28 | ||
| Manufacturing engineer | 28 | ||
| Installation engineer | 28 | ||
| Process engineer | 28 | ||
| Telecommunications engineer | 29 | ||
| Career progression opportunities | 30 | ||
| Apprentice | 30 | ||
| Operator | 31 | ||
| Technician | 31 | ||
| Technical | 31 | ||
| Professional | 31 | ||
| Management | 31 | ||
| Role definitions | 32 | ||
| Learning aim A: assessment practice | 34 | ||
| How you will be assessed | 34 | ||
| The engineering design and make process | 36 | ||
| 1. Define the problem | 36 | ||
| 2. Develop possible solutions | 36 | ||
| 3. Choose a solution | 36 | ||
| 4. Design and model the solution | 36 | ||
| 5. Evaluate the outcome | 37 | ||
| Work in a team | 37 | ||
| The engineering brief | 38 | ||
| What is an engineering brief? | 38 | ||
| Interpreting customer requirements | 38 | ||
| Criteria for an engineering brief | 40 | ||
| Physical requirements | 40 | ||
| Aesthetics | 40 | ||
| Size | 40 | ||
| Function | 41 | ||
| Performance requirements | 41 | ||
| Interpreting an engineering brief | 42 | ||
| Understanding the engineering brief | 43 | ||
| Organising your design folder | 44 | ||
| Keep all information in a design folder | 44 | ||
| Initial design using existing products | 46 | ||
| Researching existing products | 46 | ||
| Researching your initial design proposal | 48 | ||
| Researching materials for the product | 48 | ||
| Researching manufacturing processes to be used | 49 | ||
| Researching manufacturing skills needed | 49 | ||
| Producing initial design sketches in 2D and 3D | 50 | ||
| Engineering drawing standards | 51 | ||
| Design sketches in 2D and 3D | 51 | ||
| Creative thinking and evaluation techniques | 52 | ||
| Using creative thinking and evaluation techniques | 52 | ||
| Design is a process of constant evaluation | 53 | ||
| Computer-aided design (CAD) drawings | 54 | ||
| CAD packages | 54 | ||
| Final design solutions using 2D drawing techniques | 56 | ||
| 2D design drawings | 56 | ||
| Generating final design drawings | 58 | ||
| Sketches | 58 | ||
| Component drawings | 58 | ||
| Assembly drawings | 58 | ||
| Parts lists/drawings | 59 | ||
| Circuit diagrams | 59 | ||
| Final design solutions using 3D printing | 60 | ||
| Additive manufacturing | 60 | ||
| Final design solutions using physical modelling | 62 | ||
| Physical modelling | 62 | ||
| Making final design solution decisions on materials | 64 | ||
| Selection of materials | 64 | ||
| Making final design solution decisions on making techniques | 66 | ||
| Selection of making techniques | 66 | ||
| Considering quality requirements | 68 | ||
| Meeting customer requirements | 68 | ||
| Quality assurance | 68 | ||
| Working in a team and peer review | 70 | ||
| Teamwork | 70 | ||
| Peer review | 71 | ||
| Using generic work skills | 72 | ||
| Generic skills | 72 | ||
| Learning aim B: assessment practice | 74 | ||
| How you will be assessed | 74 | ||
| Component 2: Investigating an Engineering Project | 76 | ||
| Engineering materials: ferrous metals | 78 | ||
| Ferrous metals | 78 | ||
| Engineering materials: non-ferrous metals | 80 | ||
| Non-ferrous metals | 80 | ||
| Engineering materials: thermosetting polymers | 82 | ||
| Thermosetting polymers | 82 | ||
| Engineering materials: thermoforming polymers | 84 | ||
| Thermoforming polymers | 84 | ||
| Properties of engineering materials | 86 | ||
| General properties of engineering materials | 86 | ||
| Characteristics of engineering materials | 88 | ||
| Characteristics of metals | 88 | ||
| Characteristics of polymers | 89 | ||
| Components: types and characteristics | 90 | ||
