Lesson 3.3 – Teacher Notes

The following is a listing of the topical areas covered in the lesson from the course outline that will aid you in preparing to teach the lesson:

1.Structural Connections

  1. Joinery
  2. Fasteners
  3. Adhesives

2.Precision Measurement

3.Material Analysis

  1. Material Types
  2. Materials Processing Methods

4.Property Analysis

  1. Surface Area
  2. Mass
  3. Volume
  4. Material Density

5.Finite Element Analysis

  1. Force
  2. Pressure
  3. Stress

Joinery, Fasteners, and Adhesives for Wood, Metal, and Plastic

Suggestions for labeled samples of fasteners and adhesives that may be used with the optional activities are listed below.

Optional Activity 3.3.1b Wood Fasteners and Adhesives Classification

The teacher may provide samples of wood fasteners listed below, each labeled with a unique letter A through O.

Nails: / Screws:
Box / Course Thread
Brad / Fine Thread
Casing / Flat Head
Common / Oval head
Finishing / Phillips Head
Tack / Round Head
Upholstery Tack / Slotted Head
Torx Head

The teacher may provide samples of wood adhesives listed below, each labeled with a unique letter P through U.

Adhesives:
Carpenter’s Glue
Casin
Contact Cement
Hot Glue
Polyurethane or Gorilla Glue
White glue

Optional Activity 3.3.1d Metal Fasteners and Adhesive Classification

The teacher may provide samples of metal fasteners listed below, each labeled with a unique letter.

Bolts: / Washers: / Screws:
Carriage / Helical Spring Lock / Lag
Machine / Plain or Flat / Machine and cap
Stove / Toothed Lock / Set
Stud / Sheet metal
Tap / Thumb
Nuts: / Pins: / Keys:
Castle / Cotter / Gib head
Jam or Lock / Roll / Square
Machine screw nut or hex nut / Tapered / Woodruff
Wing

The teacher may provide samples of metal adhesives listed below, each labeled with a unique letter.

Adhesives:
Ana aerobics
Cyanacrylates
Epoxies
Urethanes

Optional Activity 3.3.1f Plastic Fasteners and Bonding Classification

The teacher may provide samples of Plastic Fasteners listed below, each labeled with a unique letter.

Snap fits: / Mechanical Fasteners: / Plastic Assemblies:
Annular / Metal Rivets / Boss
Cantilever / Self-tapping Screw / Living Hinge
Torsion / Stamped Sheet Metal Fasteners / Press Fit
Threaded Metal Insert

The teacher may provide samples of plastic bonding from the bonding categories below, each labeled with a unique letter.

Bonding:
Adhesive
Solvent

The following resources are provided to aid you in learning more; you may find them useful in aiding your students in their research:

Woodworking Joints:

Diynetwork. (September 15, 2006). Woodspeak: A Glossary of 30 Basic Terms to Make You a Better Woodworker. [On-line]. Available:

Wikipedia.org. (September 15, 2006). Woodworking joints. [On-line]. Available:

Glues and Adhesives:

Do it yourself. (September 15, 2006). Proper Adhesives Avoid Sticky Problems. [On-line]. Available:

Flyingtigers. (September 15, 2006). Adhesives. [On-line]. Available:

Lowes. (September 15, 2006). Guide to Glue and Adhesives. [On-line]. Available:

Popular Mechanics. (September 15, 2006). Woodworking Guide: Wood Glue. [On-line]. Available:

Azom.com. (September 15, 2006). Adhesives - Modern Types of Adhesives. [On-line]. Available:

Adhesives, Loctite, Silicones, Epoxies, and more- Versatile Industrial Products. (September 15, 2006). [On-line]. Available:

Engineering Plastics Assembly - Gluing - Solvent bonding. (September 15, 2006). [On-line]. Available:

Metal Bonding Adhesives. (September 15, 2006). [On-line]. Available:

Thermoplastic Adhesives. (September 15, 2006). [On-line]. Available:

