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Metalwork - Exam Papers - OL - Paper - 2007
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) |
![](../images/2007/o1.gif) |
This thread form is a(n): |
Buttress Thread |
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Acme Thread |
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Square Thread |
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ISO Metric Thread |
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(b) |
![](../images/2007/o2.gif) |
This tool is a(n): |
Tap Wrench |
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Adjustable Spanner |
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Box Spanner |
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Ring Spanner |
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(c) |
![](../images/2007/o3.gif) |
This fastener is a: |
Rivet |
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Nut and Bolt |
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Split Pin |
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Grub Screw |
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(d) |
![](../images/2007/o4.gif) |
This cutting tool is a: |
Straight Snips |
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Curved Snips |
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Bench Shears |
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Combination Pliers |
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(e) |
![](../images/2007/o5.gif) |
This technique is called: |
Brazing |
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Soldering |
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Hollowing |
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Punching |
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(f) |
![](../images/2007/o6.gif) |
Hand files are made from: |
High Carbon Steel |
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Mild Steel |
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Stainless Steel |
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Aluminium |
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(g) |
![](../images/2007/o7.gif) |
This instrument is a(n): |
Inside Calipers |
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Combination Set |
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Outside Calipers |
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Vernier Calipers |
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(h) |
![](../images/2007/o8.gif) |
Stocks and Dies are used for: |
Tapping |
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Screwing |
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Riveting |
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Drilling |
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(i) |
![](../images/2007/o9.gif) |
This forging technique is called: |
Upsetting |
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Hammering |
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Drawing Down |
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Forming an Eye |
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(j) |
![](../images/2007/o10.gif) |
This technique is called: |
Scrolling |
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Forming |
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Twisting |
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Bending |
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(k) |
![](../images/2007/o11.gif) |
Part ‘X’ is called the: |
Frame |
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Spindle |
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Anvil |
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Sleeve |
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(l) |
![](../images/2007/o12.gif) |
This technique is called: |
Parallel Turning |
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Taper Turning |
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Knurling |
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Facing |
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SECTION B - 20 MARKS
ANSWER ALL QUESTIONS FROM THIS
SECTION
(m) |
![](../images/2007/o13.gif) |
(i) Give three reasons why the blades of this wind generator should be made from a plastic material. |
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(ii) Name three plastic materials. |
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(n) |
![](../images/2007/o14.gif) |
(i) Why is copper used in the manufacture of solar panels? |
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(ii) List two other common uses of copper. |
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(o) |
The use of energy saving bulbs saves electricity. List four other ways to save energy in the home. |
![](../images/2007/o15.gif) |
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(p) |
(i) Filament bulbs produce light by heating a(n): |
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(ii) How would you conserve energy in the school workshop? |
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Ceramic Coil |
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Tungsten Coil |
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Brass Coil |
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Aluminium Coil |
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(q) |
(i) The current supplied by a battery is called: |
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(ii) Name each terminal: |
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Direct Current |
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Alternating Current |
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Electrical Energy |
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(a) |
(i) |
Dead mild steel contains the following amount of carbon: |
0.05% - 0.15% |
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0.25% - 0.35% |
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0.45% - 0.55% |
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(v) |
A material is said to be ductile when it can be easily: |
Stretched |
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Fractured |
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Melted |
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(ii) |
High carbon steel is sometimes called: |
Silver Steel |
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Cast Steel |
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Alloy Steel |
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(vi) |
Plastic glazing is made from: |
Phenolic Resins |
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Nylon |
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Acrylic |
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(iii) |
Tin is a(n): |
Ferrous Metal |
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Non-Ferrous |
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Metal Alloy |
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(vii) |
Do thermosetting plastics soften when heated? |
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(iv) |
Brass is an alloy of: |
Copper & Tin |
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Copper & Zinc |
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Copper & Lead |
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(viii) |
Galvanised iron is coated with: |
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(b) |
The diagram shows a Blast Furnace. Name any three of the parts labelled. |
![](../images/2007/o20.gif) |
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(c) |
Complete the chart by listing a tool for each task.
