Industrial Mechanic / Millwright Study Notes and Review: Source: PV-T May 2010 Page 1 of 53
Industrial Mechanic / Millwright Study Notes and Review: Source: PV-T May 2010 Page 1 of 53
Industrial Mechanic / Millwright Study Notes and Review: Source: PV-T May 2010 Page 1 of 53
net
Industrial Mechanic / Millwright Study Notes and Review
Questions and Answers, and various useful notes, to help you study for the
Interprovincial Examination for Industrial / Millwright / Industrial Mechanic. It is also a
great resource for your shipboard engineering knowledge.
Section Description:
5. A GOOD RULE OF THUMB FOR CALCULATING THE SAFE WORKING LOAD (S.W.L.) FOR WIRE ROPE IS
ANS. DIA. X DIA. X 8 = TONS
7. IF A WIRE ROPE HAS A CATALOUGE BREAKING STRENGTH OF 10.4 TONS, THE MAX. WORKING LOAD IS
ANS. 2.08
14. THE BRIDGE CRANE AND THE HALF GANTRY CRANE ARE VARIATIONS OF THE
ANS. GANTRY CRANE
17. THE SLING TIGHTENS ON THE LOAD AS STRAIN IS PUT ON IT IN WHICH SLING HITCH
ANS. CHOKER
19. THE IDEAL MECHANICAL ADVANTAGE OF A SIMPLE TACKLE SYSTEM EQUALS THE NUMBER OF PARTS OF
ROPES (OR FALLS)
Source : PV-T May 2010 Page 2 of 53
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Industrial Mechanic / Millwright Study Notes and Review
ANS. AT THE MOVABLE BLOCK
21. WHAT SHOULD YOU LOOK FOR WHEN INSPECTING FIBRE ROPE SLINGS
ANS. DETERIORATION DUE TO EXPOSURE, BROKEN OR CUT FIBRE, AND PROPER SPLICING
25. WHEN UNWINDING WIRE RIOE FRON A REEL BE SURE THET THE REEL
ANS. TURNS
26. WIRE ROPE THET HAS ITS STRANDS AND WIRES WOUND IN THE SAME DIRECTION
ANS. LANG LAY WIRE ROPE
27. WHEN INSTALLING U BOLT CLIPS ON A WIRE ROPE THE U OF THE CLIP SHOULD BEAR AGAINST THE
ANS. DEAD END OF THE WIRE ROPE
28. IF A U BOLT CLIP IS INSTALLED PROPERLY IT WILL PROVIDE WHAT PERCENTAGE OF THE WIRE ROPE
STRENGTH
ANS. 80%
30. HOW FAR SHOULD THE BASE OF A STRAIGHT LADDER BE PLACED FROM THE SUPPORTING WALL
ANS. OF ITS WORKING LENGTH
31. MAKE SURE THAT SCAFFOLD PLANKING DOES NOT EXTEND MORE THAN INCHES FROM CENTRE OF THE
SUPPORT BUT DOES EXTEND AT LEAST
ANS. 6 INCHES BEYOND THE CENTRE OF SUPPORT
32. GUY WIRES GIVE THE MOST SUPPORT WHEN THAT ARE POSITIONED AT AN ANGLE FROM VERTICAL OF
ANS. 458
33. THE FASTENING OF ONE PART OF A ROPE TO ANOTHER PART OF THE SAME ROPE BY INTERLACING THEM
AND DRAWING THE LOOPS TIGHT IS CALLED
ANS. KNOT
37. REASON FOR CHOPPING OFF DEAD END CABLE FROM CRANE DRUM
ANS. SHORT ENDS OD WIRE WILL FLY AROUND, CREATING A HAZARD
IF THIS INFORMATION CANNOT BE OBTAINED FROM BLUEPRINTS, SHIPPING PAPERS OR FROM ANY SOURCE, IT MAY
BE NECESSARY TO CALCULATE THE WEIGHT
EXAMPLE:
FIND THE VOLUME OF A RECTANGULAR STEEL PLATE, 6 FT. LONG AND 3 FT. WIDE AND 1 INCH THICK
OR
THE SINGLE WEIGHT IS 40.8 LBS., WHICH IS THE WEIGHT OF 1 SQ. FT. OF STEEL 1 INCH THICK WEIGHT IF STEEL PLATE
IS 18 SQ. FT. X 40.8 = 734 LBS.
