TEST CODE 01335020

FORM TP 2006111 MAY/JUNE 2006

CARIBBEAN EXAMINATIONS COUNCIL
SECONDARY EDUCATION CERTIFICATE
EXAMINATION
MECHANICAL ENGINEERING TECHNOLOGY
Paper 02 - Technical Proficiency
2 ~hours

(jLOMAY 2006 (aon!))

GENERAL DIRECTIONS;
1• This paper consists of THREE sections. You MUST answer FIVE questions.
SECTION A: 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 y hours, you are allowed 10 minutes to read through the paper. Writing MAY
begin during the 10-minute period.
3. Use sketches when necessary to support your answers.
4. Silent electronic calculators may be used.

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

Copyright © 2004 Caribbean Examinations Council ®.
All rights reserved.
01335020/F 2006
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This paper is divided into THREE sections —A, 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.
SECTION A
You are allowed to use freehand sketches or rule-assisted sketches to answer this question which
is based on Module B8 of the syllabus - Engineering Design. The question is worth 40 marks.
You are advised NOT to spend more than 50 minutes on this question.

1. Figure I, on the page opposite, shows the general outline of an incomplete arrangement of a
hoist and hook unit.
Part A is a horizontal beam which provides support for the unit. Four rollers, indicated at D, are
detailed parts of the unit, andtravel along the upper surface of the beam A. The shaft B is located
horizontally, and is 90 mm beneath the centres of the roller to support the hook, C.
Design:
(a) A housing which can be made by fabrication or casting to house the rollers at D, and
the horizontal shaft, B.
(b) A method of attaching the hook, C, to the shaft, B.
Your design should clearly show the following:
(i) The rollers, D, attached and retained to the housing and free to rotate about their
axes.
(ii) The shaft, B, in position in the housing and supported by two bronze bushings
inserted into the housing.
(iii) The shaft, B, free to rotate about its axis to facilitate the swinging movement
of the hook, C, as indicated by arrow E.
(iv) A means of retaining the shaft, B, in the housing in order to prevent axial
movement.
(v) The hook, C, attached to the shaft so that it could swivel within the shaft as
indicated by the arrows at F.
(vi) The hook being retained in the shaft.
(vii) The unit being able to move along the length of the beam, A, in both directions
as indicated by the arrows, G, but restricted from any side movement greater
than 2 mm.
Total 40 marks

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Figure I I
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0133502Q/F 2006
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 SECTIONS
You are required to answer any THREE questions from this section.
EACH question is worth 20 marks.
2. The component in Figure II is to be made from a piece of 20 mm diameter mild steel bar
100 mm long.

016 020
M12 X 1.75
45° X 2-

18 30
100

Figure II
(a) (i) List the steps of procedure to produce the component (7 marks)
(ii) With the aid of sketches, name THREE lathe tools that should be used to
produce the component in (a) (i) above. (6 marks)
(b) How is the carriage of the lathe driven when the lathe is engaged for screw cutting?
- (1 mark)
(c ) What are the THREE ways in which the work may be secured and driven in a centre
lathe? (3 marks)
(d) List THREE safety precautions that should be observed when using the centre lathe.
(3 marks)
Total 20 marks

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01335020/F 2006
Figure ELI shows a template to be produced from 3 mm thick mild steel, 130 mm long by
100 mm wide.

Figure HI
(a) (i) List the steps of procedure for marking out the template as shown.
(6 marks)
(ii) Make a list of the tools and equipment that are necessary for the marking out
~ exercise. (3 marks)
(b) (i) List the steps of procedure for cutting out the area labelled “A” on the drawing.
(4 marks)
(ii) Name the toolsused for the process in (b) (i) above. (3 marks)
(c) (i) -State TWO safety precautions to be observed when using marking out tools.
(2 marks)
(ii) State TWO safetyprecautions to be observed when cutting out the slot at
(b) (i) above. (2 marks)
Total 20 marks

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Figure IV shows a component that is to be machined on the horizontal milling machine from
a mild steel block 110 x 30 x 40 mm.