Adhesive Bonding - chemically curing adhesives. (September 15, 2006). [On-line]. Available:

A&E Television Networks: Modern Marvels: Glue URL:

Mechanical Fasteners:

Lowes. (September 15, 2006). Choosing the Right Fastener: Nails and Screws. [On-line]. Available:

Wikipedia.org. (September 15, 2006). Torx. [On-line]. Available:

Basics of Design Engineering - Fastening & Joining - Joining – Adhesives. (September 15, 2006). [On-line]. Available:

Self-Tapping Screws. (September 15, 2006). [On-line]. Available:

California Agricultural Education. (September 15, 2006). Curriculum on Agricultural Mechanics, Unit on Fasteners. [On-line]. Available:

Glossary of Terminology Related to Nuts and Bolts. (September 15, 2006). [On-line]. Available:

Mechanical fastening- threaded fasteners and blind rivets. (September 15, 2006). [On-line]. Available:

Counter Bore/Sink. (September 15, 2006). [On-line]. Available:

Insert. (September 15, 2006). [On-line]. Available:

Snap-Fits for Plastic Assembly:

Engineering Plastics Assembly - Mechanical connections - Snap fits. (September 15, 2006). [On-line]. Available:

Design for assembly. (September 15, 2006). [On-line]. Available:

Designfax - Aug 2001 - Design in Plastics- Part 5 - Plastics assembly methods. (September 15, 2006). [On-line]. Available:

Snap Fit Design. (September 15, 2006). [On-line]. Available:

Snap Latches. (September 15, 2006). [On-line]. Available:

Snap-Fit Latch Design. (September 15, 2006). [On-line]. Available:

Snap-Fits. (September 15, 2006). [On-line]. Available:

Press-Fits. (September 15, 2006). [On-line]. Available:

Welding Techniques:

Brett Martin - Semi-Finished - Foamalux - Hot Air Welding, Hot Plate Welding. (September 15, 2006). [On-line]. Available:

Plastic welding - Wikipedia, the free encyclopedia.webloc. (September 15, 2006). [On-line]. Available:

Plastics joining - Hot Gas Welding technique. (September 15, 2006). [On-line]. Available:

Ultrasonic welding - Wikipedia, the free encyclopedia. (September 15, 2006). [On-line]. Available:

Welding of Plastics. (September 15, 2006). [On-line]. Available:

Glossary – BernzOmatic. (September 15, 2006). [On-line]. Available:

General Info on Fastening, Adhesives, and Machining:

BBC – GCSE. (September 15, 2006). Bitesize Design, Resistant materials, Joining Metal. [On-line]. Available:

Joneja, Ajay. Hong KongUniversity of Science and Technology, Department of Industrial Engineering and Engineering Management (IEEM) (September 15, 2006). Lecture 8. Joining processes. [On-line]. Available:

Basics of Design Engineering - Fastening & Joining - Joining - Joining Plastic. (September 15, 2006). [On-line]. Available:

Engineering Plastics - Secondary operations - Assembly. (September 15, 2006). [On-line]. Available:

Plastic Machining & Assembly. (September 15, 2006). [On-line]. Available:

General Info for Designers:

Boss Design. (September 15, 2006). [On-line]. Available:

Cost Saving Design. (September 15, 2006). [On-line]. Available:

Living Hinge. (September 15, 2006). [On-line]. Available:

Product Disassembly

Take the time to complete the activities and projects yourself before assigning them to the students.

