Past Papers

Question 1

Problems with painting

Answer 1

Paint would scratch more easily than zinc and offer no protection Polymer powder coating is more wear-resistant than paint

Question 2

Hazards of powder coating / zinc galvanising and solutions

Answer 2

• Fumes – wear mask and use fume extraction
• Airborne particles – wear eye protection

Question 3

How is CAD used?

Answer 3

CAD software is used to draw the exact shape and dimensions of the component to be machined; this information is then converted to a Part Program that can be downloaded on to a CNC machine for the manufacture of the component.

Question 4

What should you do before doing a batch of a product in a CNC machine?

Answer 4

• To confirm that the program produces a product that meets the specification
• To check for possible collisions with ancillary equipment (clamps etc)
• To confirm cutting parameters are correct (speeds, feeds, depth of cut etc)

Question 5

2 industrial uses of robots in manufacturing

Answer 5

• Pick and Place for automated assembly from circuit boards to cars
• Processes – welding, painting, etc

Question 6

Explain the difference between CIM and CAD

Answer 6

CIM is the integration of all the functions in a manufacturing enterprise from product concept to sale and dispatch. CAD/CAM is part of a CIM system, concerned only with the design and production element of a manufacturing enterprise.

Question 7

2 uses of Industrial Control Systems in a modern factory

Answer 7

• Monitoring and adjusting environmental temperature in the workplace
• Planned maintenance procedures

Question 8

2 examples of smart materials in engineering

Answer 8

• Shape memory – simple bi-metal strip such as in Kettle or Iron
• Chromic materials – colour change in response to pressure or
temperature

Question 9

Properties of rubber

Answer 9

Grippy
Washable
Comfortable
Sweatproof

Question 10

Advantages of composite materials

Answer 10

Lightweight
Strong
Can be moulded into complex shapes
No finish required

Question 11

Disadvantages of composite materials

Answer 11

Time
Expensive
Can’t be recycled

Question 12

Dangers of lathe

Answer 12

Spinning fast

Swarf

Question 13

PPE

Answer 13

Personal Protection Equipment

Question 14

Tools for casting

Answer 14

Cope, split pattern, runner, sprue, crucible

Question 15

Tools for making holes

Answer 15

Centre punch
Drill
Twist drill

Question 16

Tools for deburring holes

Answer 16

Pillar drill

Countersink bit

Question 17

What is deburring

Answer 17

Remove sharp edges by drilling the holes

Question 18

Tools for finish surface

Answer 18

Abrasive sheets and buffing wheel

Question 19

Why finish surfaces?

Answer 19

Remove scratched and polish

Question 20

Why is steel hardened?

Answer 20

Wear resistance and increases usefulness

Question 21

Disadvantage of hardening steel

Answer 21

Makes it brittle

Question 22

Describe hardening low carbon steel

Answer 22

Heat to cherry red, dip in carbon, cool, repeat.

Question 23

Information client needs to give the designer

Answer 23

Colour
Price
Storage capacity

Question 24

Why are micrometers good?

Answer 24

Faster and more accurate

Question 25

Industrial method for cutting

Answer 25

* Stamping * Press forming * Plasma cutting * CNC milling machine

Question 26

2 environmental impacts of plastic

Answer 26

Crude oil | Non-biodegradable

Question 27

2 features for a successful vacuum formed product

Answer 27

Draft angle | No sharp corners

Question 28

2 health and safety risks when working with GRP

Answer 28

* Toxic fumes * Irritation from fibres * Explosion/fire risk * Storage leaks/contamination

Question 29

Advantages to basically anything

Answer 29

Accurate and easy

Question 30

Advantages of a just in time system

Answer 30

* less stock storage | * Less time required to locate parts

Question 31

Disadvantages of just in time system

Answer 31

* Needs a highly coordinated work force * Sharing of data * Dependant on reliable supply chains * Production may stop due to stock shortages * Less flexibility if customers require customized items

Question 32

How are robots used

Answer 32

Pick and place | Simple processes such as spot welding

Question 33

How do robots reduce health and safety risks

Answer 33

Lift heavy weights | Carry out processes in hazardous environments

Question 34

Alloy

Answer 34

Metallic material consisting of multiple metals

Question 35

Reasons why metals are alloyed

Answer 35

* Corrosion resistance * Improving material properties * fluidity * Improving machining characteristics * Hardness * Elasticity * Change melting point

Question 36

How can costs change

Answer 36

* Change in materials based on supply and demand * Energy costs * Transport costs * Unforeseen maintenance costs * Unforeseen quality control issues * Improved performance due to experience

Question 37

Fixed production costs

Answer 37

1. Set up costs 2. Machinery 3. Rates/rents for a year 4. Labour rates agreed for fixed periods of time