Longer form questions

Question 1

(c) State the essential difference between a ferrous metal and a non-ferrous metal.

Answer 1

A ferrous metal contains iron [1]
A non-ferrous metal does not contain iron [1]

Question 2

Describe how the holes could be produced in the acrylic egg holder shown in

Answer 2

Mark out the centre of the hole;

Mark out the outer circle;

Drill a pilot hole within the circular shape;

Using either a coping saw or scroll saw machine insert the blade through
the hole and cut the outline shape of the circles;

Question 3

State three advantages (other than cost) for using CAD/CNC to produce the
large number of egg holders.

Answer 3

Faster than manual method of production; [1]

The CNC is more accurate than manually; [1]

Easy to repeat additional quantities of holders [1]

The diameter of the hole can be easily changed as required; [1]

Question 4

Describe how the drive system of the pillar drill works after the machine has
been switched on. Your answer should make reference to:
 the input,
 the process,
 the output of the pillar drill.

Answer 4

) The Motor is turned on and rotates [1]
The pulley wheels/belt transfer rotary motion from the driver pulley
to the driven pulley at the front [1]
The front pulley transfers rotary motion to the drill chuck [1]

Question 5

) Outline four important features that should be considered and included
when designing and making a mould for use in the vacuum forming process.

Answer 5

Ensure a taper or draft angle is included in the mould. [1]
Make sure all corners are radiused leaving no sharp edges on the
mould. [1]
Make sure that all surfaces on the mould have a smooth finish. [1]
Make sure a releasing agent or varnish is applied to the mould. [1]
Make sure that there are no negative angles on the mould. [1]
Include venting holes in the mould where air could become
trapped. [1]
(4  [1])

Question 6

Describe the purpose of a mould in the vacuum forming process.

Answer 6

To enable the plastic to form around the mould [1] when heated [1].

Question 7

Outline four clear steps in the production of a vacuum formed product.

Answer 7

lace the mould in the vacuum forming machine. [1]
Place/lock plastic sheet on vacuum former. [1]
Turn on heater. [1]
Pull heater over plastic sheet. [1]
When plastic is soft remove/switch off heater. [1]
Operate lever to move mould up into plastic. [1]
Operate vacuum to pull plastic around mould. [1]
Release lever and allow plastic to cool. [1]
Remove plastic and mould from machine. [1]
Remove mould from plastic. [1]
Trim excess plastic from vacuum formed shape. [1]

Question 8

Explain why a chain and sprocket system is used on a bicycle.
Your answer should focus on two reasons.

Answer 8

Any two of the following:
It transfers direct motion to the back wheel [1]
It provides a direct drive [1]
It gives you a speed ratio [1]

Question 9

Explain why the chain of the chain and sprocket system requires lubrication

Answer 9

Any two of the following:
Because it is exposed to the elements [1]
It prevents rust [1]
It is necessary to lubricate the links [1]
And keep them rotating freely [1]

Question 10

How to make a PCB using chemicals and provide safety precautions

Answer 10

Chemical Method
 Design and draw a circuit diagram
 Photocopy the circuit diagram onto transparency to produce the ‘mask’
 Using a photo-resistant board, peel back the plastic cover to reveal the
sensitive coating
 Place the mask (or transparency) underneath the board
 Make sure the mask is the correct way round
 Place the board with the mask into an Ultra Violet (UV) box and close the
lid
 Switch on the UV box for a period of time, usually 2 – 3 minutes
 Remove the board and place it into a tank filled with developer fluid
 Leave in developer for about 10 seconds
 Remove from the developer, with plastic tongs, and wash with clean
water
 Place the board in an etching tank which is then heated
 Leave for 15 to 45 minutes, but, keep checking the board
 Wash with clean water
Safety Precautions:
 Plastic gloves must be used
 Wear an apron
 Use plastic tongs
 Wear safety goggles/eye protection
 Hair tied back if required
 Ensure the correct settings on the tanks and UV box
 Don’t look at the UV light
 Turn off tanks and cover when finished
 Don’t pick up the board with your bare hands
 Wash hands after use