| Engineering processes: shaping | 92 | ||
| Shaping | 92 | ||
| Engineering processes: cutting | 94 | ||
| Cutting | 94 | ||
| Engineering processes: joining | 96 | ||
| Joining | 96 | ||
| Engineering processes: forming polymers | 98 | ||
| Forming | 98 | ||
| Engineering processes: forming metals | 100 | ||
| Learning aim A: assessment practice | 102 | ||
| How you will be assessed | 102 | ||
| Practical engineering skills 1 | 104 | ||
| Observing and recording skills | 105 | ||
| Practical engineering skills 2 | 106 | ||
| Example: consider a bolt | 106 | ||
| Practical engineering skills 3 | 108 | ||
| Disassembly techniques | 110 | ||
| Safe use of disassembly techniques | 110 | ||
| Disassembly tools | 112 | ||
| The different types of tools for disassembly | 112 | ||
| Safe use of tools and equipment – disassembly/reassembly tools with settings | 112 | ||
| Product design specification (PDS) | 114 | ||
| Things you need to consider | 114 | ||
| Size and mass | 114 | ||
| Product life and reliability | 115 | ||
| Performance, function and service requirements | 115 | ||
| Economic and making considerations | 115 | ||
| Implications of standards and legislation | 115 | ||
| Safe working | 116 | ||
| Legislation | 116 | ||
| Learning aim B: assessment practice | 118 | ||
| How you will be assessed | 118 | ||
| Engineering make process 1 | 120 | ||
| Define the problem | 120 | ||
| Develop possible solutions | 121 | ||
| Choose a solution | 122 | ||
| Engineering make process 2 | 124 | ||
| Making using engineering processes | 124 | ||
| Engineering make process 3 | 126 | ||
| Inspect and test chosen solution | 126 | ||
| Evaluate the outcome of a project | 127 | ||
| Developing a production plan | 128 | ||
| Developing a typical production plan | 128 | ||
| Awareness of risks and hazards for making processes | 130 | ||
| Risks and hazards | 130 | ||
| Safe preparation, good housekeeping and close down of the work area | 132 | ||
| Making skills associated with the product to be produced | 132 | ||
| Appropriate set-up of the work area/machine | 132 | ||
| Adaptation according to inspected outcomes | 133 | ||
| Choosing suitable tools | 134 | ||
| Tools for drilling | 134 | ||
| Lathe tools | 134 | ||
| Tools for milling | 135 | ||
| Skills in observing and recording techniques | 136 | ||
| Process measurement | 136 | ||
| Comparisons | 137 | ||
| Learning aim C: assessment practice | 138 | ||
| How you will be assessed | 138 | ||
| Component 3: Responding to an Engineering Brief | 140 | ||
| Carry out a process | 142 | ||
| Engineering processes | 142 | ||
| Work instructions | 142 | ||
| Following planned procedures | 144 | ||
| Improving a production plan | 144 | ||
| Prototypes and models | 146 | ||
| Why prototype? | 146 | ||
| Testing of prototypes | 147 | ||
| Understanding how a product is assembled | 148 | ||
| Reverse engineering | 148 | ||
| Handling and using materials, equipment and machinery | 150 | ||
| Using materials | 150 | ||
| Using equipment and machinery | 151 | ||
| Recording the process | 152 | ||
| Measuring and recording data | 152 | ||
| Displaying data using charts and graphs | 154 | ||
| Types of chart | 154 | ||
| Types of graph | 155 | ||
| Displaying data using lines of best fi t | 156 | ||
| Scatter graphs | 156 | ||
| Lines and curves of best fit | 157 | ||
| Interpretation of data | 158 | ||
| Comparison of trends and patterns | 158 | ||
| Identifying anomalous results and sources of error | 159 | ||
| Evaluating processes, drawing conclusions and making recommendations | 160 | ||
| Measuring equipment | 160 | ||
| Learning aim A: assessment practice | 162 | ||