Figure IV

(a) (i) List the steps of procedure for setting up and machining the component.
(8 marks)
(ii) Sketch and name the cutter used to produce the slot at B. (2 marks)
(b) The slot at B is to be machined using a 120 mm diameter milling cutter. The cutting
’'speed of mild steel is 30 r.p.m.
(i) State the formula for calculating the r.p.m. of the cutter. (2 marks)
(ii) Calculate the revolution per minute required. (2 marks)
(c) List TWO advantages and TWO disadvantages of the conventional (up-cut) method of
milling. (4 marks)
(d) State TWO safety precautions that should be observed when using the milling machine.
(2 marks)
Total 20 marks

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 Figure V shows a rectangular block that had the area marked “A” removed by chain-drilling.
This area is to be filed flat and smooth with the comers at 90 degrees.
r-A

r*

108

180

Figure V
(a) With the aid of sketches, list the procedure for filing the area flat and smooth with the
comers at 90 degrees. (6 marks)
(b) (i) State TWO classes of files. (2 marks)
(ii) With the aid of sketches, list the MAIN differences between the two classes
named in (b) (i) above. (4 marks)
(c) (i) List TWO problems that may arise when hack-sawing copper tubing.
(2 marks)
(ii) With the aid of sketches, show how EACH of the problems, listed in (c) (i)
above, can be overcome. (4 marks)
(d) State TWO safety precautions that should be observed when using the hacksaw.
(2 marks)
Total 20 marks

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6. Figure VI shows a piece of guttering which is to be made from 22 gauge galvanized steel
sheet, as well as a bracket made from 3 mm thick galvanized sheet.

I Figure VI

I (a) Describe, with the aid of sketches, the steps of procedure required to produce the wired
edge. (5 marks)

I (b) Draw a dimensional sketch of the material to produce the gutter. (8 marks)

I (c) The Fa^e A of the bracket is to be riveted to the Back B of the gutter using FOUR snap
head rivets.
Describe, with the aid of sketches, the steps of procedure for riveting the bracket to the

I (d)
gutter using one of the rivets. (5 marks)
List TWO safety precautions that should be observed when working with sheet metal.

I (2 marks)
Total 20 marks

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 SECTION C
You are required to answer any ONE question from this section.
EACH question is worth 20 marks.
7. EITHER
Figure VII shows two pieces of 5 mm thick mild steel with flanges that are to be joined along
the edges marked “X” by electric arc welding.
X

Figure VII
(a) List the steps of procedure that should be taken to complete the job.
(5 marks)
(b) PROBLEM CAUSE REMEDY
(i) Oxidation of surface
\
(ii) Slicking of electrode
(iii) Excessive metal (wide bead)
(iv) Lack of fusion
(v) Lack of penetration

Copy the table above in your answer booklet and complete it by giving ONE cause and
the corresponding remedy for EACH of the arc welding problems listed.
(10 marks)
(c) State ONE factor that influences the choice of the size of the electrode (rod) to be used
in electric arc welding. (2 marks)
(d) State THREE safety precautions to be observed during the arc welding process.
(3 marks)
Total 20 marks
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f a a a n~y a a a /-
 DEFECT CAUSE REMEDY
(i) Distortion
(ii) Oxidation
(in) Blow holes
(iv) Lack of fusion
(v) Lack of penetration -

(e) Copy the table above in your answer booklet and complete it by giving ONE cause and
the corresponding remedy for EACH of the oxy-acetylene welding defects listed.
(10 marks)
(f) With the aid of sketches, show the relative position of the nozzle, rod and weld during
the leftward (forehand) oxy-acetylene welding process. (4 marks)
(g) Explain with the aid of labelled sketches the THREE types of flames in relation to the
gases used in the oxy-acetylene welding process. (6 marks)
Total 20 marks

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 The component shown in Figure VIII is to be produced using sand casting.

Figure VIII
(a) Develop apattern to be used in the moulding process to produce the required component.
(3 marks)
(b) With the aid of labelled sketches, list the steps of procedure for preparing the mould,
ready for pouring. (10 marks)
(c) An examination ofthe final casting revealed the presence of the following defects:
(i) Blow holes
(ii) Sand inclusion
State TWO reasons for the occurrence of EACH defect. (4 marks)
(d) Name SIX foundry tools used in the process of preparing the mould:
(3 marks)
Total 20 marks

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01335020/? 2006
(a) Use sketches to illustrate the following systems of gearing.
(i) Rack and pinion
(ii) Worm and wheel
(iii) Spur (3 marks)
(b) Give ONE application of EACH gearing system named in (a) above.
(3 marks)
(c) (i) List FOUR functions of a typical preventative maintenance system.
(4 marks)
(ii) Explain by giving TWO reasons for the importance of any TWO of the
functions listed in (c) (i) above. (4 marks)
(d) Figure IX shows the arrangement of a drill press motor and spindle pulleys in plan
view, with arrows indicating the direction of rotation of the pulleys.

Figure IX
Make a free-hand sketch of the figure in your answer booklet and indicate the following
on your sketch:
(i) The driving pulley
(ii) The driven pulley
(iii) The tight side of the belt
(iv) The slack side of the belt(4marks)
(e) Explain the importance of belt drives by highlighting TWO instances where it is more
advantageous to use a belt drive system over a gear drive system. (2 marks)
Total 20 marks