Metalwork - Exam Papers - OL - Paper - 2004

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) Screw ‘X’ is used to adjust the: Plug Tap  
Thumb Screw  
Split Die  
Tap Wrench  
(b) This technique is called: Cross Filing  
Draw Filing  
Concave Filing  
Pinning  
(c) This tool is used for: Bending  
Cutting  
Scrolling  
Folding  
(d) This holding device is a: Pin Vice  
Bench Vice  
Hand Vice  
Machine Vice  
(e) This is a(n): Square Thread  
Acme Thread  
Buttress Thread  
Metric Thread  
(f) 3mm steel plate is cut using: Straight Snips  
Bench Shears  
Brazing Torch  
Piercing Saw  
(g) Lathe tool bits are made from: Stainless Steel  
Chrome  
Aluminium  
High Speed Steel  
(h) This tool is used for: Bending Sheet Metal  
Forging Steel  
Riveting Steel Plates  
Holding Work  
(i) The arrow on the hacksaw blade indicates: A Coarse Tooth Blade  
The Direction of Cut  
A Worn Blade  
A Fine Tooth Blade  
(j) Part ‘X’ is called the: Point  
Face  
Edge  
Tang  
(k) This tool is a(n): Allen Key  
Spanner  
Adjustable Spanner  
Combination Pliers  
(l) This fastener is a: Bolt  
Rivet  
Split Pin  
Lock Nut  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
Name the labelled engine parts.
1.
2.
3.
4.
(n)
List four different machines that use petrol engines.
1.
2.
3.
4.
(o)
(i) This is a: (ii) Lubrication is used to reduce:
Slider  
Bearing  
Shaft  
Clutch  
 
(p)
(i) Bicycle wheels are made from: (ii) A dynamo converts mechanical energy into:
Copper  
Brass  
Steel  
Zinc  
Potential Energy  
Electrical Energy  
Chemical Energy  
Heat Energy  
(q)
List four differences between a modern locomotive and this locomotive.
1.
2.
3.
4.
2.
(20 Marks)
(a)
(i)

Steel is produced by combining iron with:
Copper  
Carbon  
Ore  




(v)

Iron is produced in the:
Basic Oxygen Furnace  
Electric Arc Furnace  
Blast Furnace  
(ii) Copper is a(n):
Ferrous Metal  
Non-Ferrous  
Alloy  




(vi) Battery plates are made from:
Zinc  
Lead  
Aluminium  
(iii) Metal gates are made from:
Mild Steel  
Iron  
Tin  




(vii) Plastics that cannot be softened when reheated are called:
Hard Plastics  
Thermoplastics  
Thermosetting Plastics  
(iv) Plastic curtain rails are made from:
Acrylic  
Nylon  
Polyester Resins  




(viii) Another name for glass reinforced polyester is:
Fibre Glass  
Polyvinyl Chloride  
Polyethylene  
(b) Complete the chart by matching each property to the correct definition below.
Property Definition
Toughness The ability to
Malleability The ability to
Ductility The ability to
Brittleness The tendency to
Harndess The ability to
Conductivity The ability to
Descriptions:
  • break easily when struck.
  • resist wear and scratching.
  • allow electricity to pass through.
  • withstand blows or an impact.
  • be hammered into a sheet without breaking.
  • be stretched into thin wire.
(c) Complete the chart by listing a tool for each process.
Process Tool
To flatten aluminium sheet without causing damage. Mallet
To cut an internal thread.  
To mark the position of a hole before drilling.  
To clean a pinned file.  
To draw a circle on a piece of metal.  
To cut a 20mm round mild steel bar.  
To mark out and check angles on a piece of metal.  
3.
(20 Marks)
(a) (i) Match the number to the correct mechanism.
Mechanism No.
Universal Joint  
Sprocket  
Worm Gear  
Spur Gear  
Rack and Pinion  
Parallel Linkage  
(ii) How many times will gear A have to rotate in order that gear B completes one full rotation?
 
(b) The sketch shows a machine with an input and an output.
(i) Name the input mechanism.
Ratchet  
Crank  
Pinion  
(ii) What kind of input motion is required?
Oscillating  
Reciprocating  
Rotary  
(iii) Name the output motion produced.
Linear  
Rotary  
Reciprocating  
 
(iv) Name the internal mechanism used to produce the output motion.
 
(c)
Complete the chart by listing devices that use the following mechanisms:
Mechanism Device
Ratchet  
Lever  
Pulley  
Gear Train  
Bevel Gears  
Rack & Pinion  
Square Thread  
4.
(20 Marks)
Details of a model locomotive are shown.
(i) What is the overall width and height of the Cab?
 
(ii) What is the size of radius ‘R’?
 
(iii) Describe how you would form this curve?
 
 
 
(iv) Describe how you would bend the Cab.
 
 
 
(v) List the tools used to make the axle.
 
 
 
(vi) What does ‘M4’ refer to on the axle drawing?
 
(vii) Name the mechanism used to turn the axle.
USE A PENCIL ONLY
 
 
(viii) Draw an elevation of the cab looking in the direction of arrow ‘X’.
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
5.
(20 Marks)
(a) (i) Select the correct symbols from the chart and complete the electrical circuit diagram for this project.
Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   
(ii) Match the number to the component.
Component No.
Bulb  
Buzzer  
Inntegrated Circuit  
LED  
Resistor  
(b) Match the achievement to the inventor.
Inventor No.
John Logie Baird  
Henry Maudslay  
Thomas Edison  
Henry Ford  
John Dunlop  
George Stephenson  
(c) (i) Which of these devices can store more data?
CD-ROM  
Floppy Disk  
(ii) Name two computer input devices.
1.  
2.  
(iii) List two uses for a computer in the engineering industry.
1.  
2.  
6.
(20 Marks)
(i) The design shows a photograph frame. Name one plastic material and one sheet metal material suitable for making this project. Give reasons for your choice.
Plastic :
Reason :
 
Metal ;
Reason :
 
(ii) The rectangle below shows the blank piece of material to be used to make the project. Complete the marking out and show where the bend lines should be located.
(iii) Using the chart below describe the cutting and shaping processes to be used to make the photograph frame. Also list the tools used at each stage.
Cutting : Tools Used :
   
   
   
   
Shaping : Tools Used :
   
   
   
   
(iv) How would you finish the edge of the photograph frame?
 
 
 
(v) Before designing a photograph frame what information would you need to know?