N5 Design & Manufacture Metalworking Questions
National 5 Design & ManufactureKnowledge questionsN5 Design & ManufactureMetalworking QuestionsMontrose AcademyMontrose Academy Technical Department Page 47
National 5 Design & ManufactureKnowledge questionsWhat are two differences between ferrous and non‒ferrous metals?Name two products that aluminium is commonly used to make.Circle two pure metals.AluminiumSteelBrassTinCopperBronzeWhat is an alloy?Below are a range of properties, and a description, that metals commonly have. Fill in the blanks, brittlenesshas been given as an example.Brittleness‒ Easily broken, when struck, with little or no bending at the breaking pointDuctility‒‒ Ability to resist a force without breakingConductivity‒‒ Able to be hammered out into thin sheets or small bars without crackingMontrose Academy Technical Department Page 48
National 5 Design & ManufactureKnowledge questionsName the tools shown below.Describe what a scriber is used for.You need to mark a line parallel to the edge of your metal, what tool would you use?Engineers SquareOdd Leg CalipersScriberWhat is the metal lathe used for in metalwork?Montrose Academy Technical Department Page 49
National 5 Design & ManufactureKnowledge questionsLabel the parts of the metal lathe shown below.What is stored in the headstock?Which of the following is used to move the tool post across the face of the work?Compound slideMontrose Academy Technical DepartmentCross slide Page 50
National 5 Design & ManufactureKnowledge questionsList 4 safety considerations when using the metal lathe. Which of these pictures shows the correct way of setting up lathe tools? Tick the correct box.On the following diagrams, draw an arrow to show the direction the cutting tool moves when:Parallel turning; Facing off; and Taper turning.Parallel TurningFacing OffMontrose Academy Technical Department Page 51
National 5 Design & ManufactureKnowledge questionsTaper TurningWhat is a knurling tool used for?What parts of items have knurled surfaces?What is the purpose of facing off?Notching is a process which involves the removal of material from a sheet of metal name one toolthat could be used the following environments.Industrial work place -A school workshop -Some metal can be bent using an engineers vice, folding bars and a hide mallet. Explain why a hidemallet is used.Montrose Academy Technical Department Page 52
National 5 Design & ManufactureKnowledge questionsA piece of metal requires bent and notches to be removed, which of these should be done first andwhy?Name the two tools shown in the picture below.There are a number of different types of mallet that can be used during the shaping and bending ofmetals, please name another two.Some metals need to be heated to soften them up before they can be shaped or bent, what is thisprocess called?When shaping sheet metal a wooden former could be used, give two advantages to using a woodenformer. Montrose Academy Technical Department Page 53
National 5 Design & ManufactureKnowledge questionsForging metal1. Name four pieces of essential safety equipment required to be worn while working on the Hearth.a.b.c.d.2. Why are parts formed via forging stronger than those formed via casting?3.Label the following picture with the correct names.Extraction Hoodfire bricksBrazing StationTorchBlacksmiths/chip ForgeTongs4. What does the hearth use to provide heat?5. How might you increase the size and heat of the flame produced from the torch?Montrose Academy Technical Department Page 54
National 5 Design & ManufactureKnowledge questions6. Why might fire bricks be arranged in a semi circle around an object?7. What would you use to hold hot metals securely?8. Label the following diagram correctly.9. How might you use a Hardie?10. The Swage and Fuller are other tools that use the Hardie Hole, what is their purpose?11. Why might you have to use a Flatter after using a Fuller?12. Why does the pein on a straight pein hammer run parallel to the handle?13. What is the purpose of the round Pein on a Ball Pein Hammer?Montrose Academy Technical Department Page 55
National 5 Design & ManufactureKnowledge questions14. Once heated, a piece of metal can be worked using the anvil and hammer in order to taper it to apoint. What is this process called?15. Describe how you would use an anvil to bend a piece of metal.16. What does it mean to upset a piece of metal?17. Name two forms of punching metal.18. Name the three main stages of the heat treatment process and describe why they are important.a.b.c.19. What heat treatment requires the metal to be heated until bright read then allowed to coolnaturally?20. What is the purpose of this process?21. Describe the difference between Hardening and tempering.22. What happens when a metal becomes Work Hardened?Montrose Academy Technical Department Page 56
National 5 Design & ManufactureKnowledge questionsCutting Tools1. Describe the difference between a Hacksaw and a Junior Hacksaw2. What tool would be useful for cutting curved shapes into a piece of metal?3. Why would this tool be better than a Hacksaw for cutting curved shapes?4. Describe the operation of Snips.5. When might you use Snips instead of a Hacksaw?6. Describe the process of shearing metal using a cold chisel.7. Describe the difference between Pliers and wire cutters.Montrose Academy Technical Department Page 57
National 5 Design & ManufactureKnowledge questionsFinishing metal1. Why do you need to finish metal after it has been cut?2. What is the purpose of a file?3. Why are files most efficient when pushed?4. Why should you avoid pulling files?5. Why might you require a file card?6. Why is it advantageous to use emery cloth rather than paperbacked abrasives when working withmetals?7. What is the purpose of wetting wet and dry paper?8. What is metal polish?9. What can metal polish be used to remove?Montrose Academy Technical Department Page 58
