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Metalwork - Exam Papers - OL - Paper - 2006
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.
SECTION A - 20 MARKS
ANSWER ANY TEN QUESTIONS FROM THIS
SECTION
| (a) |
 |
This is a: |
Hand File |
|
| Flat File |
|
| Square File |
|
| Round File |
|
| (b) |
 |
Part ‘X’ is called the: |
Frame |
|
| Spindle |
|
| Anvil |
|
| Sleeve |
|
| (c) |
 |
A die should be used with a(n): |
Tap Wrench |
|
| Box Spanner |
|
| Adjustable Wrench |
|
| Stock |
|
| (d) |
 |
This is a: |
Rivet Snap |
|
| Pop Riveter |
|
| Rivet Set |
|
| Bolster |
|
| (e) |
 |
This brass sheet part can be formed using
(a): |
Bench Vice |
|
| Hand Vice |
|
| Toolmaker's Clamp |
|
| Folding Bars |
|
| (f) |
 |
This is a: |
Morse Taper Sleeve |
|
| Drill Drift |
|
| Reamer |
|
| Chuck Guard |
|
| (g) |
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This lathe part is known as a(n): |
Top Slide |
|
| Tool Post |
|
| Tool Holder |
|
| Tailstock |
|
| (h) |
 |
Part ‘X’ is called the: |
Chuck Key |
|
| Chuck |
|
| Spindle |
|
| Motor |
|
| (i) |
 |
Before drilling, hole centres should be
marked with a(n): |
Pin Punch |
|
| Outside Calipers |
|
| Centre Punch |
|
| Inside Calipers |
|
| (j) |
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This instrument is a: |
Radius Gauge |
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| Wire Gauge |
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| Screw Pitch Gauge |
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| Feeler Gauge |
|
| (k) |
 |
This hammer head is made from: |
Cast Iron |
|
| High Speed Steel |
|
| High Carbon Steel |
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| Stainless Steel |
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| (l) |
 |
This fastener should be adjusted using a(n): |
Ring Spanner |
|
| Vice Grips |
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| Allen Key |
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| Box Spanner |
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SECTION B - 20 MARKS
ANSWER ALL QUESTIONS FROM THIS
SECTION
| (m) |
|
(i) |
Using the labels briefly
describe how this engine works. |
|
| (ii) |
What type of fuel does
this engine use? |
|
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| (n) |
From the history of transport,
briefly describe the contribution of one engineer. |
|
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| (o) |
List four safety
features found in modern cars. |
 |
|
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| (p) |
| (i) |
Why is aluminium used to make planes? |
(ii) |
Why is rubber used to make tyres? |
|
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| (q) |
| (i) |
Alloy wheels contain: |
(ii) |
Car batteries contain: |
 |
| Steel |
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| Tungsten |
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| Copper |
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| Aluminium |
|
|
 |
|
|
| (a) |
(i) |
The Basic Oxygen process is used
to produce: |
|
(v) |
The ability of a material to
resist wear is called: |
| Toughness |
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| Hardness |
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| Ductility |
|
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| (ii) |
Steel is an alloy of iron and: |
|
(vi) |
Soft solder is an alloy of lead
and: |
|
| (iii) |
Silver steel contains: |
|
(vii) |
Zinc is a(n): |
| Alloy |
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| Ferrous Metal |
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| Non-Ferrous Metal |
|
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| (iv) |
Bronze is an alloy of: |
| Copper & Tin |
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| Copper & Zinc |
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| Copper & Lead |
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(viii) |
Cast Iron is: |
| Ductile |
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| Brittle |
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| Malleable |
|
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| (b) |
(i) |
Low density polyethylene softens
at about: |
|
(iv) |
In the workshop, a strip heater
is
used to bend: |
|
| (ii) |
High density polyethylene can be
used to make: |
|
(v) |
Enamel is made from: |
| Polyester Resin |
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| Glass |
|
| PVC |
|
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| (iii) |
Which one of these is a
Thermoplastic? |
| Polyester Resin |
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| Nylon |
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| Phenolic Resin |
|
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(vi) |
Polyester Resin is used to make: |
| Raincoats |
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| Ornamental Castings |
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| Shopping Bags |
|
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| (c) |
Complete the chart by
listing a tool for each task. |
| Task |
Tool |
| To check drill sizes. |
Drill Gauge |
| To cut a thin piece of
copper sheet. |
|
| To hold metal while
forging. |
|
| To hold work firmly
while drilling. |
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| To find the depth of a
hole. |
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| To find the diameter of
a small drill. |
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| To tighten a nut. |
|
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| (a) |
(i) Name the
mechanism in each box. |
|
| |
| (ii) What is
the purpose of an idler gear? |
|
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| (b) |
| (i) When the
pinion turns once, the rack will move: |
| 1000
mm |
|
| 100 mm |
|
| 600 mm |
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| 200 mm |
|
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|
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(ii) If gear ‘A’
rotates at 400 RPM how fast will gear
‘B’ rotate?
(A = 10 Teeth, B = 40 Teeth) |
 |
| 400 RPM |
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| 300 RPM |
|
| 100 RPM |
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| 40 RPM |
|
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(iii) Indicate
with an arrow the direction of gear ‘X’. |
 |
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| (c) |
Name a machine that
uses each of these mechanisms: |
Machine :
________________ |
|
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Machine :
________________ |
|
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Machine :
________________ |
|
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|
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Details of the base support used
in the manufacture of the solar powered dice
game are shown. |
|
| (i) |
Calculate the measurement ‘X’ in
the drawing above. |
|
| (ii) |
Describe the procedure for
drilling the Ø10 hole. |
|
| (iii) |
What energy conversion is taking
place when the motor rotates? |
|
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| (iv) |
What tool would you use to mark
out the R55 circle? |
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| (v) |
List the steps involved in
forming the R40 curve. |
|
| (vi) |
How would you form the 20° bend? |
|
| (vi) |
What safety precautions should
you take when drilling acrylic? |
|
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| (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) |
What flows in the wires when the
LED lights? |
|
| (iii) |
What should happen when you place
your hand over the LDR? |
|
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| (b) |
(i) |
A mouse is a(n): |
(iv) |
The filament produces: |
|
| Output Device |
|
| Input Device |
|
| Process Device |
|
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| (ii) |
This device is a: |
(v) |
This is a: |
|
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| Push Switch |
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| Toggle Switch |
|
| Slide Switch |
|
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| (iii) |
Part ‘X’ is a: |
(vi) |
This component is a(n): |
|
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| Integrated Circuit |
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| PCB |
|
| LCD Display |
|
|
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| (c) |
(i) |
State three uses for
computers in schools. |
|
| (ii) |
State three uses of
electronics in the home. |
|
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| (i) |
A design for an acrylic
toothbrush holder is shown. State three reasons for selecting this material and also
state one disadvantage. |
|
| (ii) |
Draw an elevation of the
toothbrush holder when viewed from arrow ‘X’. |
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| (iii) |
Describe how you could get the
best finish possible on the edges of the holder. |
|
| (iv) |
Describe how the hole for the
glass is formed. |
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| (v) |
How is the toothbrush holder bent
to shape? Describe this process. |
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