ccea gcse specimen assessment materials for engineering and … · 2019. 9. 25. · users to stay...

CCEA GCSE SpecimenAssessment Materials for

Engineering and Manufacturing

GCSE

For first teaching from September 2017For first assessment in Summer 2018For first award in Summer 2019Subject Code: 0009

ForewordCCEA has developed new specifications which comply with criteria for GCSE qualifications. The specimen assessment materials accompanying new specifications are provided to give centres guidance on the structure and character of the planned assessments in advance of the first assessment. It is intended that the specimen assessment materials contained in this booklet will help teachers and students to understand, as fully as possible, the markers’ expectations of candidates’ responses to the types of tasks and questions set at GCSE level. These specimen assessment materials should be used in conjunction with CCEA’s GCSE Engineering and Manufacturing specification.

GCSE Engineering and ManufacturingSpecimen Assessment Materials

Contents

Specimen Papers 3

Unit 1: Controlled Assessment Task: Design 3Unit 2: Confidential Instructions to Teachers: Manufacturing

Processes (Production) 7Unit 2: Confidential Instructions to Teachers: Equipment and

Materials List (Production) 9Unit 2: Production 11Unit 3: Pre-release material: Materials, Processes and Systems 15Unit 3: Materials, Processes and Systems 19

Mark Schemes 39

General Marking Instructions 41Unit 2: Production 45Unit 3: Materials, Processes and Systems 49

Subject Code 0009

QAN 603/1671/8

A CCEA Publication © 2017

You may download further copies of this publication from www.ccea.org.uk

SPECIMEN PAPERS

General Certificate of Secondary Education2017

INSTRUCTIONS FOR THE CONTROLLED ASSESSMENT TASKYou have approximately 20 hours to complete the task.

The design portfolio should be a maximum of twelve A3 pages one side only or equivalent.All text should be font size 12. Titles should not exceed font size 16.Students can present the portfolio in an electronic format.

Quality of written communication will be assessed throughout the design portfolio.Centres select the task that is best suited to their needs.

Candidates’ work to be submitted May 2018

Engineering and ManufacturingUnit 1

Controlled Assessment Task

Design

[CODE]SPECIMEN PAPER

3

Controlled Assessment Tasks must comply with the requirements as detailed in the Subject Specification. NB: Some Controlled Assessment Tasks may constitute more than 1 page.

Please check you have all the information you need to complete the task if printing from a computer.

4

Unit 1: Design

Instructions for teachers and students

This unit is compulsory for all students.

The design portfolio should be a maximum of twelve A3 sheets on one side only or equivalent. All text should be font size 12. Titles should not exceed font size 16.

Students may present the portfolio in an electronic format.

Students should understand that the design process is non-linear and creativity should be evident throughout the process.

Students are expected to:

• analyse a given design brief and research similar products;• produce a detailed product specification;• generate a range of concept sketches;• evaluate and justify the design concept for development;• develop a final solution to meet the requirements of the specification;• produce engineering drawings of the final solution; and• present a final solution with proposals for manufacture on an industrial scale.

Quality of written communication will be assessed throughout the design portfolio.

5

Candidates must choose one of the following design tasks:

Task 1: Bicycle Maintenance Stand

Design Opportunity:

Bicycles are very popular for all age groups, however they need to be maintained regularly for users to stay safe.

You have been approached by a manufacturing company to design a portable maintenance stand that holds a bicycle at different heights to make it easier to work at for maintenance purposes. The company is looking to make a batch of 250.

Your design must:

• hold bicycles up to a maximum weight of 20kg;• allow for adjustable heights and angles to accommodate maintenance and repair of

children’s and adult’s bicycles;• incorporate a quick release mechanism;• accommodate maintenance and repair tools;• consider all safety features in relation to your design;• outline why a factor of safety would be necessary for your design;• be easily assembled and dismantled for storage and transportation; and• have a maximum weight of 8kg.

Task 2: Child’s Walker

Design Opportunity:

Walking aids help young children in their early stages of learning to walk.

A manufacturing company has approached you as a designer, to design a walker suitable for a child up to 12 months. The company is looking to make a batch of 250.

