Design and Manufacture Data Booklet. National 5, Higher and Advanced Higher

Transcription

1 Design and Manufacture Data Booklet National 5, Higher and Advanced Higher This edition: November 2018, version 1.0 Published by the Scottish Qualifications Authority The Optima Building, 58 Robertson Street, Glasgow G2 8DQ Lowden, 24 Wester Shawfair, Dalkeith, Midlothian EH22 1FD Scottish Qualifications Authority 2018

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3 Contents Anthropometric data Standing and seated figures 4 Hand and head 5 Wheelchair 5 Production costs Manufacturing processes 6 Fabrication costs 7 Assembly costs 7 Stock material sizes and costs Dressed timber, man-made boards and dowelling 8 Metal sections and sheets 9 Plastic sections, granules and sheets 10 Fixings Threaded bar, nuts, bolts and washers 12 Screws 12 Pop rivets 12 Page 3

4 Anthropometric data H P G E I J L A B C D F O N M K Standing and seated figures Adult male Adult female 4-year-old child 16-year-old boy 16-year-old girl Percentile Percentile Percentile Percentile Percentile 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th A Height B Eye level N/A N/A N/A N/A N/A N/A C Shoulder height D Elbow height N/A N/A N/A N/A N/A N/A E Shoulder width F Hip width G Vertical reach H Forward reach I Sitting height J Eye level (seated) N/A N/A N/A K Elbow height (seated) L Thigh clearance N/A N/A N/A N/A N/A N/A N/A N/A N/A M Popliteal height N Buttock-front knee length N/A N/A N/A N/A N/A N/A O Buttock-popliteal length N/A N/A N/A N/A N/A N/A P Sitting reach Page 4

5 C limit of vision A D H 30 - limit of comfortable vision B 50 - visual limit of eye F 0 - normal line of sight E G 15 - seated line of sight 70 - visual limit of eye Hand and head Adult male Adult female 4-year-old child 16-year-old boy 16-year-old girl Percentile Percentile Percentile Percentile Percentile 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th 5 th 50 th 95 th A Hand length N/A N/A N/A N/A N/A N/A B Hand breadth N/A N/A N/A N/A N/A N/A C Hand span N/A N/A N/A N/A N/A N/A D Hand thickness N/A N/A N/A N/A N/A N/A E Grip diameter INDEX finger N/A N/A N/A N/A N/A N/A F Head height G Head length H Head breadth N/A N/A N/A N/A N/A N/A Wheelchair Adult Child A Height B Length C Breadth A D E D Seat height E Arm rest height 737 N/A B C Page 5

6 Production costs Manufacturing processes The information in the following tables provides estimated costs for the commercial production of component parts. Assumptions on volume of production and economies of scale have been made to allow for comparisons between each process. Costs are for production only and do not include cost of materials, secondary processes or transportation. Small parts are less than or equal to 50 mm x 50 mm x 50 mm Medium parts are less than or equal to 150 mm x 150 mm x 150 mm Large parts are less than or equal to 300 mm x 300 mm x 300 mm Simple Medium Complex Simple solid form or basic shell structure Little surface detail or texture No ribs, webs or bosses Uniform wall thickness Complex solid form or shell structure Surface detail and texture Few manufacturing features: ribs, webs and bosses Highly complex shell structures High levels of surface detail Several manufacturing features: ribs, webs and bosses Integrated assembly features small medium large small medium large small medium large Injection moulding Die casting Compression moulding Sand casting Simple Medium Complex Simple geometric forms Little surface detail or texture Uniform wall thickness Complex geometric forms Good level of surface detail Highly complex forms High levels of surface detail small medium large small medium large small medium large Rotational moulding Vacuum forming Simple Medium Complex Simple line bends Thin sheet Complex line bends Simple geometric forms Large radii corners Highly complex line bends Complex geometric forms Small radii corners Deep drawing small medium large small medium large small medium large Press forming Page 6

7 The information in the following table provides estimated costs for extrusion. Costs are for production only and do not include cost of materials, secondary processes or transportation. Small parts are less than or equal to 10 mm x 10 mm Medium parts are less than or equal to 50 mm x 50 mm Large parts are less than or equal to 100 mm x 100 mm (price per linear metre) Simple Medium Complex Simple geometric forms Open profile L H T sections Complex geometric forms Closed profile Highly complex geometric forms small medium large small medium large small medium large Extrusion Fabrication costs Machining Wood Metal Plastic Lathe work 0 30 per feature/process 0 40 per feature/process 0 40 per feature/process Milling 0 40 per feature/process 0 40 per feature/process Drilling 0 50 per hole 0 80 per hole 0 50 per hole Cutting and forming Wood Metal Plastic Bending 1 00 per bend 0 50 per bend 0 40 per bend Cutting 0 40 per cut 0 40 per cut 0 40 per cut Finishing (price per 100 mm 2 ) Wood Metal Plastic Chrome plating Galvanising 0 15 Dip coating 0 15 Painting Powder coating 0 15 Polishing Assembly costs Wood Metal Plastic Assembling using snap fits 0 05 per part 0 05 per part Assembling using screws, nuts and bolts 0 15 per part 0 15 per part 0 15 per part Assembling using glue 0 10 per part 0 10 per part 0 10 per part Welding 0 50 per join Riveting 0 60 per rivet 0 60 per rivet 0 60 per rivet Page 7

8 Dressed timber, man-made boards and dowelling Stock material sizes and costs (*all sizes given in mm) Dressed timber (price per linear metre) Size Pine Ash Beech Mahogany Oak Man-made boards (price per 1220 mm 2440 mm sheet) Size MDF Flexi ply Plywood Hardboard Chipboard Dowelling (price per linear metre) Size Ash Beech Mahogany Oak Pine Ø Ø Ø Ø Ø Ø Ø Ø Page 8

9 Metal sections and sheets Metal sections (price per linear metre) Size Mild steel Aluminium Stainless steel Brass Round bar Flat bar Ø Ø Ø Ø Ø Square bar T section U Section I section Angle bar Square section Round tube Ø Ø Ø Ø Box section Page 9

10 Sheet metal (price per 1000 mm 1000 mm sheet) Size Mild steel Aluminium Stainless steel Brass Copper 1 mm thick mm thick Sheets 3 mm thick mm thick mm thick Perforated sheet 6 mm hole, 8 mm pitch, 1 mm thick 10 mm hole, 15 mm pitch, 3 mm thick Tred plate 3 mm thick Plastic sections, granules and sheets Plastic sections (price per linear metre) Round bar Square bar Square tube Round tube Size ABS Acrylic Polypropylene Polystyrene Polythene PVC Nylon Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Angle U channel Page 10

11 Plastic granules (price per kg) ABS Acrylic Polypropylene Polystyrene Polythene PVC Nylon Granules Plastic sheet materials (price per 1000 mm 1000 mm sheet) Size Acrylic Polypropylene Polystyrene PVC Nylon Sheets 1 mm mm mm mm Page 11

12 Fixings Threaded bar, nuts, bolts and washers Length M6 M8 M10 M12 Zinc plated threaded bar 1000 mm Zinc plated nut (price per pack of 10) Zinc plated washer (price per pack of 10) mm Nut, bolt and washer (price per pack of 10) 30 mm mm mm Screws (price per pack of 10) Length Ø 3 5 mm Ø 4 mm Ø 5 mm Ø 6 mm 20 mm mm mm CSK wood 50 mm mm mm mm mm Stainless steel self-tapping 12 mm mm Pop rivets (price per pack of 10) Length Ø 3 2 mm Ø 4 mm Ø 4 8 mm 8 mm mm mm mm 0 82 Page 12