Student Name:

Teacher Name: Mr. K. Jordan

MACKSVILLE HIGH SCHOOL 2013

YEAR: 12
COURSE:

Metal and Engineering

EXAMINATION:

Half Yearly

Time Allowed: 90 minutes

Reading Time: 5 minutes

General Instructions:
Use Blue or Black Pen
Answer each section in the space provided
Total Marks:
67

Section I Pages 24
10 marks
Attempt Questions 110
Allow about 10 minutes for this section
Section II Pages 57
15 marks
Attempt Questions 1112
Allow about 15 minutes for this section
Section III Page 8-9
12 marks
Attempt Question 13
Allow about 15 minutes for this section
Section IV Page 10-13
30 marks
Attempt Question 14 and 15
Allow about 50 minutes for this section
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Section I (10 marks)

1. A hand-held hacksaw is to be used to cut 50 1.0 mm steel tube.
What hacksaw blade would be the most efficient for this task? (1 mark)
(A) 14 teeth per 25 mm
(B) 18 teeth per 25 mm
(C) 24 teeth per 25 mm
(D) 32 teeth per 25 mm
2. Which type of fire extinguisher should be used to control an electrical fire? (1 mark)
(A) Foam
(B) Water
(C) Wet chemical
(D) Dry chemical

3. What class of safety sign features a black symbol on a yellow background in a black
triangle? (1 mark)
(A) Caution
(B) Emergency
(C) Mandatory
(D) Prohibition

4. Which of the following must be developed to complete work within a given time frame?
(1 mark)
(A) Job plan
(B) Quality control
(C) Safe work method statement
(D) Standard operating procedures

5. What angle of orthographic projection is represented by the following symbol? (1 mark)

(A) First
(B) Second
(C) Third
(D) Fourth

6. What is the name of the process where a third party hears arguments from both sides of
an industrial dispute, and then makes a legally binding decision? (1 mark)
(A) Arbitration
(B) Conciliation
(C) Mediation
(D) Reconciliation

7. Lifting heavy loads from below knee level is a common cause of back injuries in the
workplace. (1 mark)
What is the most effective method of control for reducing these injuries?
(A) Make heavy loads more compact.
(B) Slightly bend knees and use leg muscles.
(C) Avoid putting the heavy loads on the floor.
(D) Put handles on the heavy loads for a better grip.

8. What is the primary purpose of a standard operating procedure (SOP) in controlling the
quality of a manufactured product? (1 mark)
(A) The reduction and control of hazards
(B) The reduction in variation of the products
(C) The improvement of client communication
(D) The detection and reporting of product defects
9. What is the reading on the micrometer shown?

(A) 11.00
(B) 11.50
(C) 12.00
(D) 12.50
10. What does this symbol indicate on an engineering drawing or sketch? (1 mark)

(A) Datum
(B) Fillet weld
(C) Morse taper
(D) Surface finish

Section II (15 marks total)

Question 11 (10 marks)

Refer to Drawing 53 on the last page (detach) to answer parts (a) to (e).
(A) What type of view is shown? (2 mark)
........ISOMETRIC.........................................................................

(B) Calculate the distance between the top 10 mm diameter holes. Show all
working. (2 mark)
150-12-12=126
. ........................................................................................................................
(C) What does the capital letter A
viewer of the drawing? (2 mark)

and the broken line represent to the

....SECTIONAL LINE SHOWING DIRECTION OF VIEW.................

...........

(D) What bolt length (approximation) and size could be used to fix the bevel gear
support if the mount was placed inside of the bottom holes. Allow for thread
and 2 washers. Show working. (2 mark)
.........(90+3+3)+NUT+NUT+WASHER+WASHER.
..........(90+3+3)+16 + 16 =134mm.....20mm bolt...................
(E) What is the total height of the bevel gear support? (2 mark)
.......................66+38+19= 123mm..............................................................

Question 12 (5 marks)
(a) Name the bottom tap shown, and give ONE specific application.

Name: ...........Plug tap.....................................................(1 mark)

Specific application: ......Blind hole or final tap..................(1 mark)

(b) A piece of mild steel 10 mm thick requires a hole with an internal
thread,M12 1.75.
(i)

From the table provided below, select the appropriate drill size for
this thread.

Drill size = ...............10.2................................ mm .(1 mark)

(ii)
Calculate the speed at which the selected drill (from part (b) (i)
should rotate, using a cutting speed of 45 metres per minute. Show all
working. (2 Marks).
RPM

Cutting speed (m/min) 300

____________________________
Diameter of drill (mm)

RPM = 45 X 300
______________
10.2
RPM =1324
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(B)

Section III
Question 13 (12 marks)

Refer to the drawing below to answer parts (a) to (e).