Your design must:

• be suitable for a child up to 12 months;• incorporate a feature to engage the child in play;• allow the child to manoeuvre the walker with ease;• have a low centre of gravity to ensure stability;• consider all safety features in relation to your design;• outline why a factor of safety would be necessary for your design;• be capable of accommodating children up to maximum weight of 11kg; and • consider the size of the walker.

BLANK PAGE

6

CONFIDENTIAL INSTRUCTIONS TO TEACHERS

MANUFACTURING PROCESSES


[CODE]SPECIMEN

Unit 2assessingProduction

DATE OF ISSUE TO TEACHERSJanuary 2019


7

8

The practical examination set for Summer 2019 will require candidates to employ manufacturing processes in both metal and plastic.

The practical examination set for Summer 2019 will require the candidates to engage in the following processes:

• Working to given tolerances• Marking out • Cutting • Filing • Cross filing and draw filing • Centre punching/drilling• Bending

CONFIDENTIAL INSTRUCTIONS TO TEACHERS

EQUIPMENT AND MATERIALS LIST


[CODE]SPECIMEN

Unit 2assessingProduction

DATE OF ISSUE TO TEACHERSJanuary 2019


9

10

Centres must ensure that the materials are ordered well in advance of the practical examination.

Confidentiality

To maintain the integrity of the assessment, no information pertaining to this examination should be publicly released until after the examination is completed.

Information about the equipment and materials required for the unit 2 assessment must not be communicated to candidates taking the examination prior to the examination.

Equipment and Materials

It is the responsibility of the centre to ensure candidates have access to all of the equipment and materials required to complete the practical examination.

To complete the practical examination successfully each candidate will need access to the following equipment and materials.

Equipment:

• Access to a multimedia workshop capable of accommodating the required number of candidates

• Engineers vice• Hacksaw, abrafile and notcher• Pillar drill• Drill bits suitable for mild steel: 4mm, 5mm and 7mm• Drill bits suitable for acrylic: 6mm and 7mm• Counter sunk drill bit• Scriber• Engineers square• Markers blue• Centre punch• Hammer• Steel rule• Protractor• Spring divider• Box pan folder/Folding bar• Hot wire bender• Odd leg calliper• Sliding bevel• Files suitable for cross and draw filing• Wet and dry paper

Material required for each candidate:

• 1 18 SWG mild steel sheet 230 × 230mm• 1 piece of acrylic 120mm × 22mm × 3mm




Unit 2

assessing

Production

11

TIME3 hours.

INSTRUCTIONS TO CANDIDATESCandidates are expected to complete the manufacturing task from the drawings supplied using the equipment and the materials provided by the centre.Candidates are advised centre lines must remain visible on the finished product.Candidates are advised to spend the first 10 minutes reading the drawings.

INFORMATION FOR CANDIDATESThe total mark for this practical exam is 100.

12

(i)

© C

CE

A

13

(ii

)

© C

CE

A

A-B

Ben

d 90

deg

rees

6R10 6

7 AB

1515

4040

7

1515

390

03

CC

EA

Sca

le 1

:1G

CS

E E

ngin

eerin

gP

art 2

Low

er L

ink

Acr

ylic

Mat

eria

lU

nit 2

Tole

ranc

e +/

- 0.5

All

dim

ensi

ons

in m

m

A

B

BLANK PAGE

14

PRE-RELEASEMATERIAL


assessing

Materials, Processes and Systems

[CODE]SPECIMEN


15

16

The image below shows a folding exercise bike.

© uatp2/iStock/Thinkstock

Digital display monitor

Padded seat

Adjustable tension system

Non-skid foot pedals with safety straps

Dual drive system internal 2.5kg fly

Locking pin for dismantling

Adjustment for height of seat

17

Product features include:

• Powder coated tubular mild steel frame• Padded seat with height adjustment• Digital display monitor• Plastic foot pedals with safety strap• 2.5Kg flywheel with 8 step adjustable resistance system• Portable, easy to set up and compact• Adjustable foam grip handle bars• Dimensions (assembled) Height (1120 mm) - Length (750 mm) - Width (410 mm)

Pre-release investigation:

You should investigate the possible impact and use of the following where appropriate, in the design and production of the exercise bike:

• Materials and components: including application, properties, forming, supply and types of finish;

• Manufacturing processes: including joining, assembly and the application of jigs and fixtures;

• Quality control and assurance; and• Costing: including direct and indirect costs incurred in the manufacture of the bike.

