Question 1: Describe the difference between bending and folding when shaping materials. Include examples of when each technique might be used.

Answer: Bending involves applying force to curve or deform a material without breaking it, such as bending a metal strip into a curve. Folding involves creasing or bending the material sharply along a line, often to create joints or edges, like folding paper to make a box.

Question 2: Explain why shaping is an important stage in the manufacturing process.

Answer: Shaping allows manufacturers to form materials into specific sizes and shapes needed for a product, improving functionality, aesthetics, and fit. It also enables the creation of complex designs and reduces waste.

Question 3: List three different shaping techniques used in metalworking and briefly describe each.

Answer: 1. Bending: deforming metal into curves or angles using a press or hand tools. 2. Forging: shaping metal by hammering or pressing when hot. 3. Rolling: passing metal through rollers to reduce thickness and create flat sheets.

Question 4: Identify which shaping process would be most suitable for creating a curved metal handle and explain why.

Answer: Bending would be most suitable because it allows the metal to be shaped into smooth curves without breaking, especially when using appropriate tools or jigs.

Question 5: Sketch a simple plan for shaping a piece of wood into a rectangular box. Include notes on how you would achieve the edges and corners.

Answer: A correct sketch would show a rectangular wooden panel, with lines indicating cuts or joints at the edges, and notes mentioning planing or sanding to smooth edges, plus possible use of joints or fasteners to assemble the sides.

Question 6: A student needs to create a curved plastic cover for a model. Which shaping technique would be most suitable and why?

Answer: Heating and moulding the plastic (forming) would be suitable because plastic becomes flexible when heated, allowing it to be shaped into curves.

Question 7: Describe the process you would use to shape a sheet of metal into a circular disc.

Answer: The process involves cutting a circle from the sheet, then using a forming or stamping process to shape it into a smooth, flat disc, possibly with the help of a die or mould.

Question 8: Draw a diagram showing how a piece of sheet metal can be bent into an 'L' shape. Label the bend lines and any tools used.

Answer: A correct sketch would show a flat sheet with two straight edges joined at a 90-degree angle, with lines indicating the bend points, and labels for tools such as a vice, hammer, or bending jig.

Question 9: What safety precautions should be taken when shaping materials using hand tools such as hammers and chisels?

Answer: Wear safety goggles to protect eyes, use gloves to prevent cuts, ensure tools are in good condition, and work on a stable surface to avoid slips or accidents.

Question 10: Explain how the choice of material affects the shaping process. Give an example of a material that is easy to shape and one that is difficult.

Answer: Materials with good ductility, like aluminium, are easy to shape because they can be bent or stretched without breaking. Hard or brittle materials, like cast iron, are difficult to shape as they tend to crack or shatter under stress.