Metalwork - Exam Papers - OL - Paper - 2007

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 thread form is a(n): Buttress Thread  
Acme Thread  
Square Thread  
ISO Metric Thread  
(b) This tool is a(n): Tap Wrench  
Adjustable Spanner  
Box Spanner  
Ring Spanner  
(c) This fastener is a: Rivet  
Nut and Bolt  
Split Pin  
Grub Screw  
(d) This cutting tool is a: Straight Snips  
Curved Snips  
Bench Shears  
Combination Pliers  
(e) This technique is called: Brazing  
Soldering  
Hollowing  
Punching  
(f) Hand files are made from: High Carbon Steel  
Mild Steel  
Stainless Steel  
Aluminium  
(g) This instrument is a(n): Inside Calipers  
Combination Set  
Outside Calipers  
Vernier Calipers  
(h) Stocks and Dies are used for: Tapping  
Screwing  
Riveting  
Drilling  
(i) This forging technique is called: Upsetting  
Hammering  
Drawing Down  
Forming an Eye  
(j) This technique is called: Scrolling  
Forming  
Twisting  
Bending  
(k) Part ‘X’ is called the: Frame  
Spindle  
Anvil  
Sleeve  
(l) This technique is called: Parallel Turning  
Taper Turning  
Knurling  
Facing  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)

(i) Give three reasons why the blades of this wind generator should be made from a plastic material.

1.
2.
3.

(ii) Name three plastic materials.

1.
2.
3.
(n)

(i) Why is copper used in the manufacture of solar panels?

 
 
 

(ii) List two other common uses of copper.

1.
2.
(o)

The use of energy saving bulbs saves electricity. List four other ways to save energy in the home.

1.
2.
3.
4.
(p)

(i) Filament bulbs produce light by heating a(n):

 

(ii) How would you conserve energy in the school workshop?

Ceramic Coil  
Tungsten Coil  
Brass Coil  
Aluminium Coil  
 
 
 
 
(q)

(i) The current supplied by a battery is called:

 

(ii) Name each terminal:

Direct Current  
Alternating Current  
Electrical Energy  
L  
N  
E  
2.
(20 Marks)
(a)
(i)

Dead mild steel contains the following amount of carbon:

0.05% - 0.15%  
0.25% - 0.35%  
0.45% - 0.55%  




(v)

A material is said to be ductile when it can be easily:

Stretched  
Fractured  
Melted  
(ii)

High carbon steel is sometimes called:

Silver Steel  
Cast Steel  
Alloy Steel  




(vi)

Plastic glazing is made from:

Phenolic Resins  
Nylon  
Acrylic  
(iii)

Tin is a(n):

Ferrous Metal  
Non-Ferrous  
Metal Alloy  




(vii)

Do thermosetting plastics soften when heated?

Always  
Never  
Sometimes  
(iv)

Brass is an alloy of:

Copper & Tin  
Copper & Zinc  
Copper & Lead  




(viii)

Galvanised iron is coated with:

Tin  
Zinc  
Lead  
(b)

The diagram shows a Blast Furnace. Name any three of the parts labelled.

Part Name
A  
B  
C  
D  
E  
(c)

Complete the chart by listing a tool for each task.

Task Tool
To draw a circle on a piece of metal. Dividers
To draw a line at right angles to a straight edge.  
To locate the centre of a round bar.  
To hold a tap while cutting a thread.  
To accurately measure the diameter of a round bar.  
To hold small sheet metal parts while drilling.  
To remove large drills from a drilling machine.  
3.
(20 Marks)
(a)

(i) Match the number to the correct mechanism part.



Mechanism Part No.
Pulley  
Rack  
Sprocket  
Ball Bearing  
Spur Gear  
Bevel Gear  

(ii) What is a set of meshing gears called?

 
(b)

(i) Complete the chart by listing devices that use the following mechanisms:

Mechanism Device
Ratchet  
Screw Thread  
Crankshaft  
Cam  


(ii) If gear ‘A’ rotates at 150 RPM how fast will gear ‘B’ rotate? (A = 12 Teeth, B = 12 Teeth.)



200 RPM  
100 RPM  
150 RPM  
50 RPM  


(iii) Can gears be made from nylon?

 
(c)

(i) When pulled in the direction of the arrows the spring will be in:

200 RPM  
100 RPM  
150 RPM  
50 RPM  


(ii) A linkage is made up of several:

200 RPM  
100 RPM  
150 RPM  
50 RPM  


(iii) Name gear ‘X’.

 
4.
(20 Marks)

Details of a windshield used in the manufacture of a model vintage car are shown.

(i) List the tools and processes used to make the windshield.

Tools : Processes :
   
   
   


(ii) What does R10 refer to in the drawing?

 
 


(iii) Describe how you would get a smooth finish on the edge of the windshield.

 
 
 
 


(iv) What safety precautions should be observed when drilling sheet metal?

 
 
 
 


(v) Describe how you would safely drill the holes in the axle support.

 
 
 
 
 
 

(vi) What is the overall length of the axle support?

 

(vii) What is the overall width of the axle support?

 
5.
(20 Marks)
(a)

(i) A design for an illuminated display-stand is shown. The design uses a battery, a bulb and a switch. (The battery and switch are not shown.) Draw the electrical circuit diagram for this design.

Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   

(ii) Complete the chart:

Resistance can be measured using a multimeter.

Yes  
No  

A fuse is a safety device in an electrical circuit.

Yes  
No  

Aluminium is an insulator.

Yes  
No  

A car battery is made up of a number of cells joined together.

Yes  
No  
(b)

(i) A car battery is made up of a number of cells joined together.

 
 
 
 
 

(ii) Name one famous Engineering inventor. Write a brief note about this person’s invention.

Inventor's Name :
Invention :
 
 
 
(c)

(i) Name any three electronic components.

1.
2.
3.

(ii) List three devices that use electronic components.

1.
2.
3.
6.
(20 Marks)

(i) This drawing shows a bench vice and a pair of vice clamps. Name a metal suitable for making these clamps. Give a reason for your choice.

Metal :
Reason :
 

(ii) The diagram below represents a blank piece of metal to be used to make one of the vice clamps. Complete the marking out to show where the bend lines should be located.

(iii) Using the chart below describe one shaping process, one finishing process and name the tools used to make the vice clamps.

Shaping Process : Tools Used :
   
   
Finishing Process : Tools Used :
   
   

(iv) List two features of a modern lathe that are not to be found in old lathes.

 
 
 
 
 

(v) Match the number to the correct part.

Part No.
Tool Bit  
Tool Holder  
Three-Jaw Chuck  
Tailstock  
Morse Taper Sleve  
Topslide