Question 11

how to make a pcb with cnc and provide safety

Answer 11

CNC Method:
 Design and draw a circuit diagram using a CAD software package;
 Convert/export the circuit design into machine code for the CNC milling
machine or similar;
 Simulate to check that the program works;
 Insert and clamp a sacrifice board into the CNC machine to prevent
damage;
 Cut the copper clad board to correct size;
 Apply double sided tape to a copper clad board;
 Fix the board to the sacrifice board and press firmly down;
 Insert and tighten a suitable bit to the CNC mill head;
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AVAILABLE
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 Set the origin for the CNC machine and value to zero;
 Move the mill head down using the control buttons so that the bit just
touches the surface of the board (some use a thin piece of paper for
the gap);
 Select the cutting depth usually between 0.2 – 0.4 mm;
 Lock the guard door and press the green start button;
 Press the red stop button when the process is complete and remove the
PCB board.
Safety Precautions:
 Plastic gloves should be used
 Wear an apron
 Wear safety goggles/eye protection
 Hair tied back if required
 Ensure the correct settings on the CNC machine
 Never touch the tip of the bit when fitting or removing the board
 Be familiar or trained with the controls
 Make sure the clamp and double sided tape are secure

Question 12

What makes plywood such a strong material?

Answer 12

Plywood is made up of an uneven number of thin boards glued
together [1] with the grain turned at right angles alternately [1]

Question 13

Outline three stages of how the square hole may be cut out using hand tools
and/or manually operated machines.

Answer 13

Drill a hole
* Use of chisel
* Insert a blade into a coping saw and tighten
* Clamp the plywood in a wood vice
* Cut out the shape
* Remove the blade from the coping saw

Question 14

The manufacturer has decided to use computer-aided design (CAD) and
computer-aided manufacture (CAM) to make a large quantity of these puzzles.
Outline three main steps in this process.

Answer 14

Any three of the following:
* Draw on a computer the puzzle using a CAD package
* Download the computer file onto a CNC router/laser machine
* Simulate the drawing to check if the drawing is correct
* Clamp the wood into the CNC machine
* Operate/Execute the program/CNC machine
* Repeat process for mass production

Question 15

Try square use

Answer 15

check right angle/square edge
* draw a perpendicular/90 degrees line
* used on wood/plastic

Question 16

Purpose of a brass strip in a try square

Answer 16

Prevent wear on the stock

Question 17

escribe how to produce this centre line accurately

Answer 17

Use a steel rule and pencil mark the centre point of each end [1]
and draw/mark a line between each marked point [1].
Use a marking gauge [1] set to 20mm [1]

Question 18

Describe how to prepare the wood to enable the first screw to sit flush along
the centre line. It should be fitted 15mm from one end of the wood.

Answer 18

) Any four from:
Reference to clamping/alignment [1]
Measure 15 mm along the centre from one end. [1]
Mark/produce centre point/cross [1]
Drill a pilot/clearance hole [1]
Drill a countersunk hole [1

Question 19

In the heat treatment of steel explain the difference between hardening and
tempering

Answer 19

Hardening is heating the steel to ‘red’ heat [1] and cooled quickly/
plunge into cold water. [1]
Tempering is reheating the steel [1] then allowing it to cool slowly to the
required temperature and then quenching it. [1]
OR
Hardening increases hardness [1] increases tensile strength/reduces
toughness/increases brittleness. [1]
Tempering reduces hardness/increases toughness/reduces
brittleness. [1] Improves usability/more functional. [1]