OR
RULE OF THUMB - SAFE WORKING LOADS OF THE MOST MAXIMUM SAFE WORKING LOAD
COMMON WIRE ROPE USED TO COMPUTE IN TONS A TYPE ALLOY STEEL CHAIN
SINGLE VERTICLE SLING
1/8 2 3 -
3/16 2 3 -
2 4 15
5/16 2 5 30
3/8 2 6 45
7/16 2 7 65
3 11 65
9/16 3 12 95
5/8 3 12 95
4 18 130
7/8 4 19 225
1 5 26 225
1 1/8 6 34 225
1 6 37 360
1 3/8 7 44 360
1 7 48 360
1 5/8 7 51 430
1 7 53 590
2 8 71 750
2 8 73 750
2 9 84 750
2 10 100 750
3 10 106 1200
Source : PV-T May 2010 Page 6 of 53
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Industrial Mechanic / Millwright Study Notes and Review
7. WHICH OIL WILL SHOW THE SMALLEST CHANGE IN VISCOSITY FOR A GIVEN CHANGE IN TEMPERATURE
ANS. OIL (A) VISCOSITY INDEX 100
9. THE THEORY STATING THAT PRESSURE IN A CONFINED LIQUID IS DISTRIBUTED EQUALLY THROUGHOUT THE
FLUID IS
ANS. PASCALS LAW
14. SPUR GEAR, INTERNAL GEAR, SLIDING VANE AND SCREW PUMPS ARE ALL
ANS. ROTARY PUMPS
16. IN A HYDRAULIC SYSTEM REQUIRING A RANGE IN PRESSURE FROM VERY LOW TO VERY HIGH, USE A
ANS. RECIPROCATING PUMP
17. THE MOST COMMON TYPE OF PUMP USED IN HYDRAULIC SYSTEMS IS THE
ANS. ROTARY PUMP
18. TO AVOID THE POSSIBILITY OF RUPTURING THE PUMP CASING OR DISCHARGE PIPE, A POSITIVE
DISPLACEMENT ROTARY PUMP SYSTEM IS FITTED WITH
ANS. PRESSURE RELIEF VALVE
Source : PV-T May 2010 Page 7 of 53
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Industrial Mechanic / Millwright Study Notes and Review
20. WHEN A FLUID IS FLOWING AT A CONSTANT G.P.M. THROUGH TWO CONTINUOUS PIPES OF DIFFERENT
DIAMETERS THE
ANS. VELOCITY IS GREATER IN THE SMALLER PIPE
23. A SOLENOID IS OFTEN USED TO OPERATE A SMALL SPOOL VALVE THE FIRST STEP OF THE OPERATION
OCCURS WHEN
ANS. A CURRENT PASSES THROUGH THE SOLENOID
24. DIRECTIONAL CONTROL VALVES ARE IDENTIFIED BY THEIR NAME AND THE NUMBER OF
ANS. FLOW PATHS
26. THE PRESSURE AT WHICH A CHECK VALVE WILL START TO OPEN IS CALLED
ANS. CRACKING PRESSURE
29. WHAT IS ANOTHER TERM FOR THE MAXIMUM PRESSURE OD A POPPET RELIEF VALVE
ANS. SET PRESSURE
30. AN ELECTRO HYDRAULIC SERVO VALVE RECEIVES ITS OPERATING SIGNALS FROM
ANS. BOTH AN INPUT SIGNAL AND A FEED BACK SIGNAL
32. THE DIFFERENCE BETWEEN FULL-FLOW PRESSURE AND CRACKING PRESSURE IS SOMETIMES CALLED
ANS. PRESSURE OVERIDE
35. WHICH HYDRAULIC DEVIDE IS USED FOR LIFTING, TILTING, CLAMPING, OPENING, CLOSING, TURNING AND
SWINGING
ANS. ROTARY ACTUATOR
38. GENERALLY THE ROTATION OF THE SHAFT OF AN ACTUATOR DOES NOT EXCEED
ANS. 3608
39. A LARGE DIAMETER CYLINDER AND A SMALL DIAMETER CYLINDER EACH RECEIVE A FLOW OF 3 GALLONS
PER MINUTE, THEREFORE, THE
ANS. SMALLER CYLINDER TRAVELS FASTER
46. INCREASING THE FLUID FLOW THROUGH A HYDRAULIC MOTOR ALSO INCREASES
ANS. SPEED
49. IN A MECHANICAL SERVO, WHAT PART OF THE SERVO VALVE MOVES WITH THE LOAD
ANS. VALVE BODY
58. THE RESERVOIR, WHILE SUPPLING AN ADEQUATE SUPPLY OF OIL TO THE SYSTEM ALSO ALLOWS
ANS. 1. AIR IN THE SYSTEM TO ESCAPE
2. DIRT AND WATER TO SETTLE OUT
3. HEAT TO DISIPITATE
60. WHEN PRESSURE TESTING A CYLINDER THAT BUILDS UP PRESSURE UNDER NO LOAD BUT CYLINDER DOES
NOT ACTIVATE
ANS. THERE IS INTERNAL BINDING
63. THE PRESSURE AT WHICH A CHECK VALVE WILL START TO OPEN IS CALLED
ANS. ITS CRACKING PRESSURE
64. IN A HYDRAULIC SYSTEM WHAT TYPE OF VALVE REGULATES HOW SLOW OR HOW FAST
ACTUATORS OPERATE.