| How you will be assessed | 162 | ||
| Interpretation of a given brief for an engineered product | 164 | ||
| Analysing the existing product with reference to the design brief | 164 | ||
| Features of engineered products | 166 | ||
| Dimensions | 166 | ||
| Surface fi nishes | 167 | ||
| Physical form | 167 | ||
| Selecting engineering materials | 168 | ||
| Categories of material | 168 | ||
| Manufacturing processes | 170 | ||
| Cutting processes | 170 | ||
| Shaping processes | 170 | ||
| Forming processes | 170 | ||
| Joining and fabrication processes | 171 | ||
| Redesign | 172 | ||
| Identifying issues with existing designs | 172 | ||
| Concept 2D sketching | 172 | ||
| 3D sketching | 174 | ||
| Using 3D sketching | 174 | ||
| Exploded diagrams | 176 | ||
| Electronic circuit diagrams | 178 | ||
| Design for manufacture | 180 | ||
| Design approaches | 180 | ||
| Variations in form to solve a problem | 182 | ||
| Variations in approach to solve a problem | 184 | ||
| Using di\x1E erent componentry | 186 | ||
| Evaluation | 188 | ||
| Reviewing the credibility of design ideas | 188 | ||
| Selecting and justifying the most appropriate design solution | 190 | ||
| Justification of the design solution | 190 | ||
| Justification of the processes to be used | 192 | ||
| Types of process | 192 | ||
| Learning aim B: assessment practice | 194 | ||
| How you will be assessed | 194 | ||
| Analysing engineering information associated with the problem | 196 | ||
| Types of engineering information | 196 | ||
| Types of engineering working drawing | 198 | ||
| Component drawings | 198 | ||
| Assembly drawings | 198 | ||
| Repair and modification drawings | 199 | ||
| Installation diagrams | 199 | ||
| Wiring diagrams | 199 | ||
| Drawings and information | 200 | ||
| Materials and components | 200 | ||
| Dimensions | 200 | ||
| Identifying issues and causes associated with a problem | 202 | ||
| Identifying problems | 202 | ||
| Typical causes of faults | 202 | ||
| Interpreting patterns and trends related to engineering information | 203 | ||
| Selecting a solution | 204 | ||
| Approaches that can be taken | 204 | ||
| Components | 204 | ||
| Materials and manufacturing processes | 205 | ||
| Possible engineering solutions | 206 | ||
| Wider factors that need to be considered | 208 | ||
| One-off production | 208 | ||
| Batch production | 208 | ||
| Environmental impacts | 209 | ||
| Ways to improve the solution | 210 | ||
| Evaluating an existing design | 210 | ||
| Producing an alternative design solution | 212 | ||
| Reflecting on your design solution | 214 | ||
| Material properties | 214 | ||
| Material cost and availability | 214 | ||
| Processes to be used | 214 | ||
| The environment | 215 | ||
| Making recommendations for improvements to the best solution | 215 | ||
| Resources required and their use | 216 | ||
| Materials | 216 | ||
| Tools and tooling | 216 | ||
| Components | 217 | ||
| Equipment and apparatus | 217 | ||
| Presenting your solution | 218 | ||
| Drawings | 218 | ||
| Annotations | 219 | ||
| Make processes to create a prototype solution | 220 | ||
| Processes to follow and use | 220 | ||
| 3D printing – additive manufacture (AM) | 220 | ||
| Physical modelling | 220 | ||
| Following correct processes | 221 | ||
| Collecting and analysing data | 222 | ||
| Collecting data | 222 | ||
| Analysing data | 223 | ||
| Safety considerations | 224 | ||
| Risk assessments | 224 | ||
| Considering timescales | 225 | ||
| Learning aim C: assessment practice | 226 | ||
| How you will be assessed | 226 | ||
| Glossary | 228 | ||
| Index | 232 | ||
| Back Cover | Back Cover |