TEST CODE 01335020

FORM TP 2OTOO89 MAY/JUNE 2O1O

CARIBBEAN EXAMINATIONS COU NCIL

SEC ONDARY EDUCATION CERTIFICATE
EXAMINATION
MECHANICAL ENGINEERING TECHNOLOGY

Paper 02 - Technical Proficiency

2+ hours

05 MAY 2010 (a.m.)

GF'NF'R AI, DTRF'.CTIONS :

1. This paper consists of THREE sections. You MUST answer a total of FIVE questions.

SECTIONA: You must answer the COMPULSORY question from this section.

SECTION B: You must answer THREE questions from this section.

SECTION C: You must answer ONE question from this section.

2. In addition to the 2 j hours, you are allowed 10 minutes to read through the paper. Writing
MAY begin during tle lO-minute period.
a
Write your answers in the answer booklet provided.

4. Use sketches when necessary to support your answers.

5. Silent electronic calculators may be used.

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I DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO
- Copyright @ 2008 Caribbean Examinations Council
-- @.
All rishts reserved.
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 -2-
This paper is divided into THREE sections -4, B and C. You MUST answer the question from
Section
a, THREE questions from section B and oNE question from section c.

This paper contains metric dimensions only. You should work your answers in the metric system.

SECTIONA

You are allowed to use freehand sketches or rule-assisted sketches to answer this question whÍch is
based
on Module B8 of the syllabus - Engineering Design. The question is worth 40 mãrks.

You are advised Nor to spend more than 50 minutes on this questÍon.

1. Figure L, on page 3, shows an incomplete elevation and plan for a pressure juicer designed for squeez-
ing the juice from fruits. The cylinder and plunger are made from stainless steel while the column and
base are made from aluminium alloy.

The arm of the mechanism should be attached to the column and plunger and should be able to move
up and down as indicated by arrow A-8. The arm is pulled down towards "8" to squeeze the juice
and returns to the top of the arc when it is at rest.

The cylinder is to be supported by a bracket that is attached to the column and should allow for easv
removal of the cylinder to dispose of the pulp after each squeeze.

Use sketches to show clearly the following:

(a) A means of attaching the plunger to the arm at point 66C" so that they move up and down to-
gether. ( g marks)

(b) A means of attaching the arm to the column at point "D" andallowing the arm to move up and
down. ( g marks)

(c) A bracket supporting the cylinder. ( 8 marks)

(d) A means of attaching the bracket securely to the column at"E" while allowing the cylinder to
be removed easily to dispose of pulp. ( I marks)

(e) A mechanism for lifting the arm back in the raised position after each squeeze. ( 8 marks)

Total40 marks
-T
-3-

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ARMrNtÀ**o I
PosrrroN I
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---{ ,
ê PLUNGER \B\
ARM IN THE LOWEREI)
POSITION

---------'--=-
*TAINLESS srEEL
CYLINDER

COLUMN
(ALUMINI
ALLOÐ I{OLES IN BASE OF CYLINDER

SECTIONAL VATIONX-X

BASE

T -T
X

PLÄN

Figure I

GO ON TO THE NEXT PAGE

 -4-

SECTION B

You are required to answer any THREE questions from this section.
EACH question is worth 20 marks.

, Figure 2 shows a component to be made from a piece of 30 mm diameter mild steel

bar I20 mm
long. The threaded portion of the figure should be done by hand with an ¡¿^l2 x l.t dte.

M12 X 1.75 ) x45

20
DIA.20 DIA.16

Figure 2

(a) (Ð List the steps of procedure to produce the component. ( 6 marks)

(iÐ With the aid of a sketch, explain the procedure you would follow when producing
the threaded end to ensure the thread is started squarely.
( 4 marks)

(b) Briefly explain the difference between a 'rake'and a 'clearance angle'as used on a lathe
cuttingtool. (2marks)
(c) Calculate the spindle speed that is to be used to produce the2}mm diameter if the cutting
speed for mild steel is given as 30 metres per minute. ( 4 marks)
(d) state TWo ways in which the work on a centre lathe may be secured and driven.
( 2 marks)
(e) List TWO safety precautions that should be observed when using the centre lathe.