BLANK PAGE

18

Centre Number

Candidate Number


For Examiner’s use only

Question Number

Marks

1

2

3

4

5

6

7

8

9

10

11

TotalMarks

TIME2 hours.

INSTRUCTIONS TO CANDIDATESWrite your Centre Number and Candidate Number in the spaces provided at the top of this page.Write your answers in the spaces provided in this question paper.Answer all eleven questions.Answer all questions in Section A and B.Questions, 1, 2, 3, 4 and 5 of Section A refers to the pre-release material, a copy of which has been provided for you.You may use a calculator for this paper.Quality of written communication will be assessed in Question 5.

INFORMATION FOR CANDIDATESThe total mark for this paper is 100.Figures in brackets printed down the right-hand side of pages indicate the marks awarded to each part question.


assessing



19

Examiner Only

Marks Re-mark

20

Answer all questions

Section A

Questions in this section refer to the pre-release material.

1 (a) Give two reasons why tubular mild steel is an appropriate material for the main frame.

1 [1]

2 [1]

(b) Give one reason why powder coating is appropriate for the surface finish of the main frame.

[1]

(c) Fig. 1 below shows the fastening at X used to hold the Adjustable Tension System.

Fig.1

© uatp2/iStock/Thinkstock

X

Examiner Only

Marks Re-mark

21

The tool used to tighten or loosen the fastening at X is shown in Fig. 1(a) below.

(i) Name the tool used to tighten or loosen the fastening shown at X.

[1]

(ii) Give two reasons why this type of fastening is preferable to a conventional hexagonal headed bolt.

1 [1]

2 [1]

(iii) The digital display for the exercise bike contains a number of electronic components. Fig. 2 below shows a picture of a capacitor and resistor.

Give one use of a capacitor and one use for a resistor in an electronic circuit.

1 [1]

2 [1]

Fig. 2

Fig. 1(a)© Sergei_Tremasov/iStock/Thinkstock

© 3drenderings/iStock/Thinkstock © TethysImagingLLC/iStock/Thinkstock

Examiner Only

Marks Re-mark

22

2 (a) Describe two quality control checks that should be carried out on the frame and two quality control checks that should be carried out on the electronic circuit for the digital display.

Frame

[2]

Electronic circuit

[2]

(b) State two ways in which the customer can be assured of the quality of the exercise bike.

1 [1]

2 [1]

(c) Name two tools that would be used for quality control checks.

1 [1]

2 [1]

Examiner Only

Marks Re-mark

23

3 (a) The manufacturer employs 9 people who are engaged in the assembly of the exercise bike. The employees work an 8 hour shift. The target is to assemble 30 bikes (units) by the end of each shift.

What is the time required for the assembly of one bike in hours and minutes?

Show your working out in the space below.

Answer [3]

(b) The 9 employees each cost the company £70.00 a day.

(i) What is the labour cost to the company per 5 day week?


Answer [2]

Examiner Only

Marks Re-mark

24

(ii) The company needs a 15% profit on labour costs.

Calculate the labour cost for each bike to include this 15% profit?


Answer [4]

(c) The company has decided to employ three more people to increase assembly output during each shift.

How many bikes can now be assembled per shift?


Answer [3]

DO NOT WRITE ON THIS PAGE(Questions continue overleaf)

25

Examiner Only

Marks Re-mark

26

4 Fig. 3 below shows the adjusting mechanism for the height of the seat.

In the space provided, use 2D, sectional and exploded annotated

sketches with appropriate terminology to show how the adjusting mechanism could work.

Marks will be awarded for: Detail contained in the sketches [4] Quality of sketches [4] Annotation [4]

Fig. 3© uatp2/iStock/Thinkstock

Examiner Only

Marks Re-mark

27

Examiner Only

Marks Re-mark

28

5 Identify two parts of the exercise bike that would benefit from the use of jigs to aid their manufacture. Discuss how each jig helps in the production of the bike.

Quality of written communication will be assessed in this question.