ANS. FLOW CONTROL OR FLOW REGULATION VALVE
71. SUMP PUMP IMPELLERS ARE PROTECTED FROM DAMAGING PARTICLES BY FITTING THE PUMP AT THE INLET
WITH
73. STATIC SUTION LIFT IS THE DISTANCE FROM THE PUMPS CENTERLINE TO
ANS. WATER SURFACE SUCTION SIDE
74. WHEN THE LIQUID BEING PUMPED IS LOCATED ABOVE THE PUMP, IT OPERATES WITH A
ANS. SUCTION HEAD
75. THE VELOCITY HEAD PLUS ALL FRICTIONAL LOSSES AND THE STATIC HEAD EQUALS THE
ANS. TOTAL DYNAMIC HEAD
76. WHEN THE FLUID IS PUMPED INTO A VESSEL UNDER PRESSURE, THE DYNAMIC HEAD
ANS. INCREASES
82. THE PACKING GLANDS OF PUMPS HANDLING HOT MATERIALS ARE USUALLY
ANS. COOLED
85. PROPELLER PUMPS THAT HANDLE GRITTY RAW WATER ARE USUALLY MADE OF
ANS. ABRASION RESISTANT ALLOYS
87. GEAR TYPE POSITIVE DISPLACEMENT PUMPS ARE MORE PROPERLY CALLED
ANS. ROTARY PUMPS
88. ALIGNMENT BETWEEN THE END CAPS AND CASINGS OF A GEAR PUMP IS MAINTAINED BY THE
USE OF
ANS. DOWEL PINS
Source : PV-T May 2010 Page 11 of 53
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Industrial Mechanic / Millwright Study Notes and Review
89. THE FLUID CANNOT RETURN TO THE SUCTION SIDE OF A GEAR PUMP BECAUSE OF
ANS. MESHING OF THE GEARS
93. SHUTTING OF THE FLUID DISCHARGE TO AN AIR-OPERATED RECIPROCATING PUMP WILL CAUSE THE PUMP
TO
ANS. STALL
95. THE VALVES IN THE LIQUID END OF A STEAM OPERATED RECIPROCATING PUMP ARE USUALLY OF THE
ANS. VALVE PLATE TYPE
96. VALVES THAT CONTROL STEAM FLOW ON THE DRIVE SIDE OF A RECIPROCATING PUMP ARE OPERATED
ANS. MECHANICALLY
98. A RECIPROCATING PUMP THAT PUMPS FLUID ON ONE SIDE OF THE PISTON IS CALLED
ANS. SINGLE-ACTING PUMP
99. THE TWO MOST COMMON CLASSES OF METERING PUMPS ARE THE
ANS. DIAPHRAGM AND PLUNGER TYPE
100. METERING OF THE FLUID IN MANY PLUNGER PUMPS IS ACCOMPLISHED BY ADJUSTING THE
ANS. CONNECTING ROD
101. IN A HYDRAULICALLY POWERED DIAPHRAGM PUMP, THE PUMP FLUID IS METERED BY THE
ANS. PUMPING FLUID
111. A COMMON TYPE OF PACKING GLAND USED FOR INDUSTRIAL PUMPS IS THE
ANS. SOLID PACKED
112. HOW MANY PACKING RINGS MAY BE ADDED AFTER THE PUMP HAS BEEN RUNNING
ANS. 1
121. AFTER INSTALLING A GEAR PUMP AND NO FLUID WILL PUMP, FIRST CHECK
ANS. ROTATION OF PUMP
125. WHAT TYPE OF LINE SHOULD BE USED ON A HYDRAULIC MOTOR ON A VIBRATING BASE
ANS. HOSE
126. WHAT IS THE MOST IMPORTANT THING TO REMEMBER WHEN MOUNTING A PUMP ABOVE
FLUID LEVEL
ANS. SHORTEST LINE POSSIBLE WITH SLIGHT RISE IN THE SUCTION LINE TO PUMP
128. MOST IMPORTANT THING TO REMEMBER WHEN ALIGNING PUMP AND MOTOR
ANS. TEMPERATURE VARIATIONS BETWEEN PUMP AND MOTOR
130. WHAT IS THE ADVANTAGE OF A STEEL FABRICATED BASE OVER A CAST IRON BASE
