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Metalwork - Exam Papers - HL - Paper - 2006
INSTRUCTIONS
1. Answer Question 1, Sections A and B and three
other questions.
2. All answers must be written in ink on the answer book supplied.
Diagrams should be drawn in pencil.
3. Squared paper is supplied for diagrams as required.
4. Please label and number carefully each question attempted.
SECTION A - 20 MARKS
COMPULSORY
Answer any five questions
The diagram, Fig. 1, shows
some of the main parts of a basic two-stroke
engine.
Questions (b) to (e) relate to this diagram. |
| (a) |
Briefly describe, the
contribution made to technology by one of
the following people: |
| (i) |
Dugald Clerk, or |
| (ii) |
Michael Faraday, or |
| (iii) |
William Siemens. |
| (b) |
(i) |
Name the parts marked ‘A’ and
‘B’. |
| (ii) |
Explain the purpose of one of these parts. |
| (c) |
Briefly describe the function of
the Spark Plug. |
| (d) |
Explain the purpose of the fins. |
| (e) |
Describe the type of motion,
which occurs at : |
| (i) |
The Crankshaft; |
| (ii) |
The Piston. |
| (f) |
(i) |
List the metals used to
make Brass. |
| (ii) |
State two properties of
Brass. |
| (g) |
(i) |
Select the correct electronic
symbol for each of the two components
shown in Fig. 1a. |
| (ii) |
Outline the function of one of the components. |
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SECTION B - 20 MARKS
COMPULSORY
Answer any five questions
| The drawings in Fig. 1b show the
Crankcase, Piston, Electric Circuit and an assembly
drawing of the 2006 Metalwork Higher Level Project,
Model 2-Stroke Engine. |
|
| (a) |
Describe how the
Crankcase is bent to shape. |
| (b) |
List four processes used
to manufacture the piston. |
| (c) |
(i) |
Suggest a suitable drill size for the
M4 holes in the base. |
| (ii) |
Name the type of hole, which should
be drilled before the ∅10mm hole in the Sideplate. |
| (d) |
(i) |
Explain the operation of the Electric
Circuit shown. |
| (ii) |
Explain the purpose of the resistor
in the Electric Circuit. |
| (e) |
Design, using a diagram, a suitable
switch bracket to hold the push to make switch used
in the Electric Circuit |
| (f) |
Suggest two suitable
applications for a 2-Stroke Engine. |
| A simple model of a
design process is shown opposite. |
|
| (a) |
(i) |
List any three important points, which should be
considered, at the “Manufacture”
stage. |
| (ii) |
Outline three factors to be considered at the
“Evaluation” stage. |
| (b) |
The diagram in Fig. 2
shows a pair of gates which open
separately. |
|
| (i) |
Describe one improvement, which could be made, to the
gates to make them more rigid. |
| (ii) |
Show, using diagrams, how
the gates may be locked to enable:
- One side only to
lock;
- Both sides to lock.
|
| (iii) |
Name a suitable material
from which the gates may be
manufactured. |
| (iv) |
Suggest a suitable finish
for the gates. |
| Fig. 3 shows a component produced on the lathe, and two tools A and B. |
|
| (a) |
(i) |
List three turning operations required to produce the component shown. |
| (ii) |
Outline two stages needed to drill the 6mm hole. |
| (iii) |
State two safety precautions to be taken while making the component on the lathe. |
| (b) |
For the 6mm diameter hole to be drilled the component has a cutting speed of 45m/min. Using the given formula calculate the speed in RPM. (Take π as 3) |
| N |
= |
S X 1000 |
| _______ |
| π X D |
|
| (c) |
(i) |
Name both tools shown. |
| (ii) |
Explain the purpose of one of the tools shown. |
| (a) |
(i) |
Identify Furnace A. |
|
| (ii) |
List the materials used to
charge Furnace A. |
| (iii) |
Explain how heat loss is
prevented when charging Furnace A. |
| (iv) |
Describe how the Slag and
Iron are removed from Furnace A. |
| (b) |
(i) |
Identify Furnace B. |
| (ii) |
Explain the purpose of the
Lance shown. |
| (iii) |
Name the metal produced by
Furnace B. |
| (c) |
List one application
and one property of the following
alloy steels: |
| (i) |
Stainless Steel; |
| (ii) |
High Speed Steel. |
| A Forklift and two
transmission mechanisms are shown. |
|
| (a) |
(i) |
Name one suitable
material for each part identified on
the Forklift. |
| (ii) |
Outline two safety
features incorporated in the design of the
Forklift. |
| (b) |
The Forklift uses a chain and
sprocket lift mechanism. If the driving
sprocket has 18 teeth and the driven
sprocket, attached to the forks, has 54
teeth, what is the gear ratio? |
| (c) |
(i) |
Identify both Mechanisms shown. |
| (ii) |
Outline one advantage
and one disadvantage of each Mechanism. |
| (iii) |
Suggest one application for each Mechanism. |
| (iv) |
Describe how Mechanism 2 may
be modified to reverse the direction of
rotation. |
| An electric plug, wiring
cable and an electric soldering iron are
shown. |
|
| (a) |
(i) |
Name the three plug
terminals marked ‘A’, ‘B’ and ‘C’. |
| (ii) |
State which colour cable wire
should be connected to each terminal. |
| (iii) |
What is the purpose of the
fuse shown? |
| (b) |
(i) |
Explain the main difference
between Thermosetting and Thermoplastic
materials. |
| (ii) |
Name a suitable material for
the plug casing. |
| (c) |
(i) |
Outline two safety
precautions to be observed when using an
electric soldering iron. |
| (ii) |
Explain any two of the
following terms associated with soldering:
| (a) |
Tinning the bit; |
(c) |
Transformer; |
| (b) |
Active flux; |
(d) |
Sweating. |
|
| (a) |
(i) |
Identify the parts ‘A’ and ‘B’ of
the CNC Lathe shown. |
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| (ii) |
Draw a diagram, showing the
directions –X, +X, -Z and +Z, represented by the CNC jog keys. |
| (iii) |
When turning on the CNC Lathe
should the chuck rotate reverse or forward? |
| (iv) |
Outline two safety
features found on the CNC Lathe. |
| (v) |
Explain the meaning of any two of the following computer terms: |
- Menu;
- ROM;
- Virus;
- Removable disk.
|
| (b) |
(i) |
Name the parts of the micrometer
‘C’, ‘D’, ‘E’ and ‘F’. |
| (ii) |
Explain the function of the
Ratchet shown. |
| (iii) |
What is the value of the
micrometer reading shown opposite? |
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