Demonstrate knowledge of motor industry engineering tasks

Question 1

ABS Plastic can be found in

Answer 1

Grills,body and instrument pannels

Question 2

It is light, malleable and ductile. It resists corrosion and is a good conductor of heat.

Answer 2

Aluminum

Question 3

Polyethylene can be found in

Answer 3

Interior trim

Question 4

Uses in the moter industry include: rocker covers and wheel rims

Answer 4

Aluminum

Question 5

TPUR can be found in

Answer 5

Upholstery

Question 6

It is malleable, ductile and is a good conductor of heat and electricity.

Answer 6

Copper

Question 7

Acrylic be found in

Answer 7

Light lenses and covers

Question 8

Uses in the motor industry include: electrical wiring, radiators and pipes.

Answer 8

Copper

Question 9

Polyamide or nylon can be found in

Answer 9

Exterior trim, radiator tanks or gears

Question 10

It is soft, heavy, malleable and highly plasic.

Answer 10

Lead

Question 11

Polystyrene can be found in

Answer 11

Sound deadening and seat filler

Question 12

Uses in the motor industry include: batteries, wheel balance weights.

Answer 12

Lead

Question 13

Why is hardening carried out?

Answer 13

To increase resistance to penetration

Question 14

It has a low melting point and is a good conductor of electricity. It is also less likely to cause heat damage.

Answer 14

Solder

Question 15

Why is case hardening carried out?

Answer 15

Hardens the surface of the metal

Question 16

Used in the motor industry to join metals together and for making electrical connections.

Answer 16

Solder

Question 17

Why is tempering carried out?

Answer 17

To remove brittleness

Question 18

Uses in the motor industry include: filler rods for welding and electrical terminals.

Answer 18

Brass

Question 19

Why is annealing carried out?

Answer 19

To soften metal

Question 20

It resists corrosion and rusting and is a good conductor of heat and and electricity.

Answer 20

Bronze

Question 21

Why is normalizing carried out?

Answer 21

To relive internal stresses an return metal to its original standard

Question 22

Uses in tje motor industry include: brushes and thrust washers.

Answer 22

Bronze

Question 23

Before drilling a hole one must consider

Answer 23

1. The size of the drill bit
2. The need for a pilot hole
3. The cutting speed to suit the material
4. The need for lubricant to suit the material
5. The drill angles

Question 24

It resists corrosion and provides an attractive finish.

Answer 24

Chromium

Question 25

Four factors to be considered when selecting a twist drill.

Answer 25

1 Diameter of the drill 2 Length of the twist drill 3 Type of cutting tip 4 Material to be drilled

Question 26

Uses in the motor industry include: bumpers, grills and wheels.

Answer 26

Chromium

Question 27

Explain why the trailing edge of the twist drill lip must be lower than the leading edge.

Answer 27

To provide clearance for the cutting edge

Question 28

It is easily shaped and welded, it is soft and ductile.

Answer 28

Mild steel

Question 29

List three reasons why cutting fluid is used when drilling.

Answer 29

Acts as a coolant Acts as a lubricant Will improve the cutting finish

Question 30

It is very versatile, diffrent combinations of zinc and copper produce brass with different characteristics

Answer 30

Brass

Question 31

Explain why it is important to refer to the manufacturer’s charts when drilling a hole for tapping

Answer 31

Manufacturers provide tap and drill size charts to enable technicians to select the appropriate drill size to form the tapping hole and the appropriate tap to form the thread

Question 32

Uses in the motor industry include: body panels and parts that are not load bearing.

Answer 32

Mild steel

Question 33

Describe the procedure involved when sharpening a twist drill.

Answer 33

Install a fine grade wheel on the grinder. Switch on the grinding wheel. Holding the drill bit firmly, place the drill bit against the tool rest at the correct angle. Applying light pressure offer the drill bit cutting edge to the grinding wheel. Twist the drill bit to form the cutting edge clearance. Repeat this procedure for the second cutting edge. Cool the bit and check both cutting edge angles on a drill angle gauge.