ANS. EASILY MODIFIED, NOT LIABLE TO CRACK
3. WHICH OF THE FOLLOWING DESCRIBES THE HARDNESS OF PLAIN BEARINGS IN RELATION TO THE
HARDNESS OF THE COMPONENTS THEY GUIDE AND SUPPORT
ANS. SOFTER
5. IF AN ANTI-FRICTION BEARING FAILS DUE TO NORMAL USE, WHAT IS THE FAILURE CALLED
ANS. FATIGUE FAILURE
6. WHICH OF THE FOLLOWING IS AN ADVANTAGE THAT PLAIN JOURNAL BEARINGS HAVE OVER ANTI-FRICTION
BEARINGS
ANS. 1. LESS RADIAL SPACE REQUIRED
2. USUALLY A LOWER FIRST COST
3. LESS RESISTENCE TO SHOCK
8. THE CHARACTERISTIC WHICH PERMITS A PLAIN JOURNAL BEARING MATERIAL TO ABSORB DIRT IS ITS
ANS. EMBEDDABILITY
9. WHICH OF THE FOLLOWING IS NOT USUALLY PART OF A STANDARD ANTI-10. FRICTION BEARING
ANS. LUBRICATION GROOVES
13. YOU ARE GOING TO PRESS A BALL BEARING ONTO A SHAFT, WHAT MUST YOU BE CAREFUL NOT TO DO
ANS. PRESS ON THE OUTER RACE
20. WHAT LOAD DOES THE FIXED BEARING CARRY IN A FIXED AND FLOATING TWO BEARING
MOUNTING
ANS. THRUST
23. WHY DID THE FULL-TYPE BEARING FAIL WHEN IT WAS USED AS A REPLACEMENT FOR A CONRAD
BEARING
ANS. CANNOT TAKE THRUST LOADS, BECAUSE OF ITS LOADING SLOT
24. THE BALL BEARING WHICH RESISTS LOAD FROM ANY DIRECTION BEST IS
ANS. DOUBLE-ROW ANGULAR-CONTACT
25. WHICH ROLLER BEARING HAS THE GREATEST LOAD CPACITY, SIZE FOR SIZE
ANS. NEEDLE ROLLER
26. OF THE FOLLOWING ROLLER BEARING, WHICH IS DESIGNED TO CARRY COMBINED RADIAL AND
THRUST LOADS
ANS. TAPERED ROLLER
27. THE TYPE OF ROLLER BEARING MOST RESISTANT TO SHOCK AND ABRASION IS
ANS. WOUND ROLLER
29. WITH THE USE OF ACIDS OR CAUSTIC SOLUTIONS, THE BEST MATERIAL TO USE FOR BEARINGS IS
ANS. PHENOLIC PLASTIC
30. WITHOUT LOSING ANY OF ITS LOAD CARRYING CAPACITY, WHICH BEARING ADJUSTS TO
MISALIGNMENT
36. SHINY SPOTS ON THE CONTACT SURFACE OF A PLAIN JOURNAL BEARING INDICATE
ANS. IMPROPER ALIGNMENT
39. FOREIGN MATTER CAN BE EFFECTIVELY KEPT OUT OF ANTI-FRICTION BALL BEARINGS BY
ANS. SEALS AND SHIELDS
40. WHAT IS THE PURPOSE OF THE TIGHTLY WOUND ENDLESS GARTER SPRING IN AN OIL OR GREASE
SEAL
ANS. TO MAINTAIN A LIGHT PRESSURE BETWEEN SHAFT AND CONTACT MATERIAL
42. WHEN INSTALLING BEARINGS USING AN OIL BATH, THE TEMPERATURE SHOULD NOT GO ABOVE
ANS. 2508 F
43. USING BOILING WATER TO INSTALL A BEARING THE TEMPERATURE WILL NOT EXCEED
ANS. 2128 F
45. WHAT STYLE OF FRICTION BEARING SHOULD BE USED IF THE LOAD IS APPLIED PARRALLEL OR
SLIGHTLY ABOVE THE HORIZONTAL
ANS. ANGLE STYLE BEARING
IF NO VISUAL SIGNS OF DAMAGE AND WEAR ARE PRESENT, HOLD THE BEARING AND ROTATE THE OUTER
RACE SLOWLY. NEVER SPIN IT. IF ANY CLICKING OR STICKING IS FOUND, RECLEAN THE BEARING. IF AFTER
CLEANING THE CONDITION STILL EXITS, REPLACE THE BEARING.
