Metalwork - Exam Papers - OL - Paper - 2000

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) Part 'X' is called the : Spindle  
Frame  
Ratchet  
Sleeve  
(b) This condition is known as : Hardening  
Knurling  
Sweating  
Pinning  
(c) The filler metal used in brazing is : Brass  
Copper  
Lead  
Tin  
(d) This tool is a : Rivet Snap  
Rivet Set  
Pop Riveter  
Bolster  
(e) The part indicated is called the : Shank  
Body  
Land  
Web  
(f) This instrument is a : Feeler Guage  
Combination Set  
Scribing Block  
Vernier Calipers  
(g) Stocks are used to hold : Taps  
Split Dies  
Twist Drills  
Reamers  
(h) The drill bit is guided by a : Punch Mark  
Pilot Hole  
Clearance Hole  
Countersink  
(i) This centre punch is made from : Mild Steel  
High Carbon Steel  
Aluminium  
Cast Iron  
(j) This thread form is a(n) : Acme Thread  
Square Thread  
ISO Metric Thread  
Buttress Thread  
(k) This lathe part is a : Tailstock  
Toolpost  
Headstock  
Saddle  
(l) This acrylic sheet is bent using a : Bench Shears  
Strip Heater  
Soldering Stove  
Hatchet Stake  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Complete the chart :
Part Material
1. Exhaust  
2. Windscreen  
3. Seat Cover  
4. Wheel  
(ii) Who invented the pneumatic tyre ?
 
(n)
(i) Tractor Engines are powered by : (ii) Tractor engines are lubricated using :
Unleaded Petrol  
Leaded Petrol  
Diesel  
Gas  
Oil  
Air  
Water  
Cooling Fluid  
(o)
(i) This mechanism is a : (ii) The steam engine was invented by :
Scissors Jack  
Screw Jack  
Hoist  
Hand Vice  
Henry Ford  
James Watt  
John P. Holland  
Rudolf Diesel  
(p)
(i) Part 'X' is called the : (ii) A Car Battery converts chemical energy into :
Valve  
Connecting Rod  
Piston  
Spark Plug  
Mechanical Energy  
Electrical Energy  
Solar Energy  
Chemical Energy  
(q)
List four differences between this tractor and a modern tractor.
1.
2.
3.
4.
2.
(20 Marks)
(a) (i) Complete the chart :
Material List a use for each material
Acrylic Making baths
PVC  
Nylon  
Expanded Polystyrene  
Polythene  
Brass  
Copper  
Bronze  
(b)
Complete the chart :
(i) Does silver steel contain silver ? Yes  
No  
(ii) Is iron ore used to make pig iron ? Yes  
No  
(iii) Is acrylic conductive ? Yes  
No  
(iv) Has aluminium a lower melting point than steel ? Yes  
No  
(v) Can steel products be galvenised to prevent rust ? Yes  
No  
(vi) Does medium carbon steel contain less carbon than dead mild steel ? Yes  
No  
(c)
(i) Name this steel making furnace :
 
(ii) Part'X' is called the :
Tuyere  
Hearth  
Lining  
Electrode  
(iii) Which one of these metals is an alloy ?
Aluminium  
Zinc  
Brass  
Copper  
3.
(20 Marks)
(a)
(i) Match the number to the correct mechanism part.
Mechanism Part No.
Sprocket  
Ratchet  
Idler Gear  
Cam  
Pulley  
Rack  
 
(b)
(i) Indicate with an arrow the direction of gear 'X' in each of the following :
(ii) If gear 'A' rotates at 100 RPM how fast will gear 'B' rotate ?
(A = 20 Teeth, B = 10 Teeth)
100 RPM  
200 RPM  
50 RPM  
20 RPM  
(iii) Are these meshing gears known as gear trains ?
Yes  
No  
(c)
Name a mechanism used in each of the following :
Mechanism :
Mechanism :
Mechanism :
4.
(20 Marks)
A model of a Motorised Model Airboat is shown below.
(i) How is this windshield bent to shape ?
 
 
 
 
 
 
 
 
(ii) What does 'M3' refer to in the drawing of the base shown below ?   (iii) What is the distance 'X' in the drawing of the windshield shown below ?
 
 
 

Base of Airboat

Windshield
(iv) Describe how a high quality finish can be applied to the edge of the perspex base.
 
 
 
 
(v) Draw a front elevation and an end view of a hand held switch unit that could be used to operate the airboat from a distance.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
5.
(20 Marks)
(a)
(i) Match the number to the correct component.
Component No.
Resistor  
Buzzer  
Motor  
Switch  
LED  
LDR  
(ii) What does the electrical term D.C. mean ?
 
(iii) Is this component an integrated circuit ?
Yes  
No  
(b)
Select the correct symbols from the chart and complete the electrical circuit diagram for this motor control unit.
Symbols

Motor Control Unit

Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   
                   
(c)
(i) When this circuit is connected :
Both bulbs will light.  
Only bulb A will light.  
Only bulb B will light.  
Both bulbs will not light.  
(ii) The filament in this bulb is made from :
Steel  
Tungsten  
Nickel  
Gold  
6.
(20 Marks)
(i) This design shows a noughts and crosses game made from aluminium sheet. Apart from drilling, list three other processes involved in the making of this project.
1.
2.
3.
(ii) List three safety precautions you would take before drilling this piece of metal.
1.
2.
3.
(iii) Briefly describe how you would bend the aluminium sheet to the required shape.
 
 
 
 
 
 
(iv) Is aluminium a ferrous or a non-ferrous metal ?
 
(v) Draw full size, in the box below, a complete development of the noughts and crosses game showing the bend lines.
USE A
PENCIL
ONLY