( 2 marks)

Total20 marks

GO ON TO THE NEXT PAGE

a
-5-

3. The template shown in Figure 3 is to be produced from a piece of mild steel stock 3 mm thick
by 160 mm long by 1,20 mm wide. The material is prepared and ready to be marked out.

t20t30t601

:f
lool
ï

Figure 3

(a) (Ð List the steps of the procedure for marking out the template. ( 6marks)

(iÐ Identify the tools to be used for marking out the template. ( 3 marks)

(b) (Ð List the conect sequence of the operations to be performed at the bench in cut-
ting out the slot at A. ( 4 marks)

(iÐ Name the tools to be used for cutting out the slot. ( 3 marks)

(c) List TWO precautions that should be observed when cutting out the slot to ensure it is
done accurately. ( 2 marks)

(d) State TWO safety precautions that should be observed when using laying-out tools.
( 2 marks)

Total20 marks

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 -6-

4. The slot in the component shown in Figure 4 is to be produced on the horizontal milling machine.

Figure 4

(a) Sketch and name a milling cutter that could be used to produce the slot. ( 3 marks)

(b) The slot is to be produced using conventional or o'up cut" milling. With the aid of a
sketch indicating the direction of the feed, and the rotation of the cutter, outline the
steps of the procedure for producing the slot. ( 7 marks)

(c) The operation for cutting the slot is to be performed using a 100 mm diameter cutter.
If the cutting speed for the material is 30 m/min, calculate the required spindle speed
for carrying out the operation in revolutions per minute. ( 3 marks)

(d) Explain briefly what is likely to happen in EACH of the following cases:

(Ð Spindle speed is too fast.

(iÐ Feed is too fast.

(iii) Work is not securely fastened for machining operation.

(iv) Arbour nut is tightened without arbour support in place. ( 4 marks)

(e) State THREE precautions that should be taken while working on the milling machine.
(3 marks)

Total20 marks

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 -7 -

Figure 5shows the outline of a baking pan that is to be produced from sheet metal and the edge
secured with a piece of 3 mm wire.

Figure 5

(a) List TWo different types of sheet metal that could be used to make the baking pan.
( 2 marks)

(b) (Ð List FOUR properties that the materials named in (a) would be expected to have.
( 4 marks)

(iÐ Explain why any TWO of the properties listed in b (i) are important. ( 2 marks)

(c) Make a sketch of the development of the pan indicating the allowances for the seams and
wirededge. (4marks)

(d) With the aid of sketches, describe the procedure necessaty to produce the pan.
( 6 marks)

(e) State TWO safety precautions that should be observed when working with sheet metal.
( 2 marks)

Total20 marks

il

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 -8-

6. (a) Illustrate with a neat diagram EACH of the following:

(Ð Apermanent joint

(ii) A temporary joint ( 4 marks)

(b) Outline TWO circumstances under which hard soldering or brazing would be preferred to soft
soldering. ( 2 marks)

(c) State the approximate tin-lead composition of the following soft solders that would be used
for

(i) general sheet metal work

(iÐ soldering electrical components. ( 2 marks)

(d) State the difference between an 'active soldering flux' and a 'passive soldering flux'.
( 2 marks)

(e) Give an example of EACH type of flux named in (d) above. ( 2 marks)

(Ð With the aid of sketches list the steps of the procedure for completing the following types of
joints using snap head rivets.