THRUST BEARING OR TAPERED ROLLER BEARINGS CAN BE INSPECTED IN THE SAME WAY, EXCEPT PLACE
THEBEARING ON A CLEAN SURFACE AND LIGHTLY APPLY HAND PRESSURE AND ROTATE THE BEARING.
IF THE BEARINGS ARE NOT TO BE REINSTALLED AT ONCE, WRAP THEM IN A CLEAN, OIL-PROOF PAOPER,
PLACE IN A CLEAN BOX AND STORE INA DRY, DUST-FREE PLACE. WHEN THE BEARINGS ARE FOUND TO BE
DAMAGED, THE CAUSE MUST BE DETER MINED OR IT MAY OCCUR AGAIN WHEN THE NEW BEARINGS IS
INSTALLED.
IF BEARINGS MAY BE REINSTALLED, INSPECT THEM CAREFULLY. WHEN SOME DOUBT EXISTS WHETHER OR
NOT TO REPLACE THE BEARING, USE THIS REASONING --- IF FREQUENT INSPECTIONS ARE GIVEN AND THE
BEARING IS EASY TO REPLACE. THEN THE RISK OF FAILURE MAY NOT BE SO GREAT; HOWERVER, IF
INFREQUENT INSPECTION TAKE PLACE AND THE BEARING IS DIFFICULT TO REMOVE AND INSTALL, THEN
THE DOUBTFUL PART SHOULD BE REPLACED WITH A NEW ONE.
IF THE BEARINGS HAVE SEALS OR SHIELDS, ALSO INSPECT THEM FOR DAMAGE AND WEAR. IF THE SEALS
ARE NOT REMOVABLE AND THEY ARE DAMAGED OR WORN, THE WHOLE BEARING MUST BE REPLACED.
BE SURE TO REPLACE THOSE SEALS THAT ARE REPLACEABLE IF THEY ARE DEFECTIVE. WORN OR DAMAGED
SEALS WILL ALLOW DIRT AND MOISTURE TO ENTER THE BEARING AND SHORTER BEARING LIFE.
VISUALLY INSPECT THE EXTERIOR OF THE BEARING FOR CRACKS IN THE RACES, DENTED SEALS, AND
BROKEN OR DAMAGED SEPARATORS, BALLS OR ROLLERS. IF THE BEARINGS HAS BEEN OVERHEATED, IT
WILL BE A BROWNISH BLUE OR BLUISH BLACK COLOUR. IF ANY OF THESE SIGNS ARE FOUND, THE
BEARING SHOULD BE REPLACED.
INSPECT SEPARABLE BEARINGS FOR PITTED, SCRATCHED OR FLAKED BALLS, ROLLERS, OR RACES. REPLACE
THE BEARING IF ANY OF THESE SIGNS OF DAMAGE ARE FOUND.
THE INNER SURFACES AND ROLLER ELEMENTS IN A SUSPECTED NON-SEPARABLE BEARING MAY BE
EXAMINED WITH EITHER A SMALL FLASHLIGHT OR REFLECTED LIGHT FROM A STRONG LIGHT SOURCE.
ANY VISIBLE PITS OR SCRATCHES ARE SIGNS OF DAMAGE AND THE BEARING SHOULD BE REPLACED.
