Higher Level Junior Certificate Metalwork

Q1 (Section A & B) are compulsory and 3 other questions. Draw all diagrams in pencil. Label diagrams. Label and number each question Q1 Section A • Inventors (page 242 – 243 text book, Basic Engineering Technology) • 4 stroke engine- name part, explain the function / what material they are made from & why. (page 224 – 227) Inlet and outlet value / spark plug / crankshaft / piston / connecting rod / gudgeon pin fuel / examples of each type of engine eg lawnmower, motor bike, car, strimmer etc. • Thermo and thermosetting plastics / examples / applications. Raw material for plastic = crude oil. Thermo plastics can be reheated and reshaped over and over. Thermosetting can only be heated and shaped once. Thermoplastics Thermosetting Acrylic (Perspex) –lens, dentures Phenolic Resin - ashtrays Polystyrene – CD cases, burger boxes Urea Formaldehyde – white plugs PVC – guttering, window & door frames Melamine Formaldehyde - worktops Polyethylene – bottles, pipes, bags Nylon – tooth brush bristles, fishing line Ferrous and non ferrous metals / examples of each. Ferrous metals contain iron, are magnetic and will rust (iron, steel) Non ferrous metals don’t contain iron, are not magnetic and will not rust (aluminium, brass, bronze, lead, tin, copper). Alloys – a mixture of two or more metals / give examples (solder, brass, bronze) Properties of materials – ductility / hardness / tensile strength / toughness / malleability / elasticity etc. Identify electronic parts and symbols – switch / LED / resistor / variable resistor / bulb / battery / transistor / light dependent resistor / diode etc.

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Section B (Questions about Project) • Draw circuit – symbols / explain how it operates. • How certain parts were manufactured (marking out, drilling, cutting materials, filing, polishing etc). • How part was manufactured on the lathe (parallel turning, facing off, knurling). • Function of one of the parts in real life situation. • The design feature / sketch.

Q2

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Design Process 8 steps - Design Brief Problem Analysis Investigation Alternative Solutions Final Solution Manufacturing Evaluation Conclusion. Given a design – make improvements / draw a sketch. Suitable finish – painting / galvising / plastic coating.

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Q3

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Machining (Drilling and Turning) Parts of drill bit / parts of lathe / parts of column drill / what is swarf? / safety when machining – goggles, no loose clothes, one person at the machine, always get permission. Facing / parallel turning / taper turning / knurling / sliding / surfacing / parting off / drilling / lathe centre / centre drill (describe & draw diagram). Clearance / rake angle / headstock / tailstock / bed of lathe / toolpost / chuck. Calculate speed N = S x 1000 πxD Drill gauge / morse taper sleeve / drill drift / reamer / centre drill /blind hole / tapping size hole /clearance hole /counterboring / countersinking / pilot hole / taper tap / plug tap / stocks & dies / vernier callipers / micrometer / depth gauge / screw pitch gauge / feeler gauge. Production of Metals – Furnaces Name Furnace / list charge / slag / how furnace is emptied / what material is produced / how is furnace heated. Blast Furnace – charge = coke, iron ore & limestone. Hot air blown through tuyeres. Limestone combines with impurities to form slag, which sits on top of molten iron. Slag is tapped off from time to time. Produces pig iron. Basic Oxygen Furnace – charge = molten iron (from blast furnace) lime & scrap steel. Water cooled lance blows oxygen into furnace. Furnace is rotated at various positions the molten steel and the slag. Produces steel. Electric Arc Furnace – charge = scrap metal, lime, mill scale or iron ore. Furnace is heated by electric arcs produced between carbon electrodes and the charge. Produces steel. Alloys - brass = copper + zinc / bronze = copper + zinc / solder = lead + tin / high speed = carbon + steel. Properties of materials. Mechanisms Choice of materials / advantages of materials. Forces – compression, tension, bending, shear and torsion. Motion – linear, rotary, reciprocating and oscillating. Gear train /gear ratios / bevel gears / worm & wormwheel / rack & pinion / gear train / idler gear / driver & driven gear. Screw threads / linkages / levers / ratchet & pawl / chain / pulleys / chain & sprocket. Motion - linear, reciprocating, oscillating, rotary. Soldering Copper bit – conducts heat / solder = lead + tin. Safety when soldering. Passive and active flux / function of flux – remove oxides. Heat treatment – hardening, tempering, annealing, case hardening. Beaten Metalwork - hollowing, sinking, planishing, bending, twisting. Decorative Metalwork – mottling, hammering, punching, repousse, engraving, polishing, enamelling, etching, painting, lacquering, plastic coating. CNC – Computer Numerical Control Parts of a computer / computer terms – ROM, RAM, computer virus, scanner. Advantages of CNC / G & M codes / canned cycles / test run / program / define a profile / menu / safety / jog keys / X and Y co-ordinates / parts of CNC lathe. Advantages of CAD. Absolute and incremental dimensioning. 2

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Q7

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Ordinary Level Junior Certificate Metalwork
Q1 (Section A and B) are compulsory and any three other questions. Draw all diagrams in pencil Q1 Section A (12 Parts answer ten) Identify tools – practice past exam papers. Parts of the four stroke engine. Inventors. Materials Given a list of materials, give a use for each. Thermo and thermosetting plastics / examples / applications. Thermo plastics can be reheated and reshaped over and over. Thermosetting can only be heated and shaped once. Thermoplastics Thermosetting Acrylic (Perspex) –lens, dentures Phenolic Resin - ashtrays Polystyrene – CD cases, burger boxes Urea Formaldehyde – white plugs PVC – guttering, window & door frames Melamine Formaldehyde - worktops Polyethylene – bottles, pipes, bags Nylon – tooth brush bristles, fishing line Ferrous and non ferrous metals / examples of each. Ferrous metals contain iron, are magnetic and will rust (iron, steel) Non ferrous metals don’t contain iron, are not magnetic and will not rust (aluminium, brass, bronze, lead, tin, copper). Alloys – a mixture of two or more metals / give examples. Alloys - brass / bronze / solder / high speed steel. Properties of materials – ductility / hardness / tensile strength / toughness / malleability / elasticity etc. Electronics Identify electronic parts and symbols – switch / LED / resistor / variable resistor / bulb etc. Draw a circuit. Design Process 8 steps. Given a design – make improvements / draw a sketch. Suitable finish – painting/galvising/plastic coating. Machining (Drilling and Turning) Parts of drill bit / parts of column drill / what is swarf? Safety when machining – goggles, no loose clothes, one person at the machine, always get permission. Parts of lathe / Facing / parallel turning / taper turning / knurling. Drill gauge / centre drill / counter sink bit / tap & die / vernier callipers. Furnaces Name Furnace / list charge / slag / how furnace is emptied / what material is produced. 3

Mechanisms Gears / gear ratios / bevel gears / worm & wormwheel / rack & pinion. Screw threads / linkages / ratchet & pawl / chain / pulleys / bell crank / lever. Be able to identify each. Say what directions part will move. Soldering Copper bit – conducts heat / solder = lead + tin. Safety when soldering. Project Questions How part for project were made / What tools were used? / Draw circuit diagram. How were parts marked out? / What material was used and why?

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