Metalwork - Exam Papers - OL - Paper - 1999

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) A hole drilled before tapping is called a : Pilot Hole  
Tapping Hole  
Clearance Hole  
Blind Hole  
(b) The point of the scriber is ground at an angle of : 30°  
90°  
118°  
180°  
(c) This marking out tool is a(n) : Spring Dividers  
Odd Leg Callipers  
Inside Callipers  
Outside Callipers  
(d) This instrument is a(n) : Feeler Gauge  
Screw Pitch Gauge  
Wire Gauge  
Engineer's Protractor  
(e) This mallet head is made from : Mild Steel  
Rawhide  
Boxwood  
Copper  
(f) This forging technique is called : Upsetting  
Hammering  
Drawing Down  
Forming an Eye  
(g) This sheet metal joint is a : Wired Edge  
Round Edge  
Beaded Edge  
Curved Edge  
(h) This technique is called : Raising  
Planishing  
Hollowing  
Mottling  
(i) Before use, new soldering irons must be : Hardened  
Tempered  
Tinned  
Annealed  
(j) Part 'X' is called a : Lock Nut  
Wing Nut  
Thumb Screw  
Grub Screw  
(k) Part 'X' is called the : Crest  
Root  
Flank  
Pitch  
(l) A micrometer can measure to an accuracy of : 1mm  
0.1mm  
0.5mm  
0.01mm  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart by listing a material used for the manufacture of each item.
Item Material
1. Handle  
2. Engine Block  
3. Body  
4. Tyre  
(ii) Petrol engines use spark plugs.
Yes  
No  
(iii) Oil is used to lubricate petrol engines.
Yes  
No  
(n)
State two reasons why modern garden slides are made from plastic materials.
1.
 
2.
 
 
(o)
(i) This stand is formed using a : (ii) Wheelbarrow handles are made from :
Flatter  
Hardie  
Scroll Tool  
Swage  
Round Bar  
Steel Pipe  
Angle Iron  
Sheet Steel  
(p)
(i) Glasshouse frames are made from : (ii) The design on this sundial can be produced by :
Aluminium  
Bronze  
Cast Iron  
Lead  
Repoussé  
Lacquering  
Mottling  
Etching  
(q)
(i) Name the metal used to galvanise gates and fences.
Metal :
(ii) Which structure is more rigid ?
Fence A  
Fence B  
2.
(20 Marks)
(a)

(i) Complete the chart by matching one of the given materials with each item :

Metals : Copper, Stainless Steel, Aluminium, Bronze, Acrylic, PVC, Polyethylene, Nylon.

Item Material
Cutlery  
Cooking Foil  
Soldering Iron Bit  
Cast Metal Statues  
Plastic Gears  
Plastic Shopping Bags  
Plastic Windows  
Plastic Shop Signs  
(b)
Complete the chart :
(i) This furnace produces Cast Iron. Yes  
No  
(ii) This furnace uses a charge that includes coke and limestone. Yes  
No  
(iii) Oxygen is blown into this furnace. Yes  
No  
(iv) An electric arc melts the metal. Yes  
No  
(v) This furnace can be tilted to remove the molten metal. Yes  
No  
(vi) Impurities are removed in the form of slag. Yes  
No  
(c)
(i) Complete the chart by naming the parts :
Part No. Name
1.  
2.  
3.  
4.  
5.  
(ii) A computer controlled lathe is called a :
CNC Lathe  
CAD Lathe  
3.
(20 Marks)
(a)
(i) Match the number to the correct mechanism.
Mechanism No.
Worm and Wormwheel  
Cam and Follower  
Chain and Sprockets  
Ratchet and Pawl  
Rack and Pinion  
Crank and Slider  
(ii) Which one of these mechanisms is used in the centre lathe ?
 
(iii) Name another mechanism that uses one of these mechanisms.
State the number of this mechanism.
    No.  
(b)
(i) Name any two of the following mechanisms and give a different use for each one.
Number : Name of mechanism :
  and use :
Number : Name of mechanism :
  and use :
(ii) State the difference between a lever and a fulcrum.
 
 
 
(c)
Indicate with an arrow the direction of movement of part 'X' in each box.
4.
(20 Marks)
A drawing of a motorised model aeroplane is shown below. The electric motor is held in place by a holder. A development of this holder is shown over.
(i) State the steps involved in making the holder from a blank piece of metal.
 
 
 
 
(ii) Briefly explain how this holder is formed into shape.
 
 
 
 
(iii) What does 'CSK' refer to in the drawing of the holder shown above ?
 
(iv) What gauge would be used to tell the difference between a 3.2 mm and a 3.5 mm drill ?
 
(v) What safety precautions should you take when drilling sheet metal ?
 
 
 
 
(vi) The holder shown above can be made from a piece of metal measuring :
72 mm X 21 mm  
72 mm X 36 mm  
72 mm X 24 mm  
72 mm X 12 mm  
(vii) Select the correct symbols from the chart and draw the circuit diagram for the model aeroplane.
Symbols
Draw the circuit diagram in this box
                   
                   
                   
                   
                   
                   
                   
                   
5.
(20 Marks)
(a)
(i) Which colour wire connects to each plug terminal ?
Terminal No. Wire Colour
1.  
2.  
3.  
(ii) Name each plug terminal.
Terminal No. Terminal Name
1.  
2.  
3.  
(iii) What is the function of the plug fuse ?
 
 
(b)
(i) This electronic component is a(n) :
Resistor  
LDR  
LED  
Transistor  
(ii) This symbol represents a :
Switch  
Buzzer  
Loudspeaker  
Generator  
(iii) Briefly describe how the use of electronic equipment has improved our lives.
 
 
 
 
(c)
(i) Complete the chart by naming the achievement of each inventor.
INVENTOR ACHIEVEMENT
1. Wright Brothers  
2. John P. Holland  
3. John Dunlop  
4. James Watt  
5. Rudolf Diesel  
(ii) Henry Ford developed the mass production of motor cars.
Yes  
No  
6.
(20 Marks)
The design shows details of a mild steel candle holder.
(i) List three workshop processes involved in the making of part (a).
1.  
2.  
3.  
(ii) List three Lathe processes involved in the making of part (b).
1.  
2.  
3.  
(iii) List three safety precautions to be observed when operating a centre lathe.
1.  
2.  
3.  
(iv) What process should be used for joining parts (a) and (b) ?
 
(v) Draw an elevation of part (b) when viewed from arrow 'X' and then project an end elevation viewed from arrow 'Y'.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
(vi) If you were asked to design a candle-holder list three questions you would ask before making the holder.
1.  
2.  
3.