[10]28

Examiner Only

Marks Re-mark

29

Section B

6 (a) Name the mechanical system shown below in Fig. 4.

[1]

(b) Name the mechanical system shown below in Fig. 5.

[1]

(c) Outline two advantages of the mechanical system shown above in Fig. 4 when used in a product.

[2]

Fig. 4© Grassetto / iStock / Thinkstock

Fig. 5

© coddy / iStock / Thinkstock

29

Examiner Only

Marks Re-mark

30

(d) Outline two advantages of the mechanical system shown on the previous page in Fig. 5 when used in a product.

[2]

(e) On each steel bar below, use arrows to show how the following forces are applied:

• Tensile• Bending• Compressive• Shear

(i) Tensile Force

(ii) Bending Force

(iii) Compressive Force

(iv) Shear Force

[4]

30

Examiner Only

Marks Re-mark

3131

7 Fig. 6 below shows a bottle opener made from aluminium alloy.

(a) What is meant by the term alloy?

[1]

(b) Give two reasons why metals are alloyed.

[2]

(c) What kind of mechanical device does the bottle opener represent?

[1]

(d) Label, using arrows, the bottle opener in Fig. 6 above to show the load, the effort and the fulcrum. [3]

Fig. 6© PupTinnarat / iStock / Thinkstock

Examiner Only

Marks Re-mark

32

8 (a) Complete Table 1 below by stating a suitable material forming process for each of the examples shown.

Table 1

Example Material forming process

A

Plastic egg carton

BSteel car panels

C

Plastic bottle

D

Metal coat hook

[4]

32

© showcake / iStock / Thinkstock

©cla78 / iStock / Thinkstock

© tanuha2001 / iStock / Thinkstock

© CCEA

Examiner Only

Marks Re-mark

33

(b) The two main types of plastic are thermoplastic and thermosetting.

Select the plastic type that would be used for the products labelled A and C in Table 1 on the previous page.

A [1]

C [1]

(c) Product D can be finished using the process of dip coating.

Explain the process of dip coating the metal coat hook and briefly outline why it is a suitable finish.

[4]

33

Examiner Only

Marks Re-mark

34

9 Tensile test results on three metals labelled A, B and C are shown in Fig. 7 below.

(a) Using the graph in Fig. 7 above, state which metal has the highest tensile strength.

[1]

(b) Using the graph in Fig. 7, state which metal has the highest plasticity?

[1]

(c) Using an X, mark on the graph the fracture point for metal C. [1]

(d) (i) Using a Y, mark on the graph a point which is within the elastic deformation range for metal A. [1]

(ii) Using a Z, mark on the graph a point which is within the plastic deformation range for metal A. [1]

(iii) Explain the significance of the difference between plastic deformation and elastic deformation.

[2]

Fig. 7

Stress

Strain

Fig.7

A

B

C

© CCEA

Examiner Only

Marks Re-mark

35

(e) Fig. 8 below shows a reinforced crash barrier.

Explain why metal A would be a suitable material for use in a crash barrier?

[2]

©AlanP / iStock / Thinkstock

Fig. 8

Examiner Only

Marks Re-mark

36

10 (a) Complete Table 2 below indicating the most appropriate joining techniques for each of the materials listed.

Table 2

Joining Process Joining Technique

A permanent method of joining two mild steel plates togetherA semi-permanent method of joining two mild steel plates togetherA semi-permanent method of joining manufactured boardsA permanent method of joining two pieces of acrylicA permanent method of joining two pieces of hardwood

[5]

(b) Soft soldering and hard soldering (silver soldering) are two suitable joining methods for copper.

Outline two differences between soft soldering and hard soldering.

[2]

Examiner Only

Marks Re-mark

37

11 In the car manufacturing industry, robots are used for the spraying process.

(a) Why are robots used for spraying in the car manufacturing industry?

[1]

(b) Identify two other industrial processes, that can be controlled by robots and in each case give a specific reason for its use. The reasons must be different for each process.

Industrial process

1 [1]

Reason [1]

Industrial process

2 [1]

Reason [1]

(c) Outline two advantages of using an industrial manufacturing robot other than the answers given to (a) and (b) above.