Question 20

A 300mm diameter circular cutting (chopping) board, for use in a kitchen, is to
be made from a square piece of oak 400 × 400 × 20mm. A 25mm diameter hole is to
be located with its centre 40mm from the edge of the board. To avoid a sharp edge,
a small radius (curved edge) should be made on the top and bottom of the board.
Describe the manufacturing processes of marking out, drilling, cutting, shaping and
finishing of the cutting board. The description should include tools, equipment and
safety precautions directly related to the processes

Answer 20

Draw two diagonal lines or measure two lines to mark the centre of the wood
* Draw a circle radius 150 mm with a compass
* Mark out the centre of the hole for drilling 40 mm from the edge
* Before using a pillar drill, select and insert a flat bit or fostner bit of diameter
25 mm
* Check the speed of the pillar drill is correct
* Clamp the wood onto the platform of the drilling machine
* Drill the hole diameter 25 mm
* Before using a scroll saw check that the correct saw blade is installed
* Hold the wood flat with both hands rotating the wood into the saw blade
* Ensure the cutting line remains visible after cutting
* A bandfacer/linisher machine may be used to remove rough edges around the
wood
* Hold the wood flat with both hands rotating the wood on the platform of the
bandfacer/linisher
* Using sand paper and a block, smooth the top and bottom of the wood
* Apply the sand paper and block to the top and bottom edges
Safety Precautions:
* Wear safety goggles/eye protection when using the drilling machine
* Hair tied back if required when using machines
* Ensure the correct settings on the drill machine/scroll saw
* Never touch the bit/blade on a scroll saw while power is on
* Know where the off/on buttons are located on the scroll saw and drilling
machine
* Experience in using the machines
* Make sure the material is clamped for drilling

Question 21

Brass is an alloy, consisting of two metals. Name the two metals used to
produce brass.

Answer 21

Zinc [1] Copper [1]

Question 22

Identify two properties of brass.

Answer 22

Any two from:
Electrical conductivity
Thermal conductivity
Machinability
Colour
Corrosion resistant
Ductile

Question 23

) List two features of a CAD program.

Answer 23

Quick to edit the drawings
Range of tools and symbols
Reduces manufacturing times
Reuse existing designs and drawings
Can convert 2D to 3D drawings quickly
Drawings can be printed directly from the computer

Question 24

Look at the brass component in Fig. 2. Identify two possible processes to be
used by a manually operated lathe to produce this component.

Answer 24

Producing the various diameters of the component/parallel turning
Knurling
Create a chamfer/bevel/taper turning
Face off the ends of the component
Create a screw thread/threading/screw cutting

Question 25

Name the category of plastic used in vacuum forming and explain why this type
of plastic is used for this process.

Answer 25

Thermoplastic [1]
Because it will soften when heated [1] and solidify when cool/or take up
the shape of the mould or former [1]

Question 26

Purpose of an odd leg calliper

Answer 26

Scribe a line along a metal bar or sheet [1]
Scribe a line parallel to the edge of a metal bar or sheet [2]

Question 27

Outline three safety precautions that should be applied when building the
circuit (pneumatic)

Answer 27

Wear goggles
Switch off Mains air when building the circuit
Watch your hands/Beware of moving parts
Don’t blow compressed air at anyone
Check all connections before turning on the air

Question 28

An aluminium frame 200 × 200 × 1.5mm thick with a 20mm border is to be attached
to a clear acrylic sheet 200 × 200 × 3mm thick.
Four pop rivets, 6mm in diameter, are to be used to join the materials together. The
pop rivets are to be located centrally, one on each side of the frame.
Describe the process of pop riveting the materials together. This should include
marking out the positions for the rivets and also refer to the tools, equipment and
safety precautions needed for this process.

