Metalwork - Exam Papers - OL - Paper - 1997

Materials | Bench Tools | Exam Papers | Projects | Syllabus

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) This box contains : Sockets  
Spanners  
Drill Bits  
Stocks and Dies  
(b) This cutting tool is a : Straight Snips  
Universal Snips  
Curved Snips  
Bench Shears  
(c) This cutting tool is a : Counterboring Cutter  
Countersinking Cutter  
Reamer  
Centre Drill  
(d) A rivet head is formed using a : Ball Pein Hammer  
Straight Pein Hammer  
Repoussé Hammer  
Cross Pein Hammer  
(e) This tool is used for : Etching  
Engraving  
Mottling  
Enamelling  
(f) This tool is used to measure : Wire  
Drill Bits  
Taps  
Stocks  
(g) This measuring tool is a(n) : Spring Dividers  
Odd-leg Callipers  
Inside Callipers  
Outside Callipers  
(h) This lathe part is called the : Toolpost  
Headstock  
Tool Holder  
Knurling Tool  
(i) This tool is used for : Marking Out  
Drilling  
Cutting  
Sheet Metalwork  
(j) This technique is called : Forming  
Forging  
Twisting  
Scrolling  
(k) This instrument is a : Bevel Gauge  
Feeler Gauge  
Centre Square  
Dept Gauge  
(l) This thread form is a(n) : Acme Thread  
Square Thread  
ISO Metric Thread  
Buttress Thread  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart by listing a different material for each item.
Item Material
1. Sign  
2. Tyre  
3. Hub Cap  
4. Body  
(ii) Name a non-ferrous metal that is sometimes used to make car bodies.
 
(n)
The gear mechanism is to be used in a model truck. Name the gears (a) and (b) and briefly describe how they work.
Gear (a)
Gear (b)
 
 
(o)
(i) This motorbike has a(n) : (ii) This motorbike uses :
Electric Engine  
Petrol Engine  
Diesel Engine  
Calliper Brakes  
Disk Brakes  
Hub Brakes  
(p)
(i) The hull of a ship is made from : (ii) To prevent rust the propellor is made from :
Stainless Steel  
Aluminium  
Mild Steel  
Tinplate  
Mild Steel  
Bronze  
Cast Iron  
High Carbon Steel  
(q)
(i) The rope shown is in : (ii) This mechanism is a :
Compression  
Tension  
Shear  
Torsion  
Rack and Pinion  
Ratchet  
Bell Crank  
Sprocket and Chain  
2.
(20 Marks)
(a) (i) Complete the chart :
Plastic Material Thermosetting or Thermoplastic List two uses for each plastic
PVC Thermoplastic (i) Pipes (i) Windows
Acrylic   (ii) (ii)
Nylon   (iii) (iii)
(ii) Complete the chart
Metals Alloy Formed List two uses for each alloy
Chromium and Steel Stainless Steel (i) Kitchen Sink (i) Cutlery
Copper and Zinc   (ii) (ii)
Copper and Tin   (iii) (iii)
(b) Complete the chart :
(i) Brittleness is the ability of a material to resist wear.
Yes  
No  
(ii) Conductivity is the ability of a material to allow heat and electricity to flow.
Yes  
No  
(iii) Lead is a hard metal.
Yes  
No  
(iv) A Blast Furnace produces steel.
Yes  
No  
(v) Galvanised iron is mild steel coated with zinc.
Yes  
No  
(vi) Soft solder is an alloy of lead and zinc.
Yes  
No  
(c)
Complete the chart :
(i) The slots in the drill table are used for holding work.
Yes  
No  
(ii) A drift is used to remove drill bits from the chuck.
Yes  
No  
(iii) Reamers are used for finishing holes accurately.
Yes  
No  
(iv) A pilot hole must be drilled before using a large drill.
Yes  
No  
(v) A tapping hole should be larger than the tap size.
Yes  
No  
(vi) Standard drill bits have a point angle of 118°.
Yes  
No  
3.
(20 Marks)
(a)
(i) Name the part of the mechanism marked 'X' in each box.
Name :
Name :
Name :
(ii) At what speed does the driven gear rotate, if the driver gear rotates at 200 rpm ?
400 rpm  
600 rpm  
200 rpm  
800 rpm  
(iii) What is the function of the idler gear ?
 
(b)
(i) Indicate with an 'X' the pivot point in each of the following :
(iii) This device is a :
Motor  
Solenoid  
Generator  
Pump  
(c)
(i) Indicate with an arrow the direction of movement of part (x) in each box :
(iii) The power saw uses :
Reciprocating motion  
Linear motion  
Oscillating motion  
Rotary motion  
4.
(20 Marks)
(i) A model desk lamp is shown on the right. Using these symbols draw a circuit diagram for the lamp.
Draw the circuit in this box  
                   
                   
                   
                   
                   
                   
                   
                   
Symbols
(ii) Name two machines used to make the swivel.
1.  
2.  
(iii) What safety precautions should be observed when using one of these machines ?
 
 
 
(iv) What does 'M6' refer to in the drawing of the swivel shown above ?
 
 
 
 
(v) Briefly describe how the lamp shade is formed into the required shape ?
 
 
 
 
 
(vi) Make a freehand drawing (elevation only) of the arrow.
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
USE A
PENCIL
ONLY
5.
(20 Marks)
(a)
(i) Using the components named, briefly explain how the circuit works.
 
 
 
 
 
 
  (ii) This electronic symbol represents a :
Switch  
Battery  
Light Emitting Diode  
Resistor  
(b)
(i) Match the numbers to the correct parts.
Part No.
Keyboard  
Mouse  
Monitor  
Disk Drive  
(ii) Complete the chart :
(i) Computers can be used to draw plans for projects.
Yes  
No  
(ii) Computers can then be used to store these drawings.
Yes  
No  
(iii) Computers can be used to control robots and CNC lathes.
Yes  
No  
(c)
(i) Name one famous engineering inventor :
 
(ii) For what reason is this person famous ?
 
 
(iii) How has this person's invention changed the way we live ?
 
 
6.
(20 Marks)
(i) This design shows a garden ornament. List three workshop processes involved in making part (a).
1.  
2.  
3.  
(ii) List suitable metals for the following parts :
a.  
b.  
c.  
(iii) Part (d) is to be made using a lathe. Briefly describe the processes involved.
 
 
 
(iv) What metal finishing process could be used for part (b) ?
 
(v) The ornament is to be attached to a wall. Draw freehand, an elevation and an end view of a suitable wall bracket in the box below.
USE A
PENCIL
ONLY