[2]

THIS IS THE END OF THE QUESTION PAPER

38

MARK SCHEMES

39

General Certificate of Secondary Education

GENERAL MARKING INSTRUCTIONS


41

42

General Marking Instructions

IntroductionMark schemes are intended to ensure that the GCSE examinations are marked consistently and fairly. The mark schemes provide markers with an indication of the nature and range of candidates’ responses likely to be worthy of credit. They also set out the criteria which they should apply in allocating marks to candidates’ responses. The mark schemes should be read in conjunction with these general marking instructions.

Assessment objectivesBelow are the assessment objectives for GCSE Engineering and Manufacturing.

Candidates must:

AO1 Recall, select and communicate their knowledge and understanding of engineering and manufacturing in a range of contexts;AO2 Apply skills, knowledge and understanding, including quality standards in a variety of design contexts. Plan and carry out investigations and making tasks involving an appropriate range of tools, equipment, materials and processes; andAO3 Analyse and evaluate evidence, design proposals and outcomes, make reasoned judgements and present conclusions and recommendations.

Quality of candidates’ responsesIn marking the examination papers, examiners should be looking for a quality of response reflecting the level of maturity which may reasonably be expected of a 16-year-old which is the age at which the majority of candidates sit their GCSE examinations.

Flexibility in markingMark schemes are not intended to be totally prescriptive. No mark scheme can cover all the responses which candidates may produce. In the event of unanticipated answers, examiners are expected to use their professional judgement to assess the validity of answers. If an answer is particularly problematic, then examiners should seek the guidance of the Supervising Examiner.

Positive markingExaminers are encouraged to be positive in their marking, giving appropriate credit for what candidates know, understand and can do rather than penalising candidates for errors or omissions. Examiners should make use of the whole of the available mark range for any particular question and be prepared to award full marks for a response which is as good as might reasonably be expected of a 16-year-old GCSE candidate.

Awarding zero marksMarks should only be awarded for valid responses and no marks should be awarded for an answer which is completely incorrect or inappropriate.

Types of mark schemesMark schemes for tasks or questions which require candidates to respond in extended written form are marked on the basis of levels of response which take account of the quality of written communication.

Other questions which require only short answers are marked on a point for point basis with marks awarded for each valid piece of information provided.

43

Levels of responseTasks and questions requiring candidates to respond in extended writing are marked in terms of levels of response. In deciding which level of response to award, examiners should look for the ‘best fit’ bearing in mind that weakness in one area may be compensated for by strength in another. In deciding which mark within a particular level to award to any response, examiners are expected to use their professional judgement. The following guidance is provided to assist examiners.

• Threshold performance: Response which just merits inclusion in the level and should be awarded a mark at or near the bottom of the range.

• Intermediate performance: Response which clearly merits inclusion in the level and should be awarded a mark at or near the middle of the range.

• High performance: Response which fully satisfies the level description and should be awarded a mark at or near the top of the range.

Marking calculationsIn marking answers involving calculations, examiners should apply the “own figure rule” so that candidates are not penalised more than once for a computational error.

Quality of written communicationQuality of written communication is taken into account in assessing candidates’ responses to all tasks and questions that require them to respond in extended written form. These tasks and questions are marked on the basis of levels of response. The description for each level of response includes reference to the quality of written communication.

For conciseness, quality of written communication is distinguished within levels of response as follows:

Level 1: Quality of written communication is basic.Level 2: Quality of written communication is satisfactory.Level 3: Quality of written communication is good.Level 4: Quality of written communication is excellent.

In interpreting these level descriptions, examiners should refer to the more detailed guidance provided below:

Level 1 (Basic): The level of accuracy of the candidate’s spelling, grammar and punctuation is basic. The candidate makes a limited selection and use of an appropriate form and style of writing. There is little use of specialist vocabulary.

Level 2 (Satisfactory): The level of accuracy of the candidate’s spelling, grammar and punctuation is satisfactory. The candidate makes a satisfactory selection and use of an appropriate form and style of writing. There is some use of specialist vocabulary.

Level 3 (Good): The level of accuracy of the candidate’s spelling, grammar and punctuation is good. The candidate makes a good selection and use of an appropriate form and style of writing supported with good use of diagrams as required. There is good use of specialist vocabulary.