During the lesson on structural analysis and upon completing Project 3.3.6 Product Disassembly Display, students will complete the following guidelines:

  • No damage to parts during teardown
  • Teardown chart completed on each part of the product
  • Optional: Product Disassembly essay (assessed using the Product Disassembly Essay Rubric)
  • Accurately measured parts
  • Orthographic drawing done for each part
  • 3D Isometric view of each part
  • Assembled view of the product
  • Exploded presentation view
  • Preparation of your poster for the poster session using the following criteria:

Create a tri-fold display that includes the following:

  • Rendered isometric drawing with a title bar with the following information for each part of the product:
  • Name of Part
  • Dimensions of Part
  • Material of Part
  • Density of Material
  • Volume
  • Surface Area
  • Mass
  • Parts mounted on the board with corresponding label to the drawing of each part
  • Product Display Chart
  • Other information specified by your teacher, such as student names, class, period, and product title
  • Prepare a three-minute presentation that answers the following questions:
  • What are your product and its function?
  • What did you learn about the product’s mass property analysis?
  • Why or why not could you complete a finite analysis?
  • If you were able to do a finite analysis, what is the result?

Mass Property Analysis

During Activity 3.3.4 Mass Property Analysis and Optional Activity 3.3.4a-gMass Property Analysis Extras, students will encounter situations thatthey may not know how to handleon their own, such as some of the mathematics required to calculate the volume, surface area, and mass of their product parts. In addition, they will be learning how to use new software. Students should be encouraged to teach themselves through the use of the help menu and tutorials provided. The goal is to provide the students with the skills to research and discover the knowledge they need, without assistance. Be prepared, however, to answer questions, when they arise; instead of providing direct answers, provide hints as to where to find the information. Encourage the students to seek out the information independently.

Optional Activity 3.3.4f and 3.3.4gare an opportunity for students to “self test” their mass property analysis skills. Encourage them to perform this activity without notes, help menus, tutorials, or PowerPoint references.

Some students may work quickly through Optional Activity 3.3.4a-g extras; whereas, others may not. There are “go further” extensions students may work on related to the area listed at the bottom of most activities. Be prepared with change forms for different part materials or size changes to offer challenges to help students extend their learning.

Finite Element Analysis

The following website resources will assist you and the students in learning more aboutFinite Element Analysis (FEA).

Case Studies:

Ansys Design Space Helps Leading Robotics Company Reduce Weight and Save Time. (August 22, 2005). [On-line]. Available:

Ansys Design Space Helps Texas-Based Elevator Manufacturer Reduce Weight and Improve Safety. (August 22, 2005). [On-line]. Available:

White Papers:

DiGioia, Anthony, M. III, M. D. Bring Simulation to Surgery: Improving the Success Rate of Hip Replacements. (August 22, 2005). [On-line]. Available:

Leveraging Simulation: The Design Innovation Process, (August 22, 2005). [On-line]. Available:

Leveraging the Design Chain. (August 22, 2005). [On-line]. Available:

Roth, Gregory. Analysis in Action: The Value of Early Analysis. (August 22, 2005). [On-line]. Available:

The following resources are provided to aid you in learning more; you may find them useful in aiding your students in their research:

Books:

Feirer, John L. (1963). Woodworking for Industry: Technology and Practice.Peoria, Illinois: Chas. A Bennett Co., Inc.

AutoDesk Inc. (2005). Inventor (Version 10) [Computer software help menu]. CA: AutoDesk, Inc.

International Technology Education Association. (2000). Standards for technological literacy: Content for the study of technology.Reston, VA: Author. Pages 236-242

Hacker, M., Burghardt, B. (2004). Technology Education: Learning by Design. pp 538-549 Upper Saddle River,NJ: Pearson/Prentice-Hall

Compact Oxford English Dictionary of Current EnglishThird EditionOxford University Press 2006

Adams, V., Askenazi, A.(1999). Building Better Products with Finite Element Analysis pp. 9-12 Santa Fe, NM OnWord Press

Rogers, K. (Eds.). (2003). Illustrated Dictionary of Math.London, England: Usborne Publishing

Repp, Victor E. (1994). Metalwork: Technology and Practice. NY: Glencoe McGraw-Hill.

(resource for Lesson 3.4)

(resource for Lesson 3.4)

Project Lead The Way, Inc

Copyright 2007

IED – Teacher Guidelines – Support Materials – Unit 3 – Lesson 3.3 – Teacher Notes – Page 1