Metalwork - Exam Papers - OL - Paper - 1998

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 technique is called : Scrolling  
Twisting  
Bending  
Upsetting  
(b) This tool is a(n) : Adjustable Spanner  
Ring Spanner  
Open Spanner  
Box Spanner  
(c) Part 'X' is called the : Thimble  
Frame  
Ratchet  
Anvil  
(d) This lathe part is called the : Headstock  
Tailstock  
Toolpost  
Cross Slide  
(e) This technique is called : Twisting  
Forming  
Tapping  
Screwing  
(f) This tool is a : Reamer  
Twist Drill  
Counterboring Cutter  
Countersinking Cutter  
(g) Which of the tools shown opposite is used for measuring outside diameters : Tool A  
Tool B  
Tool C  
Tool D  
(h) This file should be cleaned using a : Scriber  
Dividers  
Centre Punch  
File Card  
(i) This tool is used when : Forging  
Soldering  
Drilling  
Riveting  
(j) This lathe technique is called : Knurling  
Facing  
Parallel Turning  
Taper turning  
(k) This marking out instrument is a : Scribing Block  
Vee Block  
Centre Square  
Depth Gauge  
(l) This fastener is called : Wing Nut  
Lock Nut  
Stud  
Split Pin  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Name a metal used to make bicycle frames :
 
(ii) Is this metal a ferrous or a non-ferrous material ?
 
(iii) Does this material rust ?
 
(iv) John Dunlop invented the pneumatic tyre.
Yes  
No  
(n)
Why are bicycle safety helmets made from plastic materials ?
 
 
 
 
 
(o)
(i) This mechanism uses : (ii) This brake block is made from :
Linkages  
Gears  
Pulleys  
Cams  
Acrylic  
Nylon  
Rubber  
Polythene  
(p)
(i) This device is a : (ii) The links of this chain are joined by :
Motor  
Dynamo  
Battery  
Gearbox  
Soldering  
Brazing  
Riveting  
Screwing  
(q)
(i) One turn of A = turns of B.
A = 80 Teeth
B = 20 Teeth
(ii) Part 'A' is a :
Pawl  
Ratchet  
Clutch  
Sprocket  
2.
(20 Marks)
(a)

(i) Complete the chart by matching the given metal with each item :

Metals : Copper, Cast Iron, Stainless Steel, Aluminium, Mild Steel, Brass, Lead, High Carbon Steel

Item Metal
Twist Drill  
Kitchen Sink  
Hot water Cylinder  
Forged Poker  
Soft Drinks Cans  
Brazing Spelter  
Roof Flashings  
Lathe Bed  
(b)
(i) Which one of these metals is an alloy :
Aluminium  
Brass  
Copper  
Zinc  
(ii) Which one of these metals is the hardest :
High Carbon Steel  
Mild Steel  
Copper  
Lead  
(iii) The ability of a metal to withstand wear is called :
Malleability  
Ductility  
Elasticity  
Hardness  
(c)
Complete the chart :
(i) Steel can be hardened and tempered.
Yes  
No  
(ii) Steel is produced in the Electric Arc Furnace.
Yes  
No  
(iii) Thermosetting plastics soften when heated.
Yes  
No  
(iv) Acrylic is a thermoplastic material.
Yes  
No  
(v) Brittle materials bend easily.
Yes  
No  
(vi) Bronze is an alloy of lead and zinc.
Yes  
No  
3.
(20 Marks)
(a)
(i) Indicate with an arrow the direction of movement of part (X) in each of the following.
(ii) This cam changes rotary motion into :
Linear motion  
Rotary motion  
Reciprocating motion  
Oscillating motion  
(iii) If gear 'A' rotates at 4 R.P.M. how fast will gear 'B' rotate ?
(A = 10 Teeth, B = 40 Teeth)
 
(b)
In each of the following cases name a machine that uses the given mechanism.
(Do not name the same machine twice.)
(i) Name a machine that uses a Rack and Pinion :
 
(ii) Name a machine that uses a square thread.
 
(iii) Name a machine that uses Bearings.
 
(iv) Name a machine that uses Cams.
 
(c)
(i) Indicate the direction of gear 'x' in each of the following :
(iii) This hand drill uses :
Spur Gears  
Bevel Gears  
Worm Gears  
Pulleys  
4.
(20 Marks)
Details of a model electric car is shown.
(i) Describe the stages of manufacture and the tools used to make this axle for the car.
 
 
 
 
 
 
(ii) Which of the following is used to "start the hole" when drilling the car wheels on the lathe ? (iii) The technique used to make surface 'X' is called :
Countersink tool  
Counterbore tool  
Centre drill  
Reamer  
Facing  
Parallel Turning  
Taper Turning  
Knurling  
(iv) The drawings A to C show the battery holder of the car during different stages of manufacture.
For each stage :
(a) List two tools used in marking out. (b) List two tools used in cutting this shape (c) List two other tools used to complete the battery holder.
1.
2.
1.
2.
1.
2.
(v) An isometric view and development of the battery holder used in the model electric car are shown below. Draw an elevation looking in the direction of arrow A and a plan viewed from B.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
5.
(20 Marks)
(a)
(i) Select the correct symbols from the chart and complete the electrical circuit diagram for this fuse tester.
Symbols
 
Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   
                   
(ii) Electric current can flow through plastic.
Yes  
No  
(iii) A battery supplies D.C. Current.
Yes  
No  
(b)
Using the labels, briefly explain how the circuit operates the barrier.
 
 
 
 
 
 
(c)

Complete the chart by matching the inventor to the achievement.

Inventors : Henry Ford, Rudolf Diesel, John P. Holland, James Watt, Henry Bessemer

Item Metal
1. Four Stroke Engine Karl Benz
2. Submarine  
3. Steel Making Process  
4. Diesel Engine  
5. Steam Engine  
6. Mass Production  
6.
(20 Marks)
(i) The diagram opposite shows a steel Wall Bracket and a Wooden Sign. Part A and Part B are to be joined by riveting. List three tools that should be used to complete this process.
1.  
2.  
3.  
(ii) Draw a sketch of the completed riveted joint in the box below.
 
 
 
(iii) Briefly describe how the ends of Part B are formed.
 
 
 
(iv) Why is Part A required ?
 
 
 
(v) Draw a detailed sketch showing how the wooden sign is attached to the bracket.
USE A
PENCIL
ONLY