Metalwork - Exam Papers - OL - Paper - 2008

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 holding device is a: Hand Vice  
Bench Vice  
Leg Vice  
Machine Vice  
(b) This tool is a(n): Ring Spanner  
Adjustable Wrench  
Box Spanner  
Vice Grips  
(c) Taps are used to form: Internal Threads  
Buttress Threads  
External Threads  
Acme Threads  
(d) The brass used for brazing is called: Spelter  
Solder  
Enamel  
Flux  
(e) Part ‘X’ is called the: Point  
Face  
Edge  
Tang  
(f) This technique is called: Parallel Turning  
Taper Turning  
Knurling  
Facing  
(g) The distance ‘X’ is called the: Crest  
Flank  
Root  
Pitch  
(h) A micrometer can measure to an accuracy of: 1 mm  
0.5 mm  
0.1 mm  
0.01 mm  
(i) This tool is called a(n): Outside Calipers  
Spring Dividers  
Odd Leg Calipers  
Inside Calipers  
(j) The drill point angle is: 118°  
90°  
180°  
60°  
(k) This drawing shows a: Counterbored Hole  
Contersunk Hole  
Pilot Hole  
Blind Hole  
(l) Tool ‘X’ is a: Scriber  
Parallel Punch  
Centre Punch  
Centre Square  

SECTION B - 20 MARKS

ANSWER ALL QUESTIONS FROM THIS SECTION

(m)

(i) Name any three parts in a car engine.
1.
2.
3.

(ii) Describe the purpose of any one of these engine parts.
 
 
 
 
 
(n)

List four design features of a modern bicycle.
1.
2.
3.
4.
(o)

(i):Part ‘A’ is called a:

  

(ii) The links of this chain are joined by:
Sprocket  
Linkage  
Pawl  
Ratchet  
Brazing  
Screwing  
Riveting  
Welding  
(p)

(iii):This mechanism uses a:

  

(iv) Why is a bicycle chain lubricated?
Gear  
Lever  
Caliper  
Bearing  
 
 
 
 
(q)

(v) This scissors jack uses a:

  

(vi) Car bodies are made from:
Screw mechanism  
Ratchet mechanism  
Cam mechanism  
Gear mechanism  
Copper  
Zinc  
Steel  
Iron  
2.
(20 Marks)
(a)
(i) Complete the chart:
Plastic Material Thermosetting or Thermoplastic List a use for each plastic
Polyurethane Thermosetting Flexible foam for upholstery
Polythene    
PVC    
Nylon    
(ii) Which one of these metals is an alloy?
Lead  
Brass  
Silver  
Aluminium  
(iii) Why is copper used to make electrical wire?
 
(b)
Complete the chart:

The tool shown is a straight-bit soldering iron.

 Yes  
No  

Fluxes are used to remove oxides.

 Yes  
No  

Soft solders begin to melt at 800°C.

 Yes  
No  

Resin fluxes are used for electrical work.

 Yes  
No  

Soldering iron bits are made from steel.

 Yes  
No  

Sweating is a method of soldering.

 Yes  
No  
(c)
Complete the chart:

Lathe work is sometimes called ‘turning’.

 Yes  
No  

A drill chuck can be fitted to a lathe tailstock.

 Yes  
No  

Lathe cutting tool bits are made from cast iron.

 Yes  
No  

A self-centring chuck has four jaws.

 Yes  
No  

A tool holder is used when knurling.

 Yes  
No  

A lathe can be used for screwcutting.

 Yes  
No  
3.
(20 Marks)
(a)

(i) Match the number to the correct motion type..


Motion Type No.
Rotary Motion  
Linear Motion  
Oscillating Motion  
Reciprocating Motion  

(ii) Name a machine in the school workshop that uses rotary motion.
 
(b)
(i) For each of the machines shown name a mechanism used in its operation.
(ii) If gear ‘A’ rotates at 100 RPM
how fast will gear ‘B’ rotate?
50 RPM  
100 RPM  
150 RPM  
200 RPM  
(iii) What is gear ‘C’ called?
 
(c)

(i) This metal section is known as:

  

(ii) This device uses a:
Channel Iron  
Angle Iron  
Box Iron  
Locknut  
Grub Screw  
Split Pin  

(iii) This spring is in:

  

(iv) This gear arrangement is known as a:
Shear  
Tension  
Compression  
Worm Gear  
Gear Train  
Bevel Gear  

(v) Part ‘X’ is a:

  

(vi) The linkages used are:
Strut  
Tie  
Truss  
Perpendicular  
Parallel  
Fixed  
4.
(20 Marks)

Details of a roller used in the manufacture of a model steamroller are shown.

(i) List the tools and processes used to form the M4 threads in the roller.
Tools : Processes :
   
   
   


(ii) What does M4 mean?
 
 


(iii) Describe how you would form the 3mm undercut in the roller.
 
 
 
 


(iv) What precautions should you take when soldering the electric circuit?
 
 
 
 


(v) Describe how you would accurately mark out the centre of the drill holes in the boiler bracket.
 
 
 
 
 
 

(vi) What is the overall length of the boiler bracket?
 

(vii) What is distance ‘X’?
 
5.
(20 Marks)
(a)

(i) This toy truck uses a motor to turn the front axle. A switch and a battery are also
used in the truck. Draw the electrical circuit diagram for the truck.
Draw the circuit in this box
                   
                   
                   
                   
                   
                   
                   

(ii) Complete the chart:

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

 Yes  
No  

The current supplied by a battery is called Alternating Current (AC).

 Yes  
No  

In an electronic system, a buzzer is an output device.

 Yes  
No  

An ordinary bulb has a tungsten filament.

 Yes  
No  
(b)

(i) A heater converts electrical energy into:

  

(ii) This component is a(n):
Chemical Energy  
Mechanical Energy  
Heat Energy  
LED  
LDR  
Bulb  

(iii) This device is a:

  

(iv) A mouse is a(n):
Floppy Disk  
CD  
Hard Disk  
Output Device  
Input Device  
Process Device  

(v) This component is a(n):

  

(vi) Part ‘X’ is a:
Transistor  
Integrated Circuit  
Relay  
Diode  
Fuse  
Resistor  
(c)
Complete the chart by matching the inventor(s) to the achievement.

Inventors: Henry Ford, John Dunlop, John P. Holland, Wright Brothers.
Achievement Inventor(s)
1. Aeroplane  
2. Submarine  
3. Pneumatic Tyre  
4. Mass Production  
6.
(20 Marks)

(i)This drawing shows a kitchen book holder. Name a metal suitable
for making the rods ‘X’ and ‘Y’. Give a reason for your choice.
Metal :
Reason :
 
 
 

(ii) Describe how you would join the metal rods at ‘Z’.
 
 
 
 
 

(iii) Using the chart below describe one shaping process, one finishing process and name the tools used to make the kitchen book holder.
Shaping Process : Tools Used :
   
   
Finishing Process : Tools Used :
   
   

(iv) Draw a sketch to show how you would modify the book holder to make it safer.

 

 

 

 

(v) Match the household item to the correct material.
Item No.
Cast Iron  
Aluminium  
Stainless Steel  
Polyethylene  
Nylon  
Brass