Metalwork - Exam Papers - OL - Paper - 1993

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100 Marks

INSTRUCTIONS

1. Answer question 1, sections A and B, and any three other questions.
2. Write your answers in the space provided or tick the appropriate box.
3. Hand up this paper at the end of the examination.

1.
(40 Marks)

SECTION A - 20 MARKS

ANSWER ANY TEN QUESTIONS FROM THIS SECTION

(a) The marking out tool is made from : Mild Steel  
Wrought Iron  
High Carbon Steel  
Cast Iron  
(b) The instrument is a(n) : Bevel Gauge  
Combination Set  
Odd Leg Callipers  
Depth Gauge  
(c) Hammers are classified by : Length of Shaft  
Diameter of Head  
Total Weight of Hammer  
Weight of Head  
(d) The measuring instrument is a(n) : Micrometer  
Outside Callipers  
Inside Callipers  
Vernier Callipers  
(e) The fastner is a : Lock Nut  
Rivet  
Grub Screw  
Split Pin  
(f) The technique is called : Drilling  
Countersinking  
Counterboring  
Reaming  
(g) The instrument is a : Wire Gauge  
Feeler Gauge  
Screw Pitch Gauge  
Radius Gauge  
(h) The technique is called : Forming  
Tapping  
Screwing  
Twisting  
(i) The thread form is a(n) : ISO Metric Thread  
Buttress Thread  
Acme Thread  
Square Thread  
(j) The holding device is a : Pin Vice  
Machine Vice  
Hand Vice  
Bench Vice  
(k) The tool is a(n) : Open Spanner  
Box Spanner  
Ring Spanner  
Adjustable Spanner  
(l) The technique is called : Taper Turning  
Parting  
Knurling  
Facing  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart
PART METAL
1. Kettle  
2. Plug Pin  
3. Electric Wire  
(ii) Why is the handle made from a plastics material ?
 
 
(n)
Using the labels, briefly explain how the plug is wired :
 
 
 
 
 
(o)
(i) The device is a :
Dynamo  
Motor  
Solenoid  
Relay  
(ii) This device changes electrical energy into :
Mechanical Energy  
Heat Energy  
Electrical Energy  
Chemical Energy  
(p)
(i) Most cars use a :
Copper-Acid Battery  
Lead-Acid Battery  
Zinc-Acid Battery  
Tin-Acid Battery  
(ii) Car bodies are made from :
High Carbon Steel  
Mild Steel  
Tinplate  
Silver Steel  
(q)
(i) Sketch the missing piece in picture (Y) (ii) Lubricating oil is used to :
Increase Friction  
Clean Machine Parts  
Reduce Friction  
Prevent Rust  
2.
(20 Marks)
(a) (i) Complete the chart :
Plastics Material Thermosetting or Thermoplastic List a use for each plastic
Acrylic Thermoplastic Shop signs
PVC    
Nylon    
(ii) Complete the chart :
Metal Ferrous or Non-Ferrous List a use for each metal
Brass Non-Ferrous Screws
Cast Iron    
Bronze    
(b) (i) What is an alloy ?
 
 
(ii) The ability of a material to withstand wear is called :
Strength  
Hardness  
Brittleness  
Ductility  
(iii) The ability of a material to allow heat to flow is called :
Plasticity  
Elasticity  
Malleability  
Conductivity  
(c)
(i) Name the furnace :
 
(ii) Name a material that can be hardened and tempered ?
 
(iii) List two methods of protecting steel against rust.
1.
2.
3.
(20 Marks)
(a)
(i) Indicate with an arrow the direction of movement of part (X) in each of the following :
(ii) Name a mechanism that changes rotary motion into linear motion.
 
(b)
(i) The idler gear :
changes the direction of the driven gear.  
causes the driven gear to go faster.  
causes the driven gear to go slower.  
(ii) The driven gear rotates at :
the same speed as the driver.  
a slower speed than the driver.  
a faster speed than the driver.  
(iii) Name a machine in the school workshop that uses gears.
 
(c)
(i) The mechanism uses a :
Rotary Linkage  
Parallel Linkage  
Bell Crank  
(ii) The pivot point of a lever is called the :
Tie  
Crank  
Fulcrum  
4.
(20 Marks)
(a)
(i) Match the number to the correct part.
Part No.
Feed Lever  
Pulley  
Chuck Guard  
Motor  
Pillar  
Depth Stop  
(ii) When should a pilot hole be used ?
 
(b)
(i) Name the tools :
1.  
2.  
3.  
(ii) State a reason for reaming drilled holes.
 
(c)
(i) Name the taps. (ii) A tapping hole is ?
1.  
2.  
3.  
the same size as the tap.  
smaller than the tap.  
bigger than the tap.  
5.
(20 Marks)
(a)
(i) Select the symbols from the chart and complete the electrical circuit diagram for the manicure fan.
C
O
M
P
O
N
E
N
T
S
Y
M
B
O
L
Draw the circuit in this box.
                   
                   
                   
                   
                   
                   
                   
                   
(ii) What would happen to the motor if the battery connections were reversed ?
 
(b)
(i) Name a sound device suitable for the "bent wire game" and draw its circuit symbol in the box below.
Name :
Draw the symbol in this box.    
(ii) What type of current is supplied by a battery ?
 
(c)
Complete the chart by matching the inventor to the achievement.
Inventors : Henry Bessemer, John P. Holland, Wright Brothers,
Nicholas Otto, Rudolf Diesel, John Dunlop.
Inventor Achievement
1. Henry Ford Mass Production.
2. Pneumatic Tyre.
3. Diesel Engine.
4. Submarine.
5. Steel Making Process.
6. Four Stroke Engine.
7. Aeroplane.
6.
(20 Marks)
(a)
(i) The design shows a candle holder. Name a suitable metal to make part (a) and state a reason for your choice.
Metal :
Reason :
 
 
(ii) What joining process should be used for parts (b) and (c) ?
 
(iii) List three workshop processes involved in making part (c).
1.  
2.  
3.  
(iv) What forming process should be used to make part (b) ?
 
(b)
(i) Draw freehand, an elevation and plan of the toothbrush holder in the box below.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
(ii) Name a plastics material that could be used to make this project.