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Engineering
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Base SI units used in engineeringPrefixes and powers of ten in calculationsDerived units used in mechanical and electrical engineeringConverting between units correctlyStandard form and engineering notationSignificant figures and rounding in engineering answersRearranging engineering formulae safely (with units)Checking answers using dimensional consistencySolving linear equations in engineering contextsSolving simultaneous equations for unknownsSolving quadratic equations in engineering problemsProportion, ratios and scaling for designsUsing trigonometry to find missing sides and anglesResolving forces into horizontal and vertical componentsSine rule and cosine rule in engineering trianglesDegrees and radians conversionArc length and sector area calculationsUsing vectors and components in 2D problemsUnderstanding gradient as rate of changeDifferentiating basic functions for engineering ratesUsing differentiation to find turning points (optimisation)Integrating basic functions to find totals/areasUsing integration with motion graphs (area under curve)Density, mass and volume in mechanical contextsPressure and force relationships in engineering systemsMoments and equilibrium in static systemsStress and strain: what they mean physicallyYoung’s modulus: interpreting and using the formulaShear stress and shear strain in componentsModulus of rigidity and what it tells youFactors of safety and allowable stressLinear motion with uniform acceleration (SUVAT)Newton’s laws in engineering motion problemsMomentum and impulse in collisionsConservation of momentum in engineering scenariosAngular velocity and angular accelerationCentripetal acceleration and circular motionTorque, rotational power and efficiencyRotational kinetic energy and moment of inertia ideasDensity and buoyancy: upthrust calculationsCharge, current and time relationshipsCoulomb’s law and electrostatic forceElectric field strength (two definitions) and useResistance vs resistivity (what’s different)Temperature coefficient of resistance in practiceSeries and parallel resistor networksOhm’s law and non-ohmic behaviour (recognising it)Electrical power equations (P=VI, I²R, V²/R)Electrical efficiency calculationsKirchhoff’s laws for circuit analysisMagnetism: fields and field linesMagnetic flux and flux density (B)Force on a current-carrying conductor (motor effect)Electromagnets: factors affecting strengthElectromagnetic induction: what causes an emfLenz’s law and direction of induced effectsAlternating current waveforms and key featuresPeak, period, frequency and angular frequencyRMS values and why they’re usedImpedance and phase (conceptually)Capacitive and inductive reactance (what changes them)AC power and power factor (what it means)Resonance in RLC systems (what it looks like)Transformers: stepping voltage up/down and efficiency
What “engineering sectors” means (and why it matters)Aerospace engineering: typical work and outputsAgricultural engineering: problems solved and systems usedAutomotive engineering: lifecycle from design to maintenanceBiomedical engineering: devices, safety and complianceChemical engineering: plant, processes and productsCivil engineering: infrastructure design, build and maintenanceEnergy generation engineering: solar, wind, hydro, gas, nuclearMechatronic engineering: sensors, systems and automationMarine engineering: ships and offshore installationsRail engineering: rolling stock and signalling systemsFunctional areas in engineering organisations: overviewResearch and development: turning needs into innovationsSales and marketing: market research and product positioningDesign functions: briefs, drawings and documentationProcess monitoring and control: keeping systems stableManufacturing functions: converting materials to productsMaintenance: corrective vs preventative vs predictiveQuality management: standards, checks and trend analysisEnergy management: monitoring, control and sustainabilityHealth and safety management: risk assessment and reportingRobotics in engineering: automation and hazardous environmentsCobots: designing safe human–robot collaborationDrones: engineering uses and constraintsVirtual reality: collaboration and product visualisationAugmented reality: overlays for guidance and informationCloud computing: secure storage and scalable collaborationInternet of Things: connected sensors for monitoring/controlArtificial intelligence: autonomy, data analysis and vision3D printing: prototyping vs production and customisationDigital twins: real-time monitoring and optimisationMetals: crystals, grains and grain size effectsAlloys: how solid solutions change propertiesKey pure metals used in engineering (Fe, Cu, Al, Zn, Sn, Ti…)Ferrous alloys: carbon steel types and typical usesStainless