(Ð Double-strap butt joint

(iÐ Double riveted lap joint ( 8 marks)

Total20 marks

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 -9-

SECTION C

You are required to answer ONE question from this section. EACH question is worth 20
marks.
EITHER

7A. Figure 6 shows two cylinders, "A," and "8", which are to be welded together using oxy-acetylene
welding. Cylinder o'A" has a hole that is 30 mm in diameter, while cylinder "B" has one that
is 20 mm in diameter. Both holes are to be aligned when the parts are welded together.

t- :.
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,.r

t\ DIÄ20 MM
I

DIA4O MM

DIA 60 MM DIA3O MM

Figure 6
(a) With the aid of sketches:

(Ð Indicate the preparation that should be made for welding the pieces together,
showing clearly how they will be held together during the welding process.
(3marks)
(iÐ Outline the procedure for welding the pieces together. (4 marks)

(b) With the aid of a sketch explain the leftward method of welding using the oxy-acetylene
torch. ( 3 marks)

(c) During the welding process some coÍrmon problems that may affect the operation can
arise. Copy the table below in your answer booklet and complete it to show a cause
and the method of conection for EACH of the problems shown.

Problem Cause Correction

Poor fusion
Torch backflres
Torch will not stav lit
Flame gives off soot

( 8 marks)

(d) State TWO safety precautions that should be observed while doing oxy-acetylene
welding. ( 2 marks)

Total20 marks

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 10-

OR

7B., Figure 6 shows two cylinders, "4" and "8", which are to be welded together using electric arc
welding. Cylinder "4" has a hole that is 30 mm in diameter, while cylindet ooB" has one that
is 20 mm diameter. Both holes are to be aligned when the parts are welded together.

t- \
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i.\'\
\.\t-l |

'.

i .r--'
.tt DIA2O MM

DIA4O MM

DIA6O MM DIA30 MM

Figure 6
(a) With the aid of sketches:

(Ð Indicate the preparation that should be made for welding the pieces together,
showing clearly how they will be held together during the welding process.
( 3marks)
(iÐ Outline the procedure for welding the pieces together. ( 4 marks)

(b) State TWO purposes of the electrode coatings used in the arc welding process.
( 2 marks)

(c) During the welding process some common defects occurred, Copy the table below in
your answer booklet and complete it to show a cause and the method of correction for
EACH of the defects shown.

Defects Cause Correction

Incomplete penetration
Poor firsinn
Slag inclusion
Excessive splatter

(Smarks)

(d) With the aid of a sketch briefly describe the procedure for striking and maintaining the
arc during the welding process. ( 3 marks)

Total20 marks

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 - 11 -

8. (a) Illustrate with a neat diagram EACH of the following forging processes:

(Ð Upsetting the end of a bar

(iÐ Bending a right angle

(iiÐ Drawing down a piece of round stock to a point ( 6marks)

(b) State TWO major advantages of forging a component to shape rafher than machining it
from the solid. ( 2 marks)

(c) Describe with the aid of neat diagrams how you would harden and temper the point of
a centre punch made from 0.6Vo carbon ( 4 marks)

(d) Explain the difference between the following:

(Ð Hardening and tempering ( 2 marks)

(ii) Normalizing and annealing ( 2 marks)

(e) (Ð Explain the difference between sand casting and die casting. ( 2 marks)

(iÐ Give an example of when die casting is preferued to sand casting.

( 2 marks)

Total20 marks

9. As the new laboratory technician in a high school machine shop you are responsible for main-
tenance of all machines.

(a) Copy the table below in your answer booklet and complete it by indicating the different
maintenance activities which you will perform with respect to EACH machine for EACH
of the periods specifled.

MACHINE SHOP MAINTENANCE SCHEDULE

Machines Daily Weekly Monthly Annually

Drill Press

Lathe

( 8 marks)

(b) List THREE reasons why it is important to have a preventive maintenance schedule.
( 3 marks)
 -12-

(c) State the difference between 'preventive maintenance'and 'corrective maintenance,.

( 2 marks)

(d) Name TWO different types of lubricants commonly used in the school workshop.
( 2 marks)
(e) State THREE ways in which lubricants can be applied to machines in the workshop.
( 3 marks)

(Ð Outline the procedure for applying the lubricant in any ONE of the situations stated in (e) above.
( 2 marks)

Total20 marks

END OF TEST