Metalwork

Metalwork - Exam Papers - OL - Paper - 2007

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 thread form is a(n):

Buttress Thread

Acme Thread

Square Thread

ISO Metric Thread

(b)

This tool is a(n):

Tap Wrench

Adjustable Spanner

Box Spanner

Ring Spanner

(c)

This fastener is a:

Rivet

Nut and Bolt

Split Pin

Grub Screw

(d)

This cutting tool is a:

Straight Snips

Curved Snips

Bench Shears

Combination Pliers

(e)

This technique is called:

Brazing

Soldering

Hollowing

Punching

(f)

Hand files are made from:

High Carbon Steel

Mild Steel

Stainless Steel

Aluminium

(g)

This instrument is a(n):

Inside Calipers

Combination Set

Outside Calipers

Vernier Calipers

(h)

Stocks and Dies are used for:

Tapping

Screwing

Riveting

Drilling

(i)

This forging technique is called:

Upsetting

Hammering

Drawing Down

Forming an Eye

(j)

This technique is called:

Scrolling

Forming

Twisting

Bending

(k)

Part ‘X’ is called the:

Frame

Spindle

Anvil

Sleeve

(l)

This technique is called:

Parallel Turning

Taper Turning

Knurling

Facing

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)

(i) Give three reasons why the blades of this wind generator should be made from a plastic material.

(ii) Name three plastic materials.

(n)

(i) Why is copper used in the manufacture of solar panels?

(ii) List two other common uses of copper.

(o)

The use of energy saving bulbs saves electricity. List four other ways to save energy in the home.

(p)

(i) Filament bulbs produce light by heating a(n):

(ii) How would you conserve energy in the school workshop?

Ceramic Coil

Tungsten Coil

Brass Coil

Aluminium Coil

(q)

(i) The current supplied by a battery is called:

(ii) Name each terminal:

Direct Current

Alternating Current

Electrical Energy

2. (20 Marks)

(a)

(i)

Dead mild steel contains the following amount of carbon:

0.05% - 0.15%

0.25% - 0.35%

0.45% - 0.55%

(v)

A material is said to be ductile when it can be easily:

Stretched

Fractured

Melted

(ii)

High carbon steel is sometimes called:

Silver Steel

Cast Steel

Alloy Steel

(vi)

Plastic glazing is made from:

Phenolic Resins

Nylon

Acrylic

(iii)

Tin is a(n):

Ferrous Metal

Non-Ferrous

Metal Alloy

(vii)

Do thermosetting plastics soften when heated?

Always

Never

Sometimes

(iv)

Brass is an alloy of:

Copper & Tin

Copper & Zinc

Copper & Lead

(viii)

Galvanised iron is coated with:

Tin

Zinc

Lead

(b)

The diagram shows a Blast Furnace. Name any three of the parts labelled.

Part

Name

(c)

Complete the chart by listing a tool for each task.

Task

Tool

To draw a circle on a piece of metal.

Dividers

To draw a line at right angles to a straight edge.

To locate the centre of a round bar.

To hold a tap while cutting a thread.

To accurately measure the diameter of a round bar.

To hold small sheet metal parts while drilling.

To remove large drills from a drilling machine.

3. (20 Marks)

(a)

(i) Match the number to the correct mechanism part.

Mechanism Part

No.

Pulley

Rack

Sprocket

Ball Bearing

Spur Gear

Bevel Gear

(ii) What is a set of meshing gears called?

(b)

(i) Complete the chart by listing devices that use the following mechanisms:

Mechanism

Device

Ratchet

Screw Thread

Crankshaft

Cam

(ii) If gear ‘A’ rotates at 150 RPM how fast will gear ‘B’ rotate? (A = 12 Teeth, B = 12 Teeth.)

200 RPM

100 RPM

150 RPM

50 RPM

(iii) Can gears be made from nylon?

(c)

(i) When pulled in the direction of the arrows the spring will be in:

200 RPM

100 RPM

150 RPM

50 RPM

(ii) A linkage is made up of several:

200 RPM

100 RPM

150 RPM

50 RPM

(iii) Name gear ‘X’.

4. (20 Marks)

Details of a windshield used in the manufacture of a model vintage car are shown.

(i) List the tools and processes used to make the windshield.

Tools :

Processes :

(ii) What does R10 refer to in the drawing?

(iii) Describe how you would get a smooth finish on the edge of the windshield.

(iv) What safety precautions should be observed when drilling sheet metal?

(v) Describe how you would safely drill the holes in the axle support.

(vi) What is the overall length of the axle support?

(vii) What is the overall width of the axle support?

5. (20 Marks)

(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

(ii) Complete the chart:

Resistance can be measured using a multimeter.

Yes

A fuse is a safety device in an electrical circuit.

Yes

Aluminium is an insulator.

Yes

A car battery is made up of a number of cells joined together.

Yes

(b)

(i) A car battery is made up of a number of cells joined together.

(ii) Name one famous Engineering inventor. Write a brief note about this person’s invention.

Inventor's Name :

Invention :

(c)

(i) Name any three electronic components.

(ii) List three devices that use electronic components.

6. (20 Marks)

(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.

Metal :

Reason :

(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.