Level 4 (Excellent): The level of accuracy of the candidate’s spelling, grammar and punctuation is excellent. The candidate successfully selects and uses the most appropriate form and style of writing. There is excellent use of appropriate specialist vocabulary.

BLANK PAGE

44

MARKSCHEME


[CODE]SPECIMEN

Unit 2

assessing

Production


45

AVAILABLE MARKS

46

Acrylic Part

1 Width Measure across each vertical and the base. The three measurements

within tolerance [2] marks. If outside of tolerance by +/- 1 mm [1] mark. If outside of tolerance by +/- 2 mm [0] marks.

(3 x [2]) [6]

2 Bends Bent to the correct width within tolerance [2] marks. If outside tolerance

by +/- 1 mm[1] mark. If outside of tolerance by +/- 2 mm [0] marks.

(2 x [2]) [4]

3 Three holes The three holes within tolerance along the common centre line [2] marks.

If outside tolerance by +/- 1 mm [1] mark. If outside of tolerance by +/-2 mm [0] marks.

(3 x [2]) [6]

4 Centre hole diameter 7 Centre hole correctly located [2] marks. If outside tolerance by +/- 1 mm

[1] mark. If outside of tolerance by +/- 2 mm [0] marks.

(1 x [2]) [2]

5 6 mm holes 6 mm holes correctly located [2] marks. If outside tolerance by +/- 1 mm

[1] mark. If outside of tolerance by +/- 2 mm [0] marks.

(2 x [2]) [4]

6 Radii Accuracy of each radius. High degree of precision [2] marks. Satisfactory

degree of precision [1] mark. Poor degree of precision [0] marks.

(2 x [2]) [4]

7 Alignment of two 6 mm holes High degree of accuracy in alignment [3] marks. Satisfactory degree

of accuracy in alignment [2] marks. Poor degree of alignment [1] mark. Misalignment [0] marks.

(1 x [3]) [3]

8 Quality of finish High quality of finish [3] marks. Satisfactory quality of finish [2] marks.

Poor quality finish [1] mark. Unfinished [0] marks.

(1 x [3]) [3]

AVAILABLE MARKS

47

Mild Steel Part 9 Height of platform Precise height of platform:

• From each apex to the base within tolerance [6] marks. • From each apex to the base outside of tolerance +/- 1 mm [5] marks. • From each apex to the base outside of tolerance +/- 2 mm [4] marks.• From each apex to the base outside of tolerance +/- 3 mm [3] marks.• From each apex to the base outside of tolerance +/- 4 mm [2] marks.• From each apex to the base outside of tolerance +/- 5 mm [1] marks.• From each apex to the base outside of tolerance +/- 6 mm [0] mark.

(3 x [6]) [18]

10 Angle of leg Angle of each leg within tolerance of +/- 2º [2] marks. Angle of each leg

outside tolerance by +/- 2º [1] mark. Angle of each leg outside tolerance more than +/- 2º [0] marks.

(3 x [2]) [6]

11 Quality of finish (i) Centre line visible on each leg [1] mark. Centre line not visible [0] mark. (3 x [1]) [3]

(ii) High quality of edge finish on each leg [3] marks. Satisfactory quality of edge finish on each leg [2] marks. Quality finish limited on each leg [1] mark. No attempt made to finish legs [0] marks.

(3 x [3]) [9]

12 Leg taper (i) 12 mm at base within tolerance [2] marks. Greater than tolerance by

+/- 1 mm [1] mark. Greater than tolerance by +/- 2 mm [0] marks.

(3 x [2]) [6]

(ii) 12 mm at centre line within tolerance [2] marks. Greater than tolerance by +/- 1 mm [1] mark. Greater than tolerance by +/- 2 mm [0] marks.

(3 x [2]) [6]

13 5 mm Holes (i) Located on centre line within tolerance [3] marks. Located on centre

line outside tolerance +/- 2 mm [2] marks. Located on centre line outside of tolerance +/- 3 mm [1] mark. Located on centre line outside of tolerance more than +/-3 mm [0] marks.

