2015 HIGHER SCHOOL CERTIFICATE

EXAMINATION

Engineering Studies

General Instructions Total marks 100

Reading time 5minutes
Section I Pages 211
Working time 3hours
Write using black pen 20 marks
Draw diagrams using pencil Attempt Questions 120
Board-approved calculators may Allow about 30 minutes for this section
be used
Section II Pages 1335
A formulae sheet is provided at
the back of this paper 80 marks
Write your Centre Number and Attempt Questions 2127
Student Number at the top of Allow about 2 hours and 30 minutes for this
pages13, 17, 19, 21, 25, 27 section
and35

2200
Section I

20 marks
Attempt Questions 120
Allow about 30 minutes for this section

Use the multiple-choice answer sheet for Questions120.

1 Which of the following has both magnitude and direction?

(A) Mass
(B) Scalar
(C) Speed
(D) Vector

2 Which of the following methods would be suitable to manufacture PET polymer bottles?

(A) Casting
(B) Pressing
(C) Stamping
(D) Blow moulding

3 A motor vehicle is travelling along a horizontal road.

How does an increase in velocity affect its potential energy and kinetic energy?

Potential energy Kinetic energy

(A) Increases Increases
(B) Maintains Increases
(C) Increases Decreases
(D) Maintains Decreases

2
4 A pictorial view of a block is shown.

ew
t Vi
n
Fro

Which set of views represents the block in orthogonal projection?

(A) (B)

(C) (D)

5 The teeth on a steel sprocket need to be hard.

Sprocket teeth

Which heat treatment process is most suitable for hardening the teeth?

(A) Flame heating then air cooling

(B) Flame heating then oven cooling
(C) Induction heating then quenching
(D) Induction heating then slow cooling

3
6 Which process combines data and a carrier wave to form a television signal?

(A) Compressing
(B) Encryption
(C) Modulation
(D) Multiplexing

7 Which of the lever systems would require the least force at X to balance the 100kg
mass?

100 kg X

(A)

100 kg X

(B)

100 kg X

(C)

100 kg X

(D)

4
8 Which statement best describes the difference between cast iron and steel?

(A) Steel contains more free graphite.

(B) Cast iron has higher tensile strength.
(C) Steel has higher compressive strength.
(D) Cast iron has a higher percentage of carbon.

9 Which form of the AC to DC rectification process is shown by the graphs?

V V

t t

Before rectification After rectification

(A) Full wave

(B) Half wave
(C) Smooth full wave
(D) Smooth half wave

10 The heat sink shown is used to conduct heat away from components.

Heat sink

Which row of the table identifies a suitable material and manufacturing process for the
heat sink?

Material Manufacturing process

(A) Steel Rolling
(B) Nylon Injection moulding
(C) Aluminium alloy Die casting
(D) Ceramic Compression moulding

5
11 Consider this logic circuit for turning a lamp on or off.

Switch 1

Switch 2

Switch 3 Lamp

Which set of conditions will turn the lamp on?

Switch 1 Switch 2 Switch 3

(A) Off Off Off
(B) On On On
(C) Off Off On
(D) Off On On

12 Each resistor in the diagrams below has a value of 10 W.

Which combination of resistors provides a total resistance of 15 W between X and Y ?

(A) X Y

(B)

X Y

(C)
X Y

(D)
X Y

6
13 In which direction does a reaction force act at a roller support?

(A) Parallel to the supporting surface

(B) Vertical to the supporting surface
(C) Horizontal to the supporting surface
(D) Perpendicular to the supporting surface

14 The image shows one end of an electrical spark plug used in an internal combustion
engine.

Which combination of properties would the component labelled M need to have?

(A) Electrical resistivity and machinability

(B) Electrical conductivity and machinability
(C) Electrical resistivity and temperature stability
(D) Electrical conductivity and temperature stability

7
15 Which graph best represents the relative proportions of materials used in the construction
of new, large passenger aircraft?