Answer 28

Mark out the position for the four holes
* Each hole to be centrally located, 10 mm in from one edge of the
aluminium frame/acrylic sheet and 100 mm down from the other edge
* Using a steel rule, pencil, permanent marker, try square, scriber
* Use hammer and centre punch to locate hole on aluminium frame
* Clamp the two pieces of material together and drill through both
* Using a clamp and vertical drilling machine
* Drill holes using a 6 mm drill bit or slightly larger to provide a clearance
hole
* Remove burrs on each material caused by drilling
* Insert a pop rivet into pop rivet gun/pliers
* Locate pop rivet in hole and apply pressure to gun/pliers to pull the pin
through the rivet
* This deforms the rivet slightly so that it joins the plastic and aluminium
* The pin of the rivet will break off leaving the head inside the rivet
* Repeat this process for the other three rivets
Safety Precautions:
* Ensure clamps are fully tightened for drilling
* Ensure drill is tightened in chuck
* Drill the hole steadily without making the material jump
* Wear goggles when using drilling machine and rivet gun
* Wear your hair tied back
* Ensure there is no loose clothing
* Ensure the machine guard is in position
* Ensure the drilling machine is turned off after use
* Be aware of the pin shooting out

Question 29

Most CAD software enables the design to be tested on a computer.
Identify three reasons for testing the design on a computer.

Answer 29

Reduces wasting material [1]
Checks whether or not the design can be manufactured successfully [1]
Allows the design to be altered before manufacture [1]
Saves making a model [1]
Designs can be examined in detail on the screen [1]
The design can be saved on the computer for reuse [1]

Question 30

Outline four stages in the marking out and drilling of the holes using a pillar
drilling machine.

Answer 30

Any four of the following:
Mark out sides with a pencil, steel rule and try square [1]
Mark out the holes using a marking gauge, rule and pencil [1]
Clamp the wood in a vice or jig for drilling [1]
Insert the appropriate drill bit into the pillar drill [1]
Set the depth gauge on the pillar drill [1]
Drill the pilot holes [1]
Remove wood from vice or jig [1]

Question 31

) Explain the purpose of using a countersunk bit.

Answer 31

To provide a countersunk/tapered hole [1]
For use with a countersunk screw [1]
To enable a countersunk screw [1] to sit flush with a surface [1

Question 32

Other than cost, outline two advantages that a manufactured board has
compared to natural timber

Answer 32

Comes in large sheets [1]/doesn’t warp [1]/doesn’t shrink [1]

Question 33

ii) Explain the difference between Aluminium and an Aluminium alloy.

Answer 33

Aluminium is a pure metal [1]
Aluminium alloy is a mixture of two or more metals [1]

Question 34

The end of a short length of 60mm diameter steel tube is to be brazed to the centre
of a steel plate which measures 120mm by 120mm. The steel tube should be
brazed perpendicular (at right angles) to the steel plate.
Describe the marking out process to enable the steel tube to be positioned
accurately in the centre of the steel plate and outline the main features of the brazing
process.
Your answer should make reference to the tools, equipment, preparation of the joint
and safety precautions used in this process.

Answer 34

The two pieces of steel to be brazed, are cleaned with emery cloth, or
wire brush removing grease and dirt
* Square off the end of the tube with a file
* Mark out the plate making use of marking blue, try square, steel rule, scriber,
compass
* Accurately locate the steel tube onto the plate
* Place the steel pieces on heat resistant bricks on the steel bench or
turntable or brazing hearth
* Reference to brazing equipment for the process
* A filler rod coated in a flux may be used or flux may be applied to the joint
* The joint is preheated by holding torch close to the joint
* Clamps, wire or a jig may be used to hold the two pieces of steel together
* The flame is focused at one end of the joint, raising the temperature of the
steel to a ‘red heat’
* Brazing rod is fed into the joint
* The molten brazing rod flows into the joint
* The joint is allowed to cool slowly
* When cold, a wire brush is used to clean the joint
Safety Precautions:
* Heat resistant gloves may be used
* Wear an apron
* Use clamp to hold material for brazing
* Wear goggles/eye protection
* Hair tied back if required
* Ensure there is no loose clothing
* Ensure the correct setting on the brazing equipment