steel (austenitic): why it behaves differentlyNon-ferrous alloys: Al alloys, Ti alloys, brass, bronzePolymers: amorphous structures and what that impliesThermoplastics vs thermosets vs elastomers (properties and uses)Common thermoplastics by abbreviation (PC, PS, ABS, PET, PLA, PA66)Common thermosets and typical applicationsElastomers: thermoset vs thermoplastic elastomersComposites: matrix and reinforcement rolesFibre composites: GFRP vs CFRP and why they differParticle composites: cemented carbide and what it’s forComposite structure choices (fibre alignment, matrix/reinforcement ratio)Physical properties: density, melting point, conductivity, resistivityChemical/functional properties: corrosion resistance, ferromagnetism, light transmissionMechanical properties: hardness, toughness, modulus, strengths, ductilityStrength-to-weight ratio and design decisionsHeat treatment: what it changes inside steelQuench hardening: purpose and outcomesTempering: reducing brittleness after hardeningAnnealing: softening and improving workabilityNormalising: refining grain structure and propertiesCase hardening: tough surface, ductile coreManufacturing process choice: accuracy, finish, cost and wasteForming: press work (piercing/blanking) in sheet metalForming: closed die drop forging (steel forgings)Casting: sand casting (cast iron components)Casting: hot chamber die casting (zinc alloys)Casting: investment casting (titanium components)Moulding: thermoplastic injection moulding (complex mouldings)Moulding: thermoset compression moulding (complex mouldings)Moulding: wet lay-up for GFRPMoulding: resin transfer moulding (RTM) for CFRPMachining: drilling setup for hole size and hardnessMachining: manual vertical milling (faces, edges, slots)Machining: CNC vertical milling and its advantagesMachining: manual turning (parallel turning, facing, parting)Machining: CNC turning and its advantagesMachining: surface grinding for hardened steel finishingCutting: band sawing for metalsCutting: abrasive slitting discs (grinding as cutting)Cutting: shearing/guillotining sheet metalCutting: CO₂ laser cutting for thermoplastic sheet
Turning a brief into a Product Design Specification (PDS)Writing user requirements that are testableDefining product functions clearlyAesthetics and finish: specifying what “good” looks likeDimensions and tolerances (at concept stage)Weight restrictions and why they matterErgonomics and anthropometrics in design requirementsChoosing candidate manufacturing methods for the PDSChoosing candidate materials for the PDSCost breakdowns: materials, components, labour, equipmentQuantity and batch size implicationsDesigning for safety (hazards and controls)Designing for maintenance and serviceabilityInterfaces and interactions between componentsReliability requirements and how to express themLegal requirements: intellectual property basics for designersLegal requirements: health and safety duties in designLegal requirements: environmental legislation impactsSustainability in the PDS: refuse, reduce, reuse, repurpose, recycleSelecting materials using properties from Unit 2Matching materials to function, environment and sustainabilitySelecting manufacturing processes using Unit 2 knowledgeResearching existing products to inform design ideasUsing catalogues and databases to select bought-out componentsSketching in good proportion (quick, clear communication)Isometric sketching for 3D communicationOblique drawing for quick 3D representationOrthographic sketching (single and linked views)Detail sketches with notes and technical languageGenerating multiple initial concepts (not just one)Constraints and trade-offs in early-stage ideasConsidering mechanical principles in concept sketchesAssembly arrangements and how parts will fit togetherEstimating costs during concept generationSustainability across the product life cyclePhysical modelling: choosing modelling sheet materialsPhysical modelling: casting and moulding modelling materialsModelling systems (e.g., modular kits) for mechanismsSafe and effective use of hand tools for modellingUsing 3D printing, laser cutting and CNC for prototypesSpreadsheet cost modelling: material choice changes costSpreadsheet cost modelling: labour (skilled vs unskilled)Spreadsheet cost modelling: equipment (general vs specialist)Running a design review meeting (presenting ideas clearly)Giving and receiving peer feedback professionallySelecting a preferred concept using comparison to the PDSSetting up a parametric CAD model (units, planes, files)CAD sketch commands: line, arc, circles, fillets, dimensionsCAD view controls: pan, zoom, orbitCAD editing tools: trim, rotate, extend and refineCreating 3D forms: extrude and revolveModifying 3D models: holes, chamfers, move faceBoolean operations: add, subtract, intersectUsing constraints to assemble parts in CADCAD analysis tools: mass and stress (what they’re for)Building components from sketches (2D → 3D workflows)Adding features: threads, countersinks, counterbores, filletsSketching on 3D faces to add detailIterating the CAD model to better meet the briefCost consequences of materials: volume, density and massBuilding assemblies: degrees of freedom (translation/rotation)Assembly constraints: mate, angle, insert and tangentModifying parts due to assembly constraints (design-for-assembly)Generating 2D drawings from 3D modelsDrawing standards: working to BS 8888 (or equivalent)Setting up 2D CAD: templates, limits, scale and title blocksUsing layers effectively (create, lock, freeze, visibility)Line types, hatching and conventions in drawingsUsing coordinate methods (absolute, relative, polar)Modify commands in 2D CAD (mirror, array, copy, fillet)Dimension styles and editing dimensions correctlyProducing component drawings with orthogonal viewsUsing sectional views to show internal detailProducing assembly drawings and general arrangementsCreating parts lists / bills of materials (BOM)Building a presentation pack from design documentationChoosing media: graphical vs written vs verbal communicationTone, language and handling questions in presentationsResponding constructively to feedback and updating designsReviewing where requirements were achieved in the processIdentifying stages that could be improved next timeReflective practice using the ERA cycleReflective practice using Driscoll’s modelSWOT/SOAR self-review and action planning
Understanding the project life cycle (initiation → evaluation)Clarifying a problem: what needs fixing and whyResearching a project theme using credible sourcesDefining constraints: time, cost, scope, ethics, legality, sustainabilityGenerating ideas with creativity tools (mind maps, reverse thinking, etc.)Using Six Thinking Hats to broaden solution thinkingWriting an initial specification for alternative solutionsUsing sketches, diagrams and storyboards to explain ideasOutlining processes: tools, assemblies and high-level flowchartsRough costings and budgets using a spreadsheetInitial technical estimates (mass, volume, materials, performance)Feasibility criteria: size/complexity and achievable benefitFeasibility criteria: time, budget and expertise requiredFeasibility criteria: risks, unknowns and unproven techFeasibility criteria: sustainability and environmental impactFeasibility criteria: legal constraints (e.g., H&S legislation)Selecting a solution using objective testingComparing solutions with cost–benefit thinkingUsing graphs/tables to compare solutions (bar charts, histograms, etc.)Process capability and fitness-for-purpose comparisonsResource planning: people, equipment, info and supportTime planning with a Gantt chartCritical path analysis to set prioritiesBuilding contingency into project plansMonitoring progress with milestones and regular reviewsKeeping a logbook: problems, solutions, iterations and decisionsTeacher monitoring and peer review checkpointsRisk vs issue: what each means in a projectScoring severity, probability and impactCalculating “severity” from probability × impactMitigation strategies: prevent, reduce, accept, transferManaging risks and issues throughout deliveryWriting a technical specification for the chosen solutionInterfaces: physical, software, human and electrical/electronicStandards, tolerances, security and operating conditionsReliability, maintenance and performance requirementsDesign tools: drawings, CAD, diagrams and documentationSimulation models (circuits, pneumatics/hydraulics, software models)Physical modelling and rapid prototyping choicesProcess/program design (flow charts, operation sheets)Design references: formulae, tables, pseudocode, ergonomic recordsSafety regulations relevant to the chosen specialist areaSustainability and cost/demand considerations in designCreating test plans to BS/IS where appropriateDestructive vs non-destructive testing: when to use eachUndertaking development using reporting and monitoringSafe use of machines, workshops, tools and consumablesTroubleshooting methods: expected behaviour and half-splitTroubleshooting: cause-and-effect and 5 WhysTesting against the technical specification (fitness for purpose)Collecting different data types (discrete, continuous, grouped)Analysing data using averages (mean, mode, median)Presenting data (line graphs, scatter, histograms, etc.)Professional behaviours: time management and sequencing tasksCommunication and literacy for instructions and documentationCustomer awareness and commercial fitness-for-purposeResilience, adaptability and responding to criticismIdentifying support needs (practical, academic, external)Building a project portfolio: sections and evidence typesIncluding peer reviews and tutor monitoring evidenceWriting conclusions on success against the theme and idea
