The task has been set to make a hole punch (used to punch holes in thin strips of aluminium) suitable for a student in key stage 3.
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Situation and Design Brief Situation: At Exmouth Community College, Design Technology is a compulsory lesson for students in key stage 3 (years 7, 8 and 9). During the course the students will need to be able to punch holes in a variety of materials in order to join different components together - a hole punch is required to carry out this task. The task has been set to make a hole punch (used to punch holes in thin strips of aluminium) suitable for a student in key stage 3. The only constraints are the limited resources and tools within school (unless accessible out of school) and the 40 hour practical construction time limit. As there are no other requirements of the hole-punch, the task is very open-ended; relevant research must be carried out in order to ensure every aspect of the hole-punch meets and exceeds the specified requirements. Design Brief: I will design and make a hand operated hole punch (used to punch holes in aluminium) that will be suitable for key stage 3 students to enable them to make their own 'bolt-together' modelling kit. However, firstly, I will be carrying out research into the design and production of hole punches, a specification will then be written and I shall produce a variety of possible designs and finally develop one idea which will then be constructed. Intended Users When making my hole punch many different people need to be considered. Below is a spider-diagram which explores the factors I need to take into account when considering the sorts of people that will be using and buying the product. Research into a Specification As noted in my design brief, it is vital to research specific topics before designing my hole punch. Therefore, before writing a specification I will need to explore a range of different topics surrounding the design and the construction of my product.
Considering aesthetics, ergonomics and theoretical accuracy, I give this design idea 5/10. Design Idea 4 This design idea relies on the invention of the cam. It is this component which is responsible for pushing the punch to make the hole in the aluminium. I like this design because of its originality - it is unlike the other three designs because it uses a rotary motion rather than a linear motion. Another reason why I like this design is because the user can see the hole being punched from above. However, I think that once made, the hole punch may not be efficient enough to produce accurate holes. It too, is very large, thus being heavier and more difficult for students to carry. The main concern I have with this design is the rod which connects from the cam through the post and to the handle. This could possibly be a very weak component and without consideration this may move from side to side. I think this is the design that looks the best, however in reality I do not think it would provide me with a satisfactory degree of accuracy. I give this design idea 6/10. Components Cutting List Before shaping each component I will need to cut the materials in order to begin making them. Number Name Material Bar Type Size (mm) Quantity Length Width Thickness 1 Barrel BDMS Round 42 25 25 1 2 Plunger BDMS Round 80 15 15 1 3 H-Block BDMS Flat 62 40 10 1 4 Pillar BDMS Square 107 20 20 1 5 Horizontal Linkage BDMS Flat 132 13 6 1 6 Vertical Linkages BDMS Flat 102 13 6 2 7 Handle BDMS Flat 152 13 6 1 8 Handle Block BDMS Square 22 20 20 1 9 Connector BDMS Square 32 16 3 1 10 Metal Plate BDMS Flat 142 60 6 1 11 Wooden Base MDF n/a 272 100 10 1 The table above shows the measurements, materials and quantity of each component.
I am satisfied with the way in which each of the components are joined to one another as all of the joints are very secure. I am especially pleased with the brazed components and this is a permanent fixing which very little time and is virtually unnoticeable. My main criticism with the joints is the nuts and threaded bar as this is a little loose. In every case, the bar could have been made longer and the nuts could then have been tightened further. BDMS was certainly an appropriate material to make the product with as it is easily shaped, joined and finished. It is heavier than I thought it would be, however no lighter material would have had the qualities which BDMS has. Every component does it jobs effectively as intended except the punch. The punch does not produce accurate, circular, high quality which is was meant to. I think if this was sharpened more and then hardened and tempered it may produce holes of a better quality. I think to further solve this problem I would secure a form lid above the H block to ensure the aluminium strip does not lift up when being punched. I could have saved time if I had planned my time better; I found myself constantly queuing for the milling machine and therefore when I did not have other tasks to be doing I was wasting a lot of time. Also, I decided to shorten the vertical linkages after I had drilled, filed and finished them. I could have saved a great amount of time if I had made this decision earlier on. I have enjoyed making my hole punch and have learnt a lot about planning and designing during the course. If I was to repeat this project I would concentrate more on improving the quality of the holes and concentrate less on aesthetics. ?? ?? ?? ?? GCSE Industrial Technology - Katie Heskins 8100
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