Unit 9 Engineering Processes

Project 1 – Screwdriver Students will design a screwdriver handle using Prodesktop. The blade will be added and the drawings printed in orthographic and Album format. The handle design will be transferred to the Boxford CNC lathe for manufacture. Students will also use the centre lathe to drill the hole for the blade. The blade is to be made from silver steel –hardened and tempered. The two parts are joined together using threads and/or epoxy resin adhesive.

Process	Logbook	Tools/Equipment	Skills
Design screwdriver handle using Prodesktop.	Record stages in the design process using screenshots.		CAD
Transfer design to Boxford software and manufacture from aluminium rod 25mm dia.	Record using Boxford output – Orthographic, 3D, and listing. Risk assessment for CNC lathe.	Boxford CNC lathe 25mm dia. Aluminium rod	Use CNC lathe. Check dia and stickout.
Centre drill and drill 6mm dia hole.	Risk assessment centre lathe.	Centre lathe, centre drill, 6mm dia drill.	Set up centre lathe. Use centre lathe to centre drill and then drill out to 6mm. Work safely.
Forge silver steel into screwdriver blade shape.	Draw up planning sheet/flow chart. Health and safety issues.	Brazing hearth/forge. Tongs. Anvil. Hammers. Quenching bath.	Forging – shaping hot metal using an anvil and hammer.
Anneal silver steel so that it can be filed			Annealing – heat to cherry red and allow to cool slowly
File to shape. Clean up.	Continue planning sheet	Hand file. Emery cloth, wet and dry paper.	Filing and finishing metal to a reasonable surface quality
Harden silver steel by heating to cherry red and quenching in water or quenching oil. Clean up back to silver colour and reheat to straw – allow to cool. This is tempering.	Record process of hardening and tempering. Process chart. Health and safety issues. Coshh	Hearth. Gas torch. Tongs. Quenching bath.	Hardening and tempering of high carbon steels.
Final clean up. Joining blade to handle. Choice of methods:- Use of epoxy resin. Thread cutting.	Record processes. Coshh for adhesives.	Two part epoxy resin. Tap and die, cutting compound	Thread cutting. Adhesive use.