(A) What is the total measurement of pipe needed to make the trolley?
(2 marks)

0.935 X 4 = 3.74 metres

(B) What is the total area in (meres squared) of the material needed to make the 2 trays?
Ignore folding and cutting allowances. (2 marks).
0.615 X 0.440 = 0.27 per shelf = 0.27 X 2 = 0.541
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(C) What is the total cost of the trolley using your calculations in (B) using the followings
steel prices. (6 marks total)
Pipe: 20mm steel -$2.40 a metre ___2.4 X 3.74 = 8.98_
(2 marks)
Sheet steel 0.55mm thick -$50.00 a sheet (2400mm x 1200mm) (4 marks)
1 sheet = 1.2 X 2.4 = 2.88 metres squared per sheet
From (B) 0.54metres (shelf material) / 2.88 metres = 0.1875 of the sheet.
0.1875 x $50 = $ 9.38

(D) Briefly describe the machines used to cut the sheet and the folding equipment to create
the trolley? (2 marks)

Guillotine is used to cut the sheet into sections. Corners then can be cut with tin
snips. Folded edges can be folded with either a mechanical pan brake (Manual
folder) or a magnetic folder such as the magna-bend.

Section IV (30 marks)

Question 14 (15 marks)

Explain how the use of quality improvement strategies can benefit both a metal and engineering
company and its customers (an example is Toyota which prides itself on quality)
In your response, refer to quality assurance (meeting customer needs) , planning, controlling the
production process, inspection and testing.

Quality is a key factor in industry today. If a company has good quality systems in place then the
production process is more efficient and the customer will be satisfied with the final product.
Planning is one of the first steps in a quality system. A workplace will need to plan what tasks
are to be done and in what order. These documents and information tasks can be in written form
so that individual employees can access these when working on a part or product. This may also
be in a shorter form of a job plan that will give details of a specific set task. Good planning will
require a system of accurate drawings of each part and other detailed/ assembly drawings so that
all parts can be assembled easily without errors. Errors can also be eliminated by giving clear
and accurate instructions to each member of the company or workplace.
Quality control in the workplace used to be an inspection of the final product. Today quality
control can start at the raw material and can finish before the product is shipped or delivered.
New measuring devices use electronics to increase speed and accuracy to test individual parts
such as vernier calipers, angle gauges, surface measurement and weighing devices. These
measurements need to be checked against the drawings, plan or documents so they are to
specifications. Older systems can still be accurate such as jigs and gauges specifically designed
for a project, such as a radius gauge used on a welding table which checks the table top radii on
the corners.

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Inspection of parts or a process is usually done by several employees now instead of a single
inspector. This can eliminate a error sooner in the production line or process and will limit the
amount of time wasted. An example of this could be poor quality steel produced through low
quality raw materials, causing a quality control error early in the process of producing a car
bonnet. If this was not tested early the car could be produced and in the show room before the
fault was found causing large losses of time and money for a company.
Training of employees is a high priority as businesses need to maintain quality and minimize
production costs. Training can be directed at employees to maintain and use specialised
equipment such as automated welding machines, CNC lathes and CNC cutters. These machines
require high skill levels that produce perfect results if maintained and used correctly. Although
the initial cost is high the return on investment will be also be high if the machines are matched
to the work carried out. An example of this could be a ship building company using robotic
welders that can weld straight plate sections of steel. These welders can work very fast and
accurately with minimal input once programed.
Quality assurance is the process of checking that the systems in place are being adhered to. An
example could be the manager of a smaller business has the overall responsibility of checking
that all the inspections, documents, plans and tasks are done correctly. He could liase with other
employees such as the shop foreman discussing errors and faulty parts or products. The shop
foreman would then pass on this information to the workers on the shop floor so that minor
adjustment could be made to a process or machine to minimize errors or variation.
If a quality system is employed then the product will be fit for purpose and done right the first
time ensuring high productivity and low production errors. This will make the company more
competitive and profitable.

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Question 15 (15 marks)

Explain how hazards and the risk of injury are reduced through the application of appropriate
control measures when using a portable electric power drill. Your answer may need to refer to
the hierarchy of controls.

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14

Competencies for Year 12 Metal and Engineering 2013

Apply principles of occupational health and safety in the work environment*

Plan to undertake a routine task
Apply quality procedures
Apply quality systems
Perform engineering measurements
Perform computations
Use hand tools
Use power tools/hand held operations.

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