(A) Other (B) Other

Steel Steel

Titanium Aluminium Titanium

Composite
alloy

Composite Aluminium
alloy

(C) Other (D) Other

Aluminium
alloy
Steel

Titanium Composite Aluminium

Composite alloy

Steel Titanium

8
16 A pole is supported by four cables that are attached to its top and to the sloping ground.

3
2

3
4
2
1

Which cable is shown as true length?

(A) Cable 1
(B) Cable 2
(C) Cable 3
(D) Cable 4

17 Which of the following could cause fatigue cracking in a metal?

(A) A static tensile load

(B) A substantial shock load
(C) A high compression load
(D) A cyclically applied load

9
18 What are TWO advantages of using the powder forming process to manufacture a
selflubricating bearing?

(A) Low material waste and high density

(B) High porosity and low material waste
(C) Low density and high tensile strength
(D) High quality surface finish and high tensile strength

19 The diagram shows one end of a universal I beam with access holes drilled and a
supporting bracket fixed to each side.

Which view shows the correct full section XX of the beam viewed in the direction of
the arrows?

(A) (B)

(C) (D)

10
20 The drawing represents a loaded steel beam simply supported at each end.

3 kN 7 kN UDL 500 N/m

2 m 3 kN 5m 7 kN1 m UDL 500 N/m
2m 5m 1m

5.1 kN 8.9 kN

5.1 kN 8.9 kN
Which diagram best represents the distribution of shear forces along the beam?
(A)
(A)
0
0

(B)
(B)
0
0

(C)
(C)
0
0

(D)
(D)
0
0

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2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II

80 marks
Attempt Questions 2127 Student Number
Allow about 2hours and 30minutes for this section

Answer the questions in the spaces provided. These spaces provide guidance for the expected
length of response.

Question 21 (11 marks)

Please turn over

2201 13
Question 21 (11 marks)

(a) The sketch shows an early Australian-built car.

Explain how TWO features of this early Australianbuilt car have been modified 3
in modern cars to improve their safety.

Question 21 continues on page 15

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Question 21 (continued)

(b) The diagram represents part of a cars hydraulic braking system.

Brake disc

Brake master
Brake pedal cylinder

Brake caliper

Outline the operation of this hydraulic system and its advantages over 4
mechanical systems.

Question 21 continues on page 16

15
Question 21 (continued)

(c) A hydraulic cylinder system is shown.

Cylinder A has a piston area of 100mm2. Cylinder B has a piston area of

700mm2.
Y
X

A B

(i) Calculate the force on rod Y when a force of 50 N is applied on rod X. 2

.......................................................... N

(ii) Calculate the distance rod Y would move when rod X moves 60 mm. 2

...................................................... mm

End of Question 21

16
2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 22 (12 marks)

(a) A circuit diagram of a simple radio receiver is shown.

Name the components labelled A and B and outline each components function 4
in this circuit.




(b) How have semi-conductors influenced the design of modern telecommunications 2

products?

Question 22 continues on page 18

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Question 22 (continued)

(c) A radio aerial support bracket bolted to a steel plate is shown. Complete a fully 6
sectioned front view of the bracket assembly. Apply AS1100.

A A

End of Question 22

18
2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 23 (12 marks)

(a) An image of a telephone charger is shown.

Cover

Pins

(i) The material used for the electrical pins of the telephone charger needs 2
to be a good conductor of electricity.

List TWO other engineering properties that would be relevant when

selecting the material for the pins.




(ii) The telephone charger cover is to be manufactured from a polymer. 3

Name and describe a suitable manufacturing process.




Question 23 continues on page 20

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Question 23 (continued)

(b) Contrast the key features of fixed and mobile telephone systems. 3


(c) A smart-phone transmits digital information. One step in this process is to 4

convert analogue voice data to digitised data.

V V

T T

Analogue signal Digitised signal

Outline how an analogue signal is digitised using sampling and quantising.



End of Question 23

20
2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 24 (12 marks)

(a) The photograph shows railway power cables supported by a steel column.

(i) Suggest a suitable method that could be used to protect this steel column 2
from corroding and explain how this method slows the corrosion process.