(3 x [3]) [9]

AVAILABLE MARKS

48

(ii) Location from base within tolerance [3] marks. Location from base outside tolerance +/- 2 mm [2] marks. Location from base outside of tolerance +/- 3 mm [1] mark. Location from base outside of tolerance more than +/-3 mm [0] marks.

(3 x [3]) [9]

14 7 mm centre hole Correct size of hole [2] marks. Incorrect size of hole [0] mark

(1 x [2]) [2]

Total 100

MARKSCHEME


[CODE]SPECIMEN

Unit 3

assessing



49

AVAILABLE MARKS

50

Section A

1 (a) Any two from the list below:

• Tubular steel has high tensile strength • Tubular steel is readily available • Tubular steel is relatively light • Tubular steel has a relative low cost • Tubular steel is easily shaped

(2×[1]) [2]

Correct alternative responses will be given credit.

(b) Any one from the list below:

• Durable and long lasting• Protection of the metal • Prevents the metal from corroding• Provides an attractive finish [1]


(c) (i) Allen Key [1]

(ii) Any two from the list below:

• It is aesthetically pleasing • Low profile head/sits relatively flush to the frame • To ensure the safety of the user when using the machine

(2×[1]) [2]


(iii) Any one from the list below:

Capacitor• To store electrical charge• Used in a time delay circuit

(1×[1]) [1]


Any one from the list below:

Resistor• Used to protect other components• Reduces current flow

(1×[1]) [1]


8

AVAILABLE MARKS

51

2 (a) Frame

Any two from the list below:

• Tolerance checks on the length of the steel tubing used in the frame

• The accuracy of the bends • Tolerance checks to ensure that holes are aligned and drilled at

correct position • Quality of the finish

(2×[1]) [2]


Electronic circuit


• Ensure that internal parts are secured• Correct positioning of components and wires • Functional test to ensure correct operation

(2×[1]) [2]


(b) Any two from the list below:

• Check for product reviews• Check if the product complies with BSI/CE• Check if the product has a guarantee

(2×[1]) [2]


(c) Any two from the list below:

• Inside and outside callipers • Vernier calliper • Go and no go gauge• Micrometer• Depth gauge

(2×[1]) [2]


8

AVAILABLE MARKS

52

3 (a) 8 × 9 = 72 [1] / 30 = 2.4 [1] 2 hours 24 minutes [1]

(1×[3]) [3]

(b) (i) 9 × 70 [1] × 5 = £3150 [1]

(1×[2]) [2]

(ii) 9 × 70 = 630 / 30 = 21 [1] / 100 × 15 = £3.15 [1] + £21.00 [1] = £24.15 [1]

(1×[4]) [4]

(c) 9 + 3 = 12 [1] × 8 = 96 [1] /2.4 = 40 [1]

(1×[3]) [3]

4 Possible solutions could be:

• Spring loaded with a securing pin • Threaded screw and threaded tube • Threaded screw and threaded tube with a boss/nut spot welded to

give depth of thread• The size and shape of the knob to provide leverage


ResponseType

Description Mark Band

Level of response not worthy of credit 0Basic Basic detail of the assembly of the component

with few relevant points.

Shows basic understanding of the working mechanism.

Basic quality sketches of the component.

Basic annotation and use of technical vocabulary.

[1]–[3]

Satisfactory Satisfactory detail of the assembly of the component with some relevant points.

Shows satisfactory understanding of the working mechanism.

Satisfactory quality sketches of the component.

Satisfactory annotation and use of technical vocabulary.

[4]–[6]

12

AVAILABLE MARKS

53

Good Good detail of the assembly of the component with most relevant points.

Shows good understanding of the working mechanism.

Good quality sketches of the component.

Good annotation and use of technical vocabulary.

[7]–[9]

Excellent Excellent detail of the assembly of the component with all relevant points.

Shows excellent understanding of the working mechanism.

Excellent quality sketches of the component.

Excellent annotation and use of technical vocabulary.