Source : PV-T May 2010 Page 18 of 53
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Industrial Mechanic / Millwright Study Notes and Review
PNEUMATICS & COMPRESSORS
1. WHAT IS THE MOST COMMON METHOD OF REMOVING WATER VAPOUR FROM COMMPRESSED AIR
ANS. CONDENSATION
2. THE AMOUNT OF CONDITIONING REQUIRED BY THE COMPRESSED AIR AFTER IT LEAVES THE COMPRESSER
IS DETERMENED BY THE
ANS. USE IN WHICH THE AIR IS PUT
5. IN A PNEUMATICS SYSTEM, THE FORCE THAT DOES THE WORK IS SUPPLIED IN THE FORM OF
ANS COMPRESSED AIR
10. IN MULTISTAGE COMPRESSORS, THE REQUIRED AIR PRESSURE IS CREATED BY COMPRESSING THE AIR IN
ANS TWO OR MORE UNEQUAL CYLINDERS
11. WHAT TYPE OF COMPRESSOR WILL DELIVER LARGE VOLUMES OF OIL-FREE AIR AT APPROXIMATELY 100
P.S.I
ANS. ROTARY DRY SCREW
14. DUST PARTICLES THAT CONTACT OIL SPRAY AND MIST USUALLY
ANS. COLLECT IN THE LUBRICANT
15. THE MOST EFFCIENT WAY OF REMOVING LARGE PARTICLES FROM THE AIR STREAM IS BY USING
ANS. A SURFACE FILTER
18. WHAT IS THE PURPOSE OF FLARED CONNECTIONS WITH LONG SHOULDERED NUTS
ANS. TO PROVIDE SUPPORT
Source : PV-T May 2010 Page 19 of 53
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Industrial Mechanic / Millwright Study Notes and Review
24. AUTOMATICALLY OPERATED FLOW CONTROL VALVES ARE MOST COMMONLY ACTUATED BY
ANS. SOLENOIDS
24. THE BEST LOCATION FOR A PRESSURE REGULATOR VALVE IN A PNEUMATIC SYSTEM IS
ANS. AT AN AIR STATION
29. A CYLINDER THAT PRODUCES WORK ONLY ON ITS RETURN STROKE IS CALLED
ANS. SINGLE-ACTION CYLINDER
30. A PNEUMATIC CYLINDER FURNISHES WITH THE MOUNTING LUGS OR FEET IS CLASSIFIED AS
BEING
ANS. FIXED, NON-CENTERLINE MOUNTED
33. THE PRIMARY PURPOSE OF ALL THE PRESSURE CONTROLS IN A PNEUMATIC SYSTEM IS TO
ANS. LIMIT AIR PRESSURE
34. WHICH OF THE TYPES OF RELIFE VALVES PROVIDE THE SMOOTHEST RELIFE CONTROL
ANS. DIAPHRAGM
38. THE MOST COMMON QUANTITIES MEASUREED AND CONTROLLED IN INDUSTRY ARE
ANS. TEMPERTURE, PRESSURE, FLOW AND LIQUID LEVEL
41. RATE CONTROL IN THE CONTROLLERS IS USED TO PROVIDE ADDITIONAL OUTPUT WHEN THE
PROCESS IS
ANS. CHANGING
46. ON MOST PRESSURE GUAGES A READING OF ZORE INDICATES THE GAUGE IS MEASURING
ANS. ATMOSPHERIC PRESSURE AND 30 INCHES OF MERCURY
47. THE HORSE POWER OUTPUT OF A PNEUMATIC MOTOR IS CALCULATED ON THE BASIS OF THE
MOTORS
ANS. TORQUE AND SPEED
48. ALL PNEUMATIC MOTORS ARE CONSTRUCTED WITH A MECHANICAL SEAL AND OPERATE ON THE
PRINCIPLE OF
ANS. POSITIVE DISPLACEMENT
49. WHAT IS THE MOST IMPORTANT CONSIDERATION WHEN SELECTING A PNEUMAIC MOTOR
ANS. AIR CONSUMPTION
57. IN MULTISTAGE COMPRESSORS, THE REQUIRED AIR PRESSURE IS CREATED BY COMPRESSING THE
AIR IN
ANS. TWO OR MORE UNEQUAL CYLINDERS