(ii) The column is manufactured by cold rolling 0.4% carbon steel. 2

Sketch and label the resulting microstructure.

Question 24 continues on page 22

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Question 24 (continued)

(b) A diagram of a pin-jointed, cantilever truss that supports overhead railway

power cables is shown.

1200 N

1.5 m 1.5 m 1.5 m

B C D E
1.5 m

F
750 N
A

A weight of 1200N is determined to be acting at jointC and the power cable

weight of 750N is acting at jointE.

(i) Determine the magnitude of the reaction at supportA. 2

Magnitude of reaction at A................................. N

Question 24 continues on page 23

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Question 24 (continued)

(ii) Determine the magnitude and the direction of the reaction at the pin 3
jointB.

Reaction at B ................................. N Direction ...................................

(iii) Determine the magnitude and the nature of the force in member AC. 3

Force in AC .................................... N Nature .......................................

End of Question 24

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2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 25 (12 marks)

(a) The two images show light aircraft powered by different propulsion systems. 3

Business aircraft Recreational aircraft

Identify a suitable propulsion system for each aircraft and justify your choice.







(b) Outline TWO control adjustments that can be made to vary the lift force acting 3
on an aircraft during flight.







Question 25 continues on page 26

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Question 25 (continued)

(c) An aerofoil was tested in a wind tunnel. 2

This test produced a resultant force of 350N at an angle of 10 to the lift axis.

10
Air flow

Calculate the lift to drag ratio.

Lift to Drag Ratio . ..............................

(d) Outline the ultrasonic testing process and its advantages for use in testing 4
aircraft components.

End of Question 25

26
2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 26 (13 marks)

Please turn over

2206 27
Question 26 (13 marks)

(a) A winch mechanism is used to pull a 150 kg crate up a ramp and onto a transport
vehicle.

Winch

Cable
Crate
kg
150 Ramp

25

The winch cable is parallel to the ramp.

(i) A simplified sketch of the crate, ramp and the tensile force (T) in the 2
cable is shown at the point of the crate sliding up the ramp.

Add labelled arrows to the sketch to indicate the following forces:

normal
weight
friction.

(ii) Calculate the tensile force in the cable at this point if the coefficient of 3
friction between the crate and the ramp is 0.3.

Tension in cable ............................. N

Question 26 continues on page 29

28
Question 26 (continued)

(iii) For a different situation, the tension in the cable is 910N. This winch is 2
85% efficient and has an effective drum diameter of 100mm.

What is the minimum force (F) required to operate this winch if the
effective length of the winch handle is 350mm?

0
35
F

T = 910 N 100

Force ............................................... N

Question 26 continues on page 30

29
Question 26 (continued)

(b) The steel used to manufacture the winch cable was tested using a tensometer and
the resulting details are shown on the loadextension graph.

30 Y

Z
20
Load (kN)

10

0
0.5 1 1.5 2

Extension (mm)

(i) State the significance of the three key points identified on the graph. 3
X 


Y 

Z 

Question 26 continues on page 31

30
Question 26 (continued)

(ii) The original gauge length of the steel test piece was 55mm with a 3
crosssectional area of 9.6mm2.

Using data from the loadextension graph, calculate the value of

Youngs Modulus for this steel.

Youngs Modulus .......................................... GPa

End of Question 26

Question 27 starts on page 35

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2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION
Engineering Studies
Centre Number
Section II (continued)

Student Number

Question 27 (8 marks)

An engineering team consists of a civil engineer, an electrical engineer and an 8

environmental engineer. They have been contracted by a local council to manage the
design and construction of a five metre long pedestrian bridge across a narrow creek
in a public park.

Outline how each of these engineers would contribute to the successful completion
of this project.


End of paper

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2015 Board of Studies, Teaching and Educational Standards NSW
 2015 HIGHER SCHOOL CERTIFICATE EXAMINATION

Engineering Studies

FORMULAE SHEET

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2015 Board of Studies, Teaching and Educational Standards NSW