[10]–[12]

[12]

5 Indicative content:

Identification of two areas suitable for jigs:

• Handlebar• Bend in the tubular frame• Jig for connecting the base to the foot• Jig for the drilling of the holes for adjusting the height of the seat• Jig for drilling alignment of the seat• Jig to align the two long bars with the foot and the handle bar

Reasons:

• Jigs to aid precision• Jigs to aid repeatability of components • Jigs to aid alignment • Jigs to ensure correct length • Jigs to ensure accuracy of angles • Jigs to aid welding • Jigs to ensure alignment of drilling


12

AVAILABLE MARKS

54

ResponseType

Description Mark Band

Level of response not worthy of credit [0]Basic Discussion points associated with the jigs are basic

in content and explanation.

The level of accuracy of spelling, punctuation and grammar is basic in most cases.

Form and style is generally inappropriate as is the use of specialist terms and technical vocabulary.

[1]–[3]

Satisfactory Discussion points associated with the jigs are satisfactory in content and explanation.

The level of accuracy of spelling, punctuation and grammar is satisfactory in most cases.

Form and style is generally appropriate as is the use of specialist terms and technical vocabulary.

[4]–[5]

Good Discussion points associated with the jigs are good in content and explanation.

The level of accuracy of spelling, punctuation and grammar is good in most cases.

Form and style is generally appropriate as is the use of specialist terms and technical vocabulary.

[6]–[8]

Excellent Discussion points associated with the jigs are excellent in content and explanation.

The level of accuracy of spelling, punctuation and grammar is excellent in most cases.

Form and style is appropriate as is the use of specialist terms and technical vocabulary.

[9]–[10]

[10] 10

AVAILABLE MARKS

55

Section B

6 (a) Compound gear system. [1]

(b) Pulley and belt [1]

(c) Any two from the list below:

• Positive drive • Has a range of output speeds • Can produce high torque

(2×[1]) [2] Correct alternative responses will be given credit.

(d) Any two from the list below:

• It can slip • It does not require lubrication • Quiet running.

(2×[1]) [2]


(e) (i) ! "

(ii) . $ - -

(iii) " !

(iv) .$ -

(4×[1]) [4] 7 (a) A metallic material consisting of two or more metals. [1]


• To improve corrosion resistance • To improve material properties e.g. hardness, strength• To lower the melting point• To reduce weight

(2×[1]) [2]


10

AVAILABLE MARKS

56

[1] [1]

(c) A lever [1]

(d)

(3 x [1]) [3]

8 (a)• Vacuum forming• Press forming• Blow moulding• Metal folding/bending

(4×[1]) [4]


(b)• Thermoplastic• Thermoplastic

(2×[1]) [2]

(c) The coat hook is heated to a suitable temperature and dipped [1] in a container of fluidised plastic powder. [1] The plastic provides an aesthetic finish [1] and provides protection from corrosion. [1]

(1×[4]) [4]


9 (a) C [1]

(b) A [1]

(c) At the end point. [1]

(d) (i) Any point to left of the apex of curve A. [1]

(ii) Any point to the right of the apex of curve A. [1]

(iii) Plastic deformation is permanent [1] where as elastic deformation is temporary. [1]

(1×[2]) [2]


7

10

.

.FE

L [1]

AVAILABLE MARKS

57

(e) Because the graph indicates it has high elasticity and plasticity [1] and will absorb a lot of energy from a crash. [1]

(1×[2]) [2]


10 (a)

Joining Techniques

Welding or brazing[1]

Nuts and bolts or machine screws [1]

Knock-down fittings or wood screws [1]

Liquid solvent cement or tensile cement [1]

Wood glue or Joints (mitre, dovetail, mortise and tenon, lap, biscuit and housing) [1]

[5] (b) Any two from the list below:

• Different melting points• Different solder composition • Different strength of joints - stronger joint in hard soldering

(2×[1]) [2]

11 (a) It is a hazardous environment. [1]


Industrial process• Circuit assembly• Fabrication• Placing of parts or components /pick and place

(2×[1]) [2]



Reasons:• Speed • Increased productivity• Increased efficiency • Increased profits • Precision

9

7

AVAILABLE MARKS

58

• Safety • Cost• Removes human fatigue

(2×[1]) [2]

Correct alternative responses will be given credit. (c) Any two from the list below:

• Human engagement not required• Can work 24/7• Carries out repetitive tasks

(2×[1]) [2]


7

100

ccea gcse specimen assessment materials for engineering and … · 2019. 9. 25. · users to stay...

Documents