Metalwork - Exam Papers - OL - Paper - 1996

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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 hole depth is measured using a : Surface Gauge  
Depth Gauge  
Drill Gauge  
Micrometer  
(b) The tool used to turn this screw is called a(n) : Vice Grips  
Allen Key  
Box Spanner  
Ring Spanner  
(c) This technique is called : Facing  
Parallel Turning  
Taper Turning  
Undercutting  
(d) The jaw faces of the vice are : Soft  
Smooth  
Serrated  
Knurled  
(e) The part 'X' is called the : Vernier  
Centre Square  
Bevel  
Protractor  
(f) This mallet is used for : Forging  
Hollowing  
Bending Sheet Metal  
Planishing  
(g) This chuck is held in the pillar drill by a : Screw Thread  
Drift  
Lock Nut  
Tapered Shank  
(h) This tool is used for : Screwing  
Drilling  
Twisting  
Tapping  
(i) The distance 'X' is called the : Pitch  
Root  
Flank  
Crest  
(j) The part indicated is called the : Land  
Shank  
Chisel Edge  
Flute  
(k) The bit is made from : Brass  
Copper  
Steel  
Lead  
(l) The scriber is made from : Mild Steel  
High Carbon Steel  
Aluminium  
Cast Iron  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart by listing a different metal for each item.
Item Metal
Sink  
Key  
Nail  
Drink Can  
(ii) Drink cans :
can be recycled.  
cannot be recycled.  
(n)
Why is oil used in the engine of a car ?
 
 
 
 
(o)
(i) The case is a(n) : (ii) Name each terminal :
Insulator  
Conductor  
Semi-conductor  
L  
N  
E  
(p)
(i) Household buckets are made from : (ii) Baths are made from :
Nylon  
Polyethylene  
Acrylic  
Polyurethane  
Nylon  
Polyethylene  
Acrylic  
Polyurethane  
(q)
(i) The chain links of this bicycle are joined by : (ii) This mechanism is a :
Soldering  
Riveting  
Bolting  
Brazing  
Derailleur  
Stirrup Brake  
Calliper Brake  
Hub Brake  
2.
(20 Marks)
(a) (i) Complete the chart :
Metal Type : Ferrous or Non-Ferrous
Copper Non-Ferrous
Mild Steel  
Cast Iron  
Zinc  
Lead  
Aluminium  
Tool Steel  
Tin  
(ii) Brazing Spelter is an alloy of :
Copper and Aluminium  
Copper & Tin  
Copper & Zinc  
Copper & Lead  
(b)
(i) Iron ore is smelted in the blast furnace.
Yes  
No  
(ii) The blast furnace produces steel.
Yes  
No  
(iii) The heat is produced by an electric arc.
Yes  
No  
(iv) Molten metal falls to the bottom of the furnace.
Yes  
No  
(v) Impurities form to make slag.
Yes  
No  
(vi) The furnace can be rotated.
Yes  
No  
(c)
State a different use for any five of the steel sections :
(i) Sheet Steel :
(ii) Round Bar :
(iii) Angle Iron :
(iv) Steel Pipe :
(v) I Girder :
(vi) Square Bar :
3.
(20 Marks)
(a)
(i) Name the part of the mechanism marked 'X' in each box.
Name :
Name :
Name :
Name :
Name :
Name :
(ii) Name a machine that uses this mechanism :
 
(b)
(i) Name this thread :
 
(ii) Name a mechanism which uses this thread :
 
(iii) When the pinion turns once, the rack will move :
1000 mm  
100 mm  
600 mm  
200 mm  
(c)
(i) Which of these gates is the most rigid ?
Gate A  
Gate B  
Gate C  
(ii) A lever is a bar which can rotate about a fixed point called a :
Load  
Pivot  
Linkage  
4.
(20 Marks)
A model electronic wind indicator is shown below.
1. Arrow Shaft
2. Arrow
3. Brush
4. Bearing
5. Slide Plate
6. Cover
7. Cap Nut
(i) How is the arrow joined to the arrow shaft ?
 
(ii) What are the functions of part 3 and parts 7 ?
 
 
 
(iii) List two precautions necessary when drilling the perspex cover.
1.
 
2.
 
(iv) Briefly describe how the arrow is made.
 
 
 
 
 
 
 
 
(v) Make a freehand drawing (elevation only) of the arrow.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
5.
(20 Marks)
(a)
The electric circuit diagram of this lifting mechanism is shown below.
(i) Name the component A & B.
A.  
B.  
(ii) Using this circuit, state the direction in which the weight travels :
 
(b)
(i) Indicate with an arrow the direction of gear 'D'.
(ii) A motor converts electrical energy into mechanical energy.
Yes  
No  
(iii) The motor in the above lifting mechanism uses :
D.C. current.  
A.C. current.  
(c)
Briefly explain the difference between a motor and a dynamo.
 
 
 
 
 
 

Motor

Dynamo
6.
(20 Marks)
(a) The design shows a model aircraft and stand
(i) Briefly explain how the stand is made from a mild steel bar.
 
 
 
(ii) List two hand tools which are used to make this stand.
1.  
2.  
(iii) The stand is to be coated with a plastic material. Give two reasons why this process is necessary.
1.  
2.  
(iv) Briefly describe this plastic coating process.
 
 
 
 
 
 
(b) Design a bracket to hang this sign on the wall.
USE A
PENCIL
ONLY