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Task |
Tool |
To draw a circle on a piece of metal. |
Dividers |
To draw a line at right angles to a straight edge. |
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To locate the centre of a round bar. |
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To hold a tap while cutting a thread. |
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To accurately measure the diameter of a round bar. |
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To hold small sheet metal parts while drilling. |
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To remove large drills from a drilling machine. |
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(a) |
(i) Match the number to the correct mechanism part.
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![](../images/2007/o21.gif)
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Mechanism Part |
No. |
Pulley |
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Rack |
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Sprocket |
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Ball Bearing |
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Spur Gear |
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Bevel Gear |
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(ii) What is a set of meshing gears called?
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(b) |
(i) Complete the chart by listing devices that use the following mechanisms:
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Mechanism |
Device |
Ratchet |
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Screw Thread |
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Crankshaft |
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Cam |
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(ii) If gear ‘A’ rotates at 150 RPM how fast will gear ‘B’ rotate? (A = 12 Teeth, B = 12 Teeth.)
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![](../images/2007/o22.gif)
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200 RPM |
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100 RPM |
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150 RPM |
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50 RPM |
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(iii) Can gears be made from nylon? |
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(c) |
(i) When pulled in the direction of the arrows the spring will be in: |
![](../images/2007/o23.gif) |
200 RPM |
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100 RPM |
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150 RPM |
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50 RPM |
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(ii) A linkage is made up of several: |
![](../images/2007/o24.gif) |
200 RPM |
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100 RPM |
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150 RPM |
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50 RPM |
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(iii) Name gear ‘X’. |
![](../images/2007/o25.gif) |
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Details of a windshield used in the manufacture of a model vintage car are shown. |
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(i) List the tools and processes used to make the windshield. |
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(ii) What does R10 refer to in the drawing? |
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(iii) Describe how you would get a smooth finish on the edge of the windshield. |
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(iv) What safety precautions should be observed when drilling sheet metal? |
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(v) Describe how you would safely drill the holes in the axle support. |
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(vi) What is the overall length of the axle support? |
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(vii) What is the overall width of the axle support? |
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(a) |
(i) A design for an illuminated display-stand is shown. The design uses a battery, a bulb and a switch. (The battery and switch are not shown.) Draw the electrical circuit diagram for this design. |
Draw the circuit in this box |
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(ii) Complete the chart: |
Resistance can be measured using a multimeter. |
Yes |
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No |
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A fuse is a safety device in an electrical circuit. |
Yes |
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No |
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Aluminium is an insulator. |
Yes |
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No |
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A car battery is made up of a number of cells joined together. |
Yes |
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No |
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(b) |
(i) A car battery is made up of a number of cells joined together. |
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(ii) Name one famous Engineering inventor. Write a brief note about this person’s invention. |
Inventor's Name : |
Invention : |
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(c) |
(i) Name any three electronic components. |
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(ii) List three devices that use electronic components. |
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(i) This drawing shows a bench vice and a pair of vice clamps. Name a metal suitable for making these clamps. Give a reason for your choice. |
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(ii) The diagram below represents a blank piece of metal to be used to make one of the vice clamps. Complete the marking out to show where the bend lines should be located. |
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(iii) Using the chart below describe one shaping process, one finishing process and name the tools used to make the vice clamps. |
Shaping Process : |
Tools Used : |
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Finishing Process : |
Tools Used : |
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(iv) List two features of a modern lathe that are not to be found in old lathes. |
![](../images/2007/o31.gif) |
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(v) Match the number to the correct part. |
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Part |
No. |
Tool Bit |
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Tool Holder |
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Three-Jaw Chuck |
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Tailstock |
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Morse Taper Sleve |
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Topslide |
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