BTEC First Engineering
Teaching and Assessment Pack
Unit 1: The Engineered World
Activity Engineering processes
sheet 2 Learning aim A (Topic A2)
Task 1
Which pieces of machinery would be used for each of the following machining activities? Put ‘yes’ or
‘no’ in the relevant boxes.
Centre lathe Milling machine Pillar drill
Cutting round holes Yes Yes Yes
Cutting slots No Yes No
Knurling Yes No No
Cutting shoulders Yes No No
Shaping round bar Yes No No
Shaping square bar No Yes No
Cutting a thread Yes Yes No
Centre lathe Lathe Operations (Animation) - YouTube, Lathe Operations: Different Operations
Performed on Lathe Machine - YouTube Lathe - Parts | Basic Mechanical Engineering | Benchmark
Engineering - YouTube
Milling machine Different Types of Milling Cutters & Operations Explained - YouTube
Pillar drill How to Safely and Correctly use a Pillar Drill (aka Bench Drill) - YouTube
Difference between milling and drilling Differences between Drilling and End Milling (Drill Vs End
Mill) - YouTube
Task 2
Name four hazards associated with all machining processes.
Hazard 1 Flying Swarf and chips - Sharp hot metal chips can be ejected at high speed.
Hazard: Cuts, eye injuries, burns.
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Hazard 2 Entanglement in rotating parts - Loose clothing, hair, or jewelry can get caught in
rotating spindles, chucks, or drills.
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BTEC First Engineering
Teaching and Assessment Pack
Unit 1: The Engineered World
Hazard: Serious injury (pull-in accidents).
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Hazard 3 Noise and vibration -
Prolonged exposure to machine noise and vibration can cause hearing damage and
hand-arm vibration syndrome (HAVS).
Control: Wear hearing protection, use anti-vibration gloves, maintain machines to reduce
vibration.
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Hazard 4 contacts with sharp tools or hot workpieces - Cutting tools and freshly machined
parts are sharp and can retain heat.
Hazard: Cuts, burns.
Control: Use gloves when handling workpieces (after they stop rotating), allow cooling,
handle tools carefully.
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Task 3
Investigate the following forming processes. For each, give:
a short description of the process
examples of products made using that process
reasons why the process is used for your named product.
Casting
Description Examples Reasons
Sand casting Molten metal is poured into a Engine blocks, Low cost for large parts,
mould made of sand, which pump housings, suitable for complex
is packed around a pattern. machine bases. shapes, handles large
After cooling, the sand mould components.
is broken away.
Die casting Molten metal is forced into a Car gearbox High precision, good
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© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free.
BTEC First Engineering
Teaching and Assessment Pack
Unit 1: The Engineered World
Description Examples Reasons
steel mould (die) under high casings, alloy surface finish, ideal for
pressure. Produces accurate, wheels, toy cars. mass production.
repeatable parts.
Investment A wax pattern is coated with Turbine blades, Excellent detail and
casting ceramic, then melted away to jewellery, medical accuracy, can produce
leave a cavity. Molten metal implants. complex and thin-walled
is poured into the cavity to shapes.
form the part.
Permanent Reusable metal moulds are Pistons, automotive Good dimensional
mould casting filled with molten metal by parts, cookware. accuracy, stronger than
gravity or low pressure. sand cast parts,
economical for medium-
volume production.
Forging
Description Examples Reasons
Drop forging A heated workpiece is placed Wrenches, Produces very strong
in a die and hammered with crankshafts, parts with good grain
repeated blows to take the connecting rods. structure, ideal for safety-
die shape. critical components.
Press forging A heated billet is slowly Gears, shafts, Allows better control over
pressed into a die using high aircraft parts. deformation, good for
force, deforming the material large parts, consistent
into shape. quality
Upset forging Involves increasing the Bolts, fasteners, Efficient for producing
diameter of a section by valves. strong threaded parts,
compressing its length (end improves strength at
or middle). stressed sections.
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© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free.