Metalwork - Exam Papers - HL - Paper - 1995

100 Marks

INSTRUCTIONS

1. Answer Question 1, Sections A and B and three other questions.
2. All answers must be written in ink on the answer book supplied. Diagrams should be drawn in pencil.
3. Squared paper is supplied for diagrams as required.
4. Please label and number carefully each question attempted.

1.
(40 Marks)

SECTION A - 20 MARKS
COMPULSORY
Answer any five questions

(a) Describe briefly, the contribution made to technology by one of the following :-
Henry Ford;
William Parsons;
and Fr. Nicholas Callan.

(b) The illustration shows parts of a single cylinder engine. Identify any four of the parts A, B, C, D, E and F.

(c) Explain the purpose of shaft F.

(d) With the aid of a sketch, describe another drive method which could be used instead of the two gear wheels H.

(e) List three metalworking processes which require the use of safety visors or goggles.

(f) Explain the following :

  1. the pitch of a screw thread;
  2. the set of a hacksaw blade.

(g) Name and match any two of the symbols 1, 2, 3 and 4 with two of the components A, B, C and D.

SECTION B - 20 MARKS
COMPULSORY
Answer any five questions

The diagram shows an electro-magnetic braking mechanism.

(a) If part A is rotating, describe how the mechanism is used to slow it down.

(b) Name any three of the parts: C, D, E, F and G.

(c) Draw a cross-sectional view of part B and explain us construction.

(d) Name a material suitable for part L and state one property of this material.

(e) With the aid of a sketch, explain how parts H and S are used to adjust the mechanism.

2.
(20 Marks)
WARNING : Don't forget to return this section with your answer book (if question 2 is attempted) or otherwise marks will be lost.

(a) Name four stages in the design process.

(b) The flower basket shown is to he fixed to the wall of a house. Design a decorative bracket which can be mounted on the wall and used to hang the basket. Your design should incorporate:

  1. a means of fixing the bracket to the wall;
  2. the removal of the basket from the bracket.
Rough sketches to illustrate your ideas should be drawn in your answer book. Select a final solution and make a working drawing of the bracket (elevation and end view) on the squared paper below.

(c) Show by means of a sketch how part A of the basket may be made in the metalwork room.

(d) Since the bracket is to be used outdoors, explain how corrosion of the parts may be prevented.

                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
3.
(20 Marks)

An illustration of a modern motorcycle is shown opposite. Answer any five questions.

(a) Name and state the materials used in the manufacture of parts A, B and C.

(b) State one property of each of the materials listed.

(c) What is meant by the term "pneumatics" ?

(d) State the function of the part shown in Fig. X and give a brief description of how it works.

(e) Describe briefly one of the following processes:

  1. plastic dip-coating or
  2. enamelling.

(f) What damaging effect does the use of engines have on the environment ?

4.
(20 Marks)

(a)

  1. Identify the type of furnace shown opposite.
  2. What kind of metal is produced by this furnace ?
  3. What materials are used to charge the furnace ?
  4. Name the gas that is blown into the furnace through part B.
  5. Explain the part played by the named gas in the metal production process.

(b)

  1. Name two alloys which may be made from the list of elements in the table opposite. Name the elements used to make each of these two alloys.
  2. Describe one use for each of the alloys you have chosen.




Aluminium
Zinc
 Iron
Silicon		 Tin
Carbon
Lead
Copper
5.
(20 Marks)

A bench-type drilling machine is shown opposite.

(a) Name the pans A, B, C and D.

(b) Name the item of equipment that is generally attached to Part D when the drilling machine is in use in the classroom.

(c) Show by means of a sketch how this piece of equipment is secured to Part D.

(d) Describe, with the aid of a sketch, how Part B actually moves Part A.

(e) Explain what is a

  1. countersunk hole,
  2. counterbored hole.
6.
(20 Marks)

The scriber shown in the diagram is lo he made in a metalwork classroom.

(a)

  1. Suggest a suitable type of steel for the scriber.
  2. Explain how the steel should be softened before it is shaped.
  3. Describe how the scriber is hardened and tempered. State which of the parts A, B and C require this treatment.
  4. At what angle should the point be ground on section A.

(b) Explain any three of the following terms

  1. Brittleness
  2. Ductility
  3. Conductivity
  4. Tensile Strength
7.
(20 Marks)

(a) The diagram shows a machined part with diameters :
Ø10mm x 16mm long ;
Ø14 mm x 16 mm long ;
Ø22 mm x 35 mm long.
Make a drawing of this part and dimension it using either :

  1. absolute dimensioning or
  2. incremental dimensioning.

Name the system of dimensioning used in your drawing.

(b) Describe for the above part how :

  1. a CNC programme is written ; or
  2. a profile is defined
(c) Explain what is meant by a CAM and CAD process.

(d) Give two advantages of each process.