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Metalwork - Exam Papers - HL - Paper - 1999
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.
SECTION A - 20 MARKS
COMPULSORY
Answer any five questions
| (a) |
Describe in two sentences, the contribution
made to technology by one of the following people:
Carl Benz,
Thomas Edison,
Harry Ferguson. |
| (b) |
The diagram shows the main parts of a
four-stroke engine. |
| (i) |
What is the purpose of part A? |
| (ii) |
Name part B and state its function. |
| (c) |
The piston is shown moving downwards:
describe what is happening during this stroke of the
engine cycle. |
| (d) |
Explain what causes the piston to move
down during the power stroke. |
| (e) |
Part C is a cap screw. With the aid of
a sketch, show how this screw can be prevented from
becoming loose due to vibration. |
| (f) |
Define any two of the following material
properties:
Ductility,
Brittleness,
Conductivity,
Elasticity. |
| (g) |
Identify and name any two of the four
electronic components shown. |
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SECTION B - 20 MARKS
COMPULSORY
Answer any five questions
| The drawing shows the elevation and plan of the
1999 Metalwork Higher Level Project - a Motorised
Three-Wheel Vehicle. |
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| (a) |
With the aid of sketches, explain the
purpose of parts 15 and 16. How is part 16 fixed
to the axle (part 5) ? |
| (b) |
Draw a circuit diagram for the vehicle,
showing: A power source, a switch, and a motor. |
| (c) |
Sketch the development of part 2. Describe
how the two holes are drilled in line, and how the
part is bent to shape. |
| (d) |
State the procedure to be followed
in the making of one of the rear wheels. |
| (e) |
Describe, with the aid of sketches,
how part 3 is joined to part 2. |
| (f) |
Design suitable handle-bars for the
vehicle. Your design should show clearly the method
of fixing the handle-bars to the steering rod. |
| (g) |
Part 1 is made from a thermoplastic.
Name the type of material used in your examination
project and explain the steps required to produce
the 40° angle. |
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| WARNING : Don't forget to return
this section with your answer book (if question
2 is attempted) or otherwise marks will be
lost. |
A simple model of a design process is shown.
| (a) |
State two advantages of using
such a model. |
| (b) |
Explain what the Develop the
idea stage means. |
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| (c) |
The diagram shows a toothbrush
/ glass holder designed and made by a student. |
| (i) |
With the aid of sketches and notes
(On the squared paper overleaf) you are
required to show two improvements to this
design. |
| (ii) |
Show on your design how the holder
may be fitted to a wall.
(iii) Name a material suitable for this
project. |
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| On the squared section below, show how
you would redesign the toothbrush / glass
holder. |
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USE A
PENCIL
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| (c) |
(iii) |
A suitable material
for this project is :
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| (a) |
The part shown is to be turned
on a centre lathe from a 30 mm diameter
aluminium bar, shown on the drawing. |
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(i) |
Explain, with the aid of a sketch,
how the 19mm diameter section is turned.
State how you would measure this diameter. |
| (ii) |
What turning operation is required
to produce the angled end (60°) of the
part? Describe how the lathe is set up
to turn this angle. |
| (iii) |
What precautions must you take
before starting a lathe ? |
| (b) |
A 5 mm hole is to be drilled
through the finished part. If the surface
cutting speed of aluminium is 60m/min, calculate
the speed in rev/min at which the part should
rotate during this drilling operation. Use
the formula given below :
N = (S x 1000) / ( π x D)
(Take π as 3 for this calculation). |
| (c) |
Explain any two of the following
terms: Rake angle, Multi-point cutting tool,
Clearance angle, Swarf. |
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| (a) |
Identify the type of furnace
shown. |
| (b) |
What is the charge for this
furnace ? |
| (c) |
Explain the purpose of parts
E and B, and state what is happening in
the area at D. |
| (d) |
What is the function of the
door at A ? |
| (e) |
With reference to parts C and
B, describe how the furnace is emptied. |
| (f) |
A furnace of this Type operates
in Ireland. Where is it located ? |
| (g) |
Combinations of elements used
to make four alloys are listed in the table
at A, B, C and D. |
| (i) |
Name and identify three of the alloy/combinations. |
| (ii) |
List one important property of the
three alloys you have named. |
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Compositions |
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Compositions |
| A |
Copper + Zinc |
C |
Iron + Carbon |
| B |
Tin + Lead |
D |
Tin + Copper |
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An illustration of a garden tractor with a grass cutting attachment (part D) is shown.
| (a) |
Name suitable material for the
manufacture of the bonnet B, and the seat
C. State one property of each material which
makes it suitable for this use. |
| (b) |
The lamp (bulb) at A is specified
as 12 Volts and 21 Watts. Explain what the
terms Volts and Watts mean. |
| (c) |
The wheels at E are steered
by a rack and pinion gear system. With the
aid of a sketch explain how a rack and pinion
gear works or explain any other mechanism
which could be used to steer the wheels.
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| (d) |
The cutting blade in the deck
D is 30" and is driven by a vee belt and
pulley mechanism. Explain with the aid of
a sketch the meaning of this statement. |
| (e) |
The deck is galvanised. What
is meant by galvanised? State one reason
for galvanising the deck. |
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The centre punch in the diagram is the
type commonly used in engineering rooms.
| (a) |
(i) |
Name a suitable material for the
manufacture of a centre punch. |
| (ii) |
Explain how the material may be
softened before it is machined to shape. |
| (iii) |
Describe how the punch is hardened.
State which of the parts A, B or C require
this treatment. |
| (iv) |
Name the heat treatment process
carried out after hardening. |
| (v) |
To what angle should the point P
be ground ? |
| (b) |
List two safety precautions
to be taken during a heat treatment process. |
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| (a) |
Name the modem technological machine
tool shown in the above diagram. |
| (b) |
Name the jog key required to move
the cutting tool in each one of the directions
:- 1, 2, 3 and 4, shown in the diagram. |
| (c) |
With reference to parts D and
E, explain how these movements are done automatically. |
| (d) |
For the machining process, in
which direction should the chuck rotate ?
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| (e) |
Describe the stages of production
(using this machine) for making the component
shown. |
| (f) |
Explain the meaning of any three
of the following terms: ROM; Program; DOS;
3.5" Floppy disk; CAD. |
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