Metalwork - Exam Papers - OL - Paper - 2005

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 screw can be turned using a(n): Allen Key  
Open Spanner  
Adjustable Spanner  
Ring Spanner  
(b) One complete turn of the Thimble will move the Spindle: 0.01 mm  
0.11 mm  
0.10 mm  
1.00 mm  
(c) This is a: Taper Tap  
Split Die  
Tap Wrench  
Plug Tap  
(d) These plates were joined by: Brazing  
Soldering  
Bolting  
Riveting  
(e) This tool is a: Bench Vice  
Hand Vice  
Toolmaker's Clamp  
Pin Vice  
(f) A lathe toolholder is held in a: Tailstock  
Chuck  
Toolpost  
Headstock  
(g) This instrument is a(n): Inside Callipers  
Vernier Callipers  
Outside Callipers  
Odd-Leg Callipers  
(h) Part ‘X’ is called the: Body  
Flute  
Shank  
Flank  
(i) Brass used for brazing is called: Solder  
Flux  
Silver Solder  
Spelter  
(j) Part ‘X’ is called a: Vice Clamps  
Vice Grips  
Jaw Face  
Fixed Jaw  
(k) This technique is called: Drilling  
Counterboring  
Reaming  
Countersinking  
(l) This fastener is a: Bolt  
Grub Screw  
Thumb Screw  
Lock Nut  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)
(i)  List three materials used in the manufacture of this computer system:
1.  
2.  
3.  
(ii)  Name the labelled parts:
X.  
Y.  
Z.  
(iii)  Which one of the labelled parts is an input device?
                                                                      
(n)
Name part ‘X’ and briefly describe its function.
 
 
 
 
(o)
(i)  Domestic heaters are rated at: (ii)  What type of current does a battery operated drill use?
100 Volts       
110 Volts  
200 Volts  
220 Volts  
                      
(p)
(i)  A toaster converts electrical energy into: (ii)  The filament in a bulb is made from:
Potential Energy       
Electrical Energy  
Chemical Energy  
Heat Energy  
Steel        
Tungsten  
Copper  
Aluminium  
(q)
Scrolls are used to decorate the side panels of this table.
Where else would you see scrollwork? List three examples.
1.
2.
3.
2.
(20 Marks)
(a)

(i)  Iron ore is Iron
that is chemically
combined with:
Oxygen  
Nitrogen  
Sulphur  

(v)  Cast Iron is
produced in the:
Cupola Furnace     
Basic Oxygen Converter  
Electric Arc Furnace  

(ii)  Brass is an
alloy of:
Copper & Zinc   
Copper & Lead  
Copper & Tin  

(vi)  High Speed Steel
is used to make:
Gates  
Pipes  
Cutting Tools  

(iii)  Silver Steel
contains about:
1% Carbon     
3% Carbon  
6% Carbon  

(vii)  Which one of these
metals is the best
conductor of heat?
Steel  
Lead  
Copper  

(iv)  Galvanised Iron
is coated with:
Tin     
Aluminium  
Zinc  

(viii)  Cooking foil is
made from:
Tin  
Aluminium  
Steel  
(b) Describe how steel is produced in the Blast Furnace.
 
 
 
 
 
 
 
 
 
 
 
 
(c)

(i)  Acrylic sheet is
also known as:
Bakelite     
Perspex  
Fibreglass  

(iv)  The main raw
material for
plastic is:
Gas        
Oil  
Silk  

(ii)  Bearings and
gears can be
made from:
Nylon  
Acrylic  
PVC  

(v)  Which one of
these is a
Thermoplastic?
Polyester Resin      
Phenolic Resin  
Polyethylene  

(iii)  Which one of
these is a
Thermosetting
Plastic?
Bakelite  
Nylon  
Acrylic  

(vi)  Sheet Acrylic is a:
Hard material     
Brittle material  
Tough material  
3.
(20 Marks)
(a) (i)  Indicate with an arrow the direction of movement of part ‘X’ in each of the following:
(ii)  There are four basic types of motion; name one:
 
(b) (i)  Structures are used to carry: (iv)  Point ‘X’ is called the:
Loads     
Levers  
Mechanisms  
Lever  
Fulcrum  
Linkage  
(ii)  This spring is in: (v)  Gear ‘X’ is called the:
Shear      
Tension  
Compression  
Worm  
Pinion  
Idler  
(iii)  Part ‘X’ is a: (vi)  The linkages used are:
Strut  
Tie  
Truss  
Perpendicular      
Parallel  
Fixed  
(c) Complete the chart by listing devices that use the following mechanisms.
Mechanism Device
Rack & Pinion Pillar Drill
Cam  
Crank & Slider  
Spring  
Sprocket  
Ratchet  
Clutch  
4.
(20 Marks)
Details of a bracket used in the manufacture of the desk fan are shown.
(i)  What is the overall width and height of the bracket?
 
(ii)  What safety precautions should be taken when
drilling sheet metal?
 
 
 
 
(iii)  Describe how the 40mm x 25mm slot is formed in the bracket.
 
 
 
 
(iv)  What does R20 refer to in the drawing of the base?
 
(v)  List the steps involved in producing the 5xM4 holes.
 
 
 
 
(vi)  List some disadvantages of using perspex for the base.
 
 
 
 
(vii)  Describe how a high quality finish can be achieved on the edge of the base.
 
 
 
 
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.
Motor  
LED  
Solenoid  
Push Switch  
Toggle Switch  
1. 2. 3. 4. 5.
(b) (i)  An LDR is a(n): (iv)  These bulbs are connected in:
Output Device      
Input Device  
Process Device  
Parallel     
Series  
Series & Parallel  
(ii)  This device is a: (v)  A buzzer is a(n):
Motor  
Dynamo  
Battery  
Output Device     
Input Device  
Process Device  
(iii)  Electrical solder has a core of: (vi)  Electric current is produced by the movement of:
Tin  
Flux  
Lead  
Protons  
Neutrons  
Electrons  
(c) Name any two inventors and briefly describe their achievements.
Inventor 1 :
 
 
 
Inventor 2 :
 
 
 
6.
(20 Marks)
(i)  A design for a bending jig made from steel is shown. Describe how you would drill the Ø12 holes.
 
 
 
(ii)  How would you hold part ‘A’ when drilling?
 
 
 
(iii)  Briefly describe the steps involved in making Part ‘B’ on a Centre Lathe.
 
 
 
 
(iv)  What safety precautions should be observed when operating a Centre Lathe?
 
(v)  Draw an elevation of part (B) when viewed from arrow ‘X’ and then project an end elevation viewed from arrow ‘Y’.
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
(vi)  List the main differences between a Centre Lathe and a CNC lathe.