Metalwork - Exam Papers - OL - Paper - 1992

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 cutting tool is a : Tap  
Stocks  
Die Nut  
Split Die  
(b) The part indicated is called the : Body  
Land  
Flute  
Shank  
(c) This technique is called : Facing  
Surfacing  
Knurling  
Sliding  
(d) The instrument is a : Feeler Gauge  
Screw Pitch Gauge  
Wire Gauge  
Radius Gauge  
(e) The tool is a(n) : Dot Punch  
Parallel Pin Punch  
Centre Punch  
Automatic Centre Punch  
(f) The sign warns of a : Toxic Hazard  
Fire Hazard  
Corrosive Hazard  
Radiation Hazard  
(g) The measuring instrument is a : Micrometer  
Vernier Callipers  
Depth Gauge  
Combination Set  
(h) The lathe bed is made from : Wrought Iron  
Mild Steel  
Cast Iron  
High Speed Steel  
(i) The thread form is a(n) : ISO Metric Thread  
Buttress Thread  
Acme Thread  
Square Thread  
(j) The holding device is a : Pin Vice  
Vee Block and Clamp  
Hand Vice  
Toolmaker's Clamp  
(k) The tool is a(n) : Drill Drift  
Rivet Snap  
Allen Key  
Centre Square  
(l) The technique is called : Twisting  
Bending  
Drawing Down  
Forming  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) List two car parts made from different metals.
PART METAL
1.  
2.  
(ii) Name the plastics material sometimes used to make car bodies.
 
(n)
Using the labels, briefly explain how the scissors jack works.
 
 
 
 
 
(o)
(i) Car door handles are sometimes plated with :
Tin  
Zinc  
Chrome  
Silver  
(ii) This plating prevents :
 
 
(p)
(i) The cooling fan is driven by a :
Cam and Follower  
Gear System  
Ratchet and Pawl  
Pulley System  
(ii) Name the gear mechanism
 
 
(q)
(i) Indicate with an arrow the direction of part (a).
(ii) Indicate with an arrow the direction of point (b) when the pedal is pressed.
2.
(20 Marks)
(a) (i) Complete the chart :
Material List a use for each material
Tungsten Used for making electric light bulbs
Lead  
Stainless Steel  
PVC  
Bronze  
Acrylic  
Zinc  
(ii) Name a raw material used in the production of plastics.
 
(b) (i) Are plastics good conductors of electricity ?
Yes  
No  
(ii) Will thermosetting plastics soften when re-heated ?
Yes  
No  
(iii) Is brass an alloy of copper and zinc ?
Yes  
No  
(iv) Is lead a hard material ?
Yes  
No  
(c)
(i) Name the furnace.
 
(ii) What metal is produced by this furnace ?
 
(iii) The metal produced is a :
Ferrous material  
Non-ferrous material  
3.
(20 Marks)
(a)
(i) A block diagram for the control system of a tap is shown. Complete the block diagrams for the Calliper Brake and Torch.
INPUT
Turn
Handle
CONTROL
Screw
Thread
OUTPUT
Valve
Open
INPUT


CONTROL


OUTPUT


INPUT


CONTROL


OUTPUT


(b) List four "need to know" instructions necessary before designing and making a * Candle Holder in the workshop.
1.
2.
3.
4.
* You may choose a different project if you wish.
In that event insert the title in the box -------->
 
(c) Complete the chart by matching the engineer to the achievement. Engineers : John Dunlop, Henry Ford, Henry Maudslay, James Watt.
Engineer Achievement
1. Karl Benz Petrol Car
2. Mass production
3. Pneumatic tyre
4, Steam engine
5. Screw micrometer
4.
(20 Marks)
(a) (i) Why is a soldering iron made with a copper bit ?
 
 
(ii) Briefly describe how the bit is tinned.
 
 
(iii) Why is a flux used when soft soldering ?
 
 
(iv) Soft solder is an alloy of which two metals ?
 
(b)
(i) Name the process.
 

Heat

Quench
(ii)What metal is used to make cold chisels ?
 
(c)
(i) Name the process.
 
(ii)Name another metal finishing process.
 
5.
(20 Marks)
(a)
(i) Complete the chart by matching the symbols with the components.
USE A
PENCIL
ONLY
SYMBOLS
             
(ii) Select the symbols form the chart and complete the electrical circuit diagram for the model boat.
Draw the circuit in this box.
                   
                   
                   
                   
                   
                   
                   
                   
(b)
(i) When the motor turns clockwise the vehicle moves :
Forward  
Backward  
(ii) Name a machine driven by an electric motor, that is used in :
(a) the home.
(b) the workshop.
(a)  
(b)  
(c)
(i) The gear used is a : (ii) The driven gear (Y) rotates at :
Spur  
Bevel  
Radial  
Worm  
200 RPM  
300 RPM  
100 RPM  
250 RPM  
6.
(20 Marks)
(a)
(i) The design shows a balancing project. Name a suitable metal to make part (a) and state a reason for your choice.
Metal :
Reason :
 
 
(ii) The balance weights may need to be detached for adjustment. What joining process should be used for parts (b) and (c).
 
(iii) List three workshop processes involved in making part (a).
1.  
2.  
3.  
(iv) Briefly explain how part (c) is drilled
 
 
 
 
(b)
Make a freehand sketch, in the box below, of a wall bracket for the hanging basket.
USE A
PENCIL
ONLY