61. THE COMPRESSING LOADS OF A WET SCREW COMPRESSOR ARE DRIVEN WITHOUT
ANS. TIMING GEARS
63. THE MOST EFFICIENT METHOD OF CONTROLLING THE OURPUT OF A CENTRIFUGAL COMPRESSOR
IS BY
ANS. SPEED VARIATION
70. WHAT PRIME MOVERS ARE USED WHEN A COMPRESSOR USES VARIABLE SPEED CONTROL
METHOD
ANS. STEAM ENGINE, STEAM TURBINE AND INTERNAL COMBUSTION ENGINE
81. WHAT IS THE REASON FOR A COMPRESSOR TO BE UNABLE TO REACH REQUIRED PRESSURE
ANS. AIR LEAKS OR BLOW BY
2. WHAT TYPE OF CONVEYOR PROVIDES THE SIMPLEST AND MOST ECONOMICAL METHOD OF TRANSPORTING
GOODS
ANS GRAVITY CONVEYORS
3. ON THE POWER AND FREE CONVEYORS WHAT HOLDS THE POWER AND FREE TRACKS FIRMLY IN THE
CORRECT POSITION WITH EACH OTHER
ANS. YOKES
8. TO TRACK A BELT WHICH IS RUNNING OFF AT THE HEAD PULLY YOU SHOULD
ANS. TIGHTEN AGAINST THE SIDE RUNNING OFF
14. HOW ARE THE BOLT HOLES MARKED OFF ON THE BELT FOR MOUNTING THE BUCKETS
ANS. STEEL SQUARE
18. SHORT PITCH AND HALF PITCH SCREW CONVEYORS ARE MOSTLY USED ON
ANS. VERTICAL OR INCLINED CONVEYORS
Source : PV-T May 2010 Page 24 of 53
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Industrial Mechanic / Millwright Study Notes and Review
20. LAP JOINTS ARE MADE BY LAPPING THE ENDS OVER EACH OTHER FOR A DISTANCE OF
ANS. EQUAL TO THE WIDTH OF THE BELT
24. WHEN MEASURING A BELT THAT IS TO BE JOINED WITH A CEMENT SPLICE, ALLOWANCE MUST BE MADE
FOR THE
ANS. OVERLAP
25. WHAT TYPE OF TRANSFER WOULD BE USED TO MOVE A PIECE OF SHEET METAL (LAYING FLAT) IN ANY
DIRECTION HORIZONTALLY
ANS. BALL TRANSFER
26. WHAT TYPE OF BEARING IS BEST USED IN SCREW CONVEYOR HANGERS T0 ASSURE ACCURATE
ALIGNMENT OF THE BEARING WITH THE AXIS OF THE CONVEYOR SCREW
ANS. SELF-ALIGNING BALL BEARING
28. WHEN A THRUST BEARING IS INSTALLED ON A SCREW CONVEYOR, HOW IS THE LOCATION OF THE THRUST
BEARING DETERMINED
ANS. DEPENDING ON THE DIRECTION OF MATERIAL TRAVEL
30. TO TRACK A CONVEYOR BELT WHICH IS RUNNING OFF IN THE CENTRE SECTION YOU SHOULD
ANS. 1. MOVE THE SIDE OF THE IDLER THAT THE BELT IS RUNNING OFF IN THE SAME DIRECTION THE BELT IS
TRAVELLING
2. SHIM THE SIDE OF THE IDLER THAT THE BELT IS RUNNING OFF
33. WHEN FORMING A COMPOUND VERTICAL CURVE, THE PURPOSE OF THE STRAIGHT SECTION OF THE TRACK
IS TO GAIN
ANS. THE REQUIRED ELEVATION
34. WHAT CAN BE USED TO FEED BOTTLES INTO A BOTTLE WASHING MACHINE FROM A SLAT BAND CHAIN
ANS. A SERIES OF SEPARATION PLATES AND DUPLES ROLLER CHAIN
35. WHICH CONVEYOR CHAIN BY ITS SIMPLE DESIGN PERMITS ASSEMBLY DISMANTLING WITHOUT THE USE OF
TOOLS
36. AN ACCEPTABLE METHOD USED TO DETERMINE CHAIN SAG ON CHAIN DRIVE EQUIPMENT IS TO
COMPUTE
ANS. 4% OF THE DISTANCE BETWEEN SHAFT CENTRES
38. THE PURPOSE OF LEATHER WASHERS BETWEEN THE BUCKETS AND THE