Question 34

It is relatively light but strong. It is also cheap to manufacture.

Answer 34

High tensile steel

Question 35

List three outcomes that should be avoided when drilling a hole.

Answer 35

``` A rough hole An oversize bore A split drill web Damaged corners Drill breakage ```

Question 36

Uses in the motor industry include: chassis rails, front and rear impacts bars and body panels

Answer 36

High tensile steel

Question 37

State a safety precaution that must be observed when using drilling equipment to protect tools and equipment.

Answer 37

Inspect tools prior to use – leads, plugs, drill body, drill bit Use a RCD Use tools correctly Select the correct drill bit for the task Always use the guards provided Check that the machine is securely mounted Check the condition of the guards Adjust the machine correctly prior to use Only drill suitable materials Use correct drilling speeds Use appropriate cutting fluid Clean the machine after use

Question 38

It is relatively hard and strong.

Answer 38

Spring steel

Question 39

Taps

Answer 39

is designed to cut internal threads into a hole in metal objects, allowing bolts or studs to be fitted.

Question 40

Uses in the motor industry include: coil and leaf springs.

Answer 40

Spring steel

Question 41

Dies

Answer 41

A die is designed to cut external threads

Question 42

Its rust resistant and hard wearing.

Answer 42

Stainless steel

Question 43

Thread files

Answer 43

A thread file is used to repair an external thread.

Question 44

Uses in the motor industry include: exhaust system components and some body parts.

Answer 44

Stainless steel

Question 45

Sleeve thread inserts

Answer 45

A thread insert is used when there is not enough material around the hole or when a specific thread is required.

Question 46

Its very ridged and strong in compression. Cast into intricate shapes and forms a good wearing surface.

Answer 46

Cast iron

Question 47

Outline the procedure involved when cutting a thread in a blind hole using taps.

Answer 47

Step 1 Consult with the manufacturer’s tapping and drilling chart and select the appropriate drill bit and tap. Step 2 Drill the tapping hole. Step 3 Using the taper tap and carry out steps 3 - 6 as above. Do not force the taper tap at the bottom of the hole as the tap may break off. Step 4 Remove the taper tap and clean out the hole. Step 5 Install the intermediate tap and repeat steps 3 – 4. Step 6 Install the bottoming tap and repeat steps 3 – 4.

Question 48

Uses in the motor industry include: cylinder blocks, cylinder heads and other housing.

Answer 48

Cast iron

Question 49

Outline the procedure involved when installing a thread insert.

Answer 49

1. Select a thread insert kit to suit the thread diameter and pitch required. 2. Select the correct drill bit from the kit. 3. Drill out the original thread. 4. Select the appropriate tap. 5. Tap the new thread. 6. Fit the Heli-coil onto the installation tool supplied in the kit ensuring that the tang on the Heli-coil is firmly inserted into the slot of the installation tool. 7. Screw in the Heli-coil into the tapped hole. This reduces the diameter of the Heli-coil allowing it to be threaded into place. 8. When the Heli-coil is in place, break off the tang.

Question 50

Its strong and can be forged.

Answer 50

Medium carbon steel

Question 51

Cable ties

Answer 51

Can be used when securing wiring harnesses, steering rack boots and wheel covers

Question 52

Uses in the motor industry include: crankshafts, connecting rods, gears and camshafts.

Answer 52

Medium carbon steel

Question 53

Clamps

Answer 53

To secure exhaust pipes and radiator hoes

Question 54

Its hard and strong

Answer 54

High carbon steel

Question 55

Double sided | tape

Answer 55

Can be used when securing exterior protective mouldings, decals and badges.

Question 56

Uses in the motor industry include: cutting tools, files, taps dies and punches.

Answer 56

High carbon steel

Question 57

Lockwire

Answer 57

To secure c.v. boots and rack and pinion boots

Question 58

Studs

Answer 58

Dave, nah just kidding. Use to securely clamp components together