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Camping tents, canopies and promotional marquees are often constructed using interlocking flexible tube framing and moulded joints - Leaving Cert Engineering - Question 6 - 2017
Question 6
Camping tents, canopies and promotional marquees are often constructed using interlocking flexible tube framing and moulded joints. (i) Name a process used to manuf... show full transcript
Worked Solution & Example Answer:Camping tents, canopies and promotional marquees are often constructed using interlocking flexible tube framing and moulded joints - Leaving Cert Engineering - Question 6 - 2017
Step 1
Name a process used to manufacture the thermoplastic tubes and a process used to manufacture the thermoplastic joints.
Answer
The process used to manufacture the thermoplastic tubes is Extrusion. This involves feeding plastic granules from a hopper into a heated chamber, where it is melted and then formed into the desired shape through a die.
The process used for the thermoplastic joints is Injection Moulding. In this process, molten plastic is injected into a mould to create complex shapes.
Step 2
Describe the principle of operation for the manufacturing process used to make the thermoplastic tubes.
Answer
The extrusion process operates by first feeding plastic pellets into a hopper. A rotating screw then moves the pellets into a heated barrel, where they are softened. This molten plastic is forced through a die at the end of the barrel, shaping it into a continuous profile, such as tubes. Once shaped, the extruded product is cooled and can be cut into desired lengths.
Step 3
Select a suitable thermoplastic for the frame tubing and give one reason for your selection.
Answer
Nylon is a suitable thermoplastic for the frame tubing. The reason for this selection is its strength combined with lightweight properties, making it ideal for applications where durability and flexibility are paramount.
Step 4
Step 5
Outline two reasons for the use of ABS in the manufacture of toys.
Answer
- Lightweight material: ABS is easy to mold and creates lightweight products, which is essential for children's toys.
- Impact resistance: ABS offers excellent impact resistance, ensuring that toys can withstand rough handling.
Step 6
Explain the polymerisation process used to produce ABS.
Answer
ABS is produced through addition polymerization. In this process, long chains of molecules are formed by the repetitive addition of monomers. Initially, the individual monomers are activated and bonded, leading to a polymer chain that incorporates the properties of each constituent monomer.
Step 7
Describe Calendering.
Answer
Calendering is a manufacturing process used to create thin sheets or films. It involves passing a feed material through a series of heated rollers which reduce its thickness and create uniform sheets. This process is typically used for thermoplastics and can produce finished materials that can be easily cut or rolled.
Step 8
Describe Plastic Pultrusion.
Answer
Plastic Pultrusion is an extrusion process tailored for producing continuous lengths of composite materials by pulling them through a heated die. In this process, reinforcing materials like fibers are saturated with resin before being pulled into the die. The heating causes polymerization, and the product emerges in a constant cross-section.
Step 9
Step 10
Step 11
Describe Compression moulding.
Answer
Compression moulding is a method suitable for thermosetting plastics. It involves placing a pre-measured amount of the material into a heated mould. The application of heat and pressure forces the material to fill the mould's shape. Once cooled, the mould is removed, producing the final product, which often requires trimming.