National 5 Design & ManufactureKnowledge questions10. What can be used to ensure metal remains shiny?11. Describe two methods of protecting ferrous metals?Montrose Academy Technical Department Page 59
National 5 Design & ManufactureKnowledge questionsHolding tools1. What can be used with the engineer’s vice to allow you to work with plastics and soft metals?2. Why do engineer’s vices overhang the edge of the workbench?3. What is a machine vice used for?4. What is the purpose of the v shaped grooves in the jaws of the machine vice?5. When might you use a hand vice?6. What do folding bars allow you to achieve?7. Describe the operation of mole grips.Montrose Academy Technical Department Page 60
National 5 Design & ManufactureKnowledge questionsDrilling metal1. Before drilling any metal it must be2. What three tools can be used to mark out the position of a hole to be drilled?3. Why would you use a centre punch prior to drilling?4. Why might the drill bit break as a result of sideways movement?5. How should you hold metal to be drilled?6. What kind of drill bit should be used when drilling metal?7. Describe Swarf and how it may be removed?Montrose Academy Technical Department Page 61
National 5 Design & ManufactureKnowledge questionsSand CastingLabel the parts of the casting box shown.Sprue pins are used to create channels for the moulten metal to be poured. What are the names of thesechannels? What are these channels used for?Name of the channelWhat is it used for?Montrose Academy Technical Department Page 62
National 5 Design & ManufactureKnowledge questionsThe pattern has to have sloping sides on it. Why is this?What do you have to sprinkle over the pattern before putting sand over it?How do you know when to stop pouring the metal?Montrose Academy Technical Department Page 63
National 5 Design & ManufactureKnowledge questionsDie CastingWhen should die casting be used instead of sand casting?What is the mould made from in die casting?Explain, in your own words what happens in the process of die casting.Die PreperationInjectionMontrose Academy Technical Department Page 64
National 5 Design & ManufactureKnowledge questionsEjectionShakeoutMontrose Academy Technical Department Page 65
National 5 Design & ManufactureKnowledge questionsComplete the table below.Advantages of Die CastingMontrose Academy Technical DepartmentDisadvantages of Die Casting Page 66
National 5 Design & ManufactureKnowledge questionsDip CoatingWhat is dip coating?What safety equipment has to be used when dip coating?Explain the process of dip coating.123Montrose Academy Technical Department Page 67
National 5 Design & ManufactureKnowledge questions45Metal can also be coated with a number of different materials to protect it.PaintingSpray paintingLacqueringMontrose Academy Technical Department Page 68
National 5 Design & ManufactureKnowledge questionsDip CoatingGalvanisingBluingMontrose Academy Technical Department Page 69
National 5 Design & ManufactureKnowledge questionsJoining MetalPut the following methods of joining metal into the table. Indicate whether each method is permanent ornon permanent.Epoxy ResinSolid RivetsPop RivetsMachine ScrewsWashersSelf tapping screwsSolderingBrazingWeldingNutsBoltsThreadingArc WeldingSpot WeldingMethod of joining metalProcess or tool for joining metalPermanentSemipermanent1. Adhesives2. Mechanicalfixing3. SolderingMontrose Academy Technical Department Page 70
National 5 Design & ManufactureKnowledge questions4. Brazing5. WeldingName the rivets below.Apart from speed of use, name one advantage of using pop rivets over solid rivets.How does this advantage effect mass production techniques?Montrose Academy Technical Department Page 71
National 5 Design & ManufactureKnowledge questionsNuts, Bolts & Machine ScrewsWhat is a nut used for?What does a nut have to be used alongside?What is one advantage of using a wingnut?What is the difference between a bolt and a machine screw?What is a washer?Why are self tapping screws made of hardened steel?Montrose Academy Technical Department Page 72
National 5 Design & ManufactureKnowledge questionsName the driving tools shown below.Montrose Academy Technical Department Page 73
National 5 Design & ManufactureKnowledge questionsTaps & DiesWhat are Taps used for?What is the name of this tool and what is it used for?Name each of the types of taps available and describe the use of each one.Name of tapUseMontrose Academy Technical Department Page 74
National 5 Design & ManufactureKnowledge questionsWhat is meant by a blind hole?What are Dies used for?What is the name of this tool and what is it used for?Why do we chamfer a metal rod before cutting an outside thread in it?What should we use to help us cut this thread?Montrose Academy Technical Department Page 75
National 5 Design & ManufactureKnowledge questionsSoldering, Brazing & WeldingWhat tools are used when soldering and does this happen at low, medium or high temperatures?What tools are used when brazing and does this happen at low, medium or high temperatures?What is stronger; welding, brazing or soldering?What can happen if the settings on an arc welder or spot welder are incorrect?Montrose Academy Technical Department Page 76
National 5 Design & ManufactureKnowledge questionsWhat needs to be produced before a rapid prototyping model is created?Name the advantages of using rapid prototyping to make models.1.2.3.4.5.6.7.Montrose Academy Technical Department Page 104
N5 Design & Manufacture Metalworking Questions Montrose Academy . National 5 Design & Manufacture Knowledge questions Montrose Academy Technical Department Page 48 What are two differences between ferrous and non‒ferrous metals? Name
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