Metalwork - Exam Papers - OL - Paper - 2003

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 cutting tool is a : Fret Saw  
Junior Hacksaw  
Coping Saw  
Pad Saw  
(b) This tool is used when : Riveting  
Drilling  
Threading  
Soldering  
(c) This measuring instrument is a(n) : Vernier Callipers  
Outside Callipers  
Micrometer  
Depth Gauge  
(d) Part 'X' is called the : Flat Edge  
Safe Edge  
Double Cut  
Single Cut  
(e) This tool is a : Machine Vice  
Hand Vice  
Vice Grips  
G-Clamp  
(f) Part 'X' of the thread is called the : Flank  
Lead  
Pitch  
Crest  
(g) This fastener is a : Rivet  
Lock Nut  
Bolt  
Grub screw  
(h) This lathe operation is called : Parting  
Threading  
Knurling  
Facing  
(i) This lathe part is called a : Tailstock  
Three Jaw Chuck  
Headstock  
Topslide  
(j) This cutting tool is a : Twist Drill  
Reamer  
Centre Drill  
Countersinking Drill  
(k) This tool is called a(n) : Socket  
Ring Spanner  
Adjustable Spanner  
Ratchet  
(l) This marking out tool is called a(n) : Inside Callipers  
Odd Leg Callipers  
Spring Dividers  
Scriber  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i) Name a metal used to make the engine case 'X' :
 
(ii) Is this metal ferrous or non-ferrous ?
 
(iii) Does this metal rust ?
 
(iv) The exhaust pipe 'Y' is usually coated with a metal. Name this metal.
 
(n)
State the function of a spark plug.
 
 
 
 
(o)
(i) Part 'X' is called the :
Valve  
Connecting Rod  
Piston  
Crankshaft  
(ii) Name a device other than a lawnmower that can be driven by a small petrol engine.
 
(p)
List four differences between this bicycle and a modern bicycle.
1.
2.
3.
4.
(q)
(i) One turn of A = turns of B
(ii) Indicate with an arrow the fulcrum point of the brake lever.
2.
(20 Marks)
(a) Complete the chart :
Material List a use for each material
Nylon  
Copper  
PVC  
Stainless Steel  
Brass  
Polythene  
Mild Steel  
Zinc  
(b) Complete the chart :
(i) Can thermosetting plastics be re-shaped ? Yes  
No  
(ii) Is aluminium ore called bauxite ? Yes  
No  
(iii) Is copper a good conductor of heat ? Yes  
No  
(iv) Is bronze an alloy of copper and tin ? Yes  
No  
(v) Is cast iron used to make fire grates ? Yes  
No  
(vi) Is mild steel an alloy ? Yes  
No  
(c)
(i) Complete the chart by naming the parts :
Part No. Name
1.  
2.  
3.  
4.  
5.  
(ii) Stepped pulleys in a pillar drill are used to :
Change the speed  
Change the feed  
3.
(20 Marks)
(a)
(i) Match the number to the correct mechanism.
Part No.
Bell Crank  
Calliper Brake  
Bevel Gears  
Parallel Linkage  
Gear Train  
Pulley System  
 
(ii) Which one of these mechanisms is used in a hand drill ?
 
(iii) Name another machine that uses one of these mechanisms. State the number of this mechanism.
 
No.
 
(b)
(i) Indicate the direction of the gear 'X' in each of the following :
(ii) Gear 'X' is a :
Spur Gear  
Bevel Gear  
Worm Gear  
Helical Gear  
(c)
(i) Name 'X' :
 
(ii) When the pinion turns once, the rack will move :
1000mm  
200mm  
600mm  
100mm  
(iii) Name a machine that uses a rack and pinion :
 
4.
(20 Marks)
Details of a model aeroplane are shown.
(i) Describe the stages involved in marking out and bending the undercarriage to shape
 
 
 
 
(ii) What workshop tool is used to check the angles on the undercarriage.
 
(iii) Describe how the slots in the fuselage are marked out.
 
 
 
(iv) Explain the function of the following components in the aeroplane.
Component Function
Battery  
Switch  
Motor  
(v) Design a support for the tail-wheel in the grid below.
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
USE A
PENCIL
ONLY
 
5.
(20 Marks)
(a)
(i) Select the correct symbols from the chart and complete the circuit diagram for the battery operated drill.
Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   
                   
(ii) State one advantage of battery operated drills.
 
 
Component Symbol
(b)
(i) Match the number to the correct symbol.
Component No.
Bulb  
LDR  
LED  
Switch  
Buzzer  
Transistor  
(ii) What does the electrical term A.C. mean ?
 
(iii) Is this component a resistor ?
Yes  
No  
(c)
(i) Name one famous Engineering inventor :
 
(ii) What did this person invent ?
 
 
(iii) How has this person's invention changed the way we live ?
 
 
6.
(20 Marks)
(i) This design shows a desk ornament. List three tools used to make Part 'A'.
1.  
2.  
3.  
(ii) List suitable materials for the parts labelled 'A', 'B' and 'C'.
A.  
B.  
C.  
(iii) Briefly describe the stages involved in making Part 'D' on the lathe.
 
 
 
 
 
 
(iv) You are required to design a different base for the ornament. Using good proportions make a neat freehand drawing of your design in the grid below.
USE A
PENCIL
ONLY
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
(v) Can the tailstock on the lathe be used for drilling ?
Yes  
No