ANS. 1.ABSORB THE SHOCK AS BUCKETS PASS OVER THE PULLEY
2. HELP TO SEAL BOLT HOLES AGAINST MOISTURE
40. WHY DO INDIVIDUAL ROLLER CHAIN ASSEMBLIES HAVE AN ADVANTAGE OVER OTHER ROLLER CHAIN
ASSEMBLES
ANS. 1.APPROX. 180 DEGREES WRAP AROUND EACH SPROCKET
2.SUITABLE FOR REVERSING
43. ON SOME PNEUMATIC CONVEYORS WHAT INTRODUCES A FIXED AMOUNT OF SOLIDS INTO THE AIR
STREAM AND ALSO ACTS AS AN AIR SEAL
ANS. A SCREW FEEDER WITH ROTARY AIR LOCK
44. LAP JOINTS OF AN ELEVATOR BELT ARE MADE BY LAPPING THE ENDS OVER EACH OTHER FOR A
DISTANCE EQUAL TO
ANS. THE WIDTH OF THE BELT
NOTE: IF PULLEY DIAMETERS ARE SMALL, USE A HINGED TYPE TWO-PLATE FASTENER OR MAKE THE
JOINT A 45 DEGREE ANGLE AND USE STANDARD TWO-PLATE FASTENERS
NOTE: IF PULLEY DIAMETERS ARE SMALL, USE A HINGED TYPE TWO-PLATE FASTENER OR MAKE THE
JOINT 45 DEGREE ANGLE AND USE STANDARD TWO-PLATE FASTENERS
DRIVES
1. THE VARIABLE OUTPUT SPEED OF A BELT TYPE VARIABLE SPEED DRIVE IS CONTROLLED WITH
ANS. ADJUSTABLE PULLY FLANGES
2. THE SHAFT BEARINGS USED TO PREVENT GREASE FROM GETTING ON THE DRIVING BELT OF A
VARIABLE SPEED UNIT ARE
ANS. SEALED FOR LIFE
3. THE SIZES OF A V BELT ARE DESIGNATED BY NUMBERS OR LETTERD GROUPS, BUT THE ACTUAL
SIZE IS DETERMINED BY ITS
ANS. CROSS-SECTIONAL AREA
4. WHEN MULTIPLE DRIVE V BELTS ARE MADE TO GETHER IN THE FORM OF ON COMMON BELT,
THEY ARE CALLED
ANS. GROUP BELTS
6. TIMING BELTS ARE MADE WITH MOULDED TEETH ON THE INSIDE FACE TO PROVIDE A
ANS. POSITIVE TRANSFER OF POWER
7. UNLIKE STANDARD V BELTS, THE PITCH LINE OF A TIMING BELT IS LOCATED ON THE
ANS. CHORD LINE
10. WHAT TYPE OF SPEED CHANGE CAN BE MADE BY A MANUALLY ADJUSTABLE SHEAVE
ANS. SMALL
14. WHAT TYPE OF SIDEBARS ARE USED FOR HEAVY DUTY FABRICATION
ANS. STRAIGHT AND OFFSET
15. A MODIFIED LEAF CHAIN THAT FORMS A TOOTH PATTERN WHEN IT IS ASSEMBLED IS A
ANS. SILENT DRIVEN CHAIN
16. WHICH DRIVE CHAIN SHOULD BE USED WHEN OPERATING IN CORROSIVE OR WET CONDITIONS
Source : PV-T May 2010 Page 28 of 53
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Industrial Mechanic / Millwright Study Notes and Review
ANS. CAST CHAIN
17. SPROCKETS ARE FREQUENTLY DESCRIBED BY THE LETTERS A, B AND C. THESE LETTERS
REFER TO THE
ANS. CLASS OF THE HUB
18. ALL DRIVE CHAINS HAVING OFFSET SIDEBAR CONSTRUCTION ARE FURNISHED IN
ANS. SINGLE PITCH MULTIPLES
20. THE OUTPUT SPEED OF A GEAR SPEED REDUCER IS DETERMINED BY THE REDUCERS
ANS. INPUT SPEED AND RATIO
26. THE DISTANCE FROM THE CENTRE OF ONE TOOTH TO THE CENTRE OF THE NEXT TOOTH ON THE
PITCH CIRCLE IS CALLED THE
ANS. CIRCULAR PITCH
27. THE CLEARANCE BETWEEN MATING TEETH OF TWO GEARS AT THE PITCH LINE IS CALLED
ANS. BACKLASH
29. THE DISTANCE THAT ONE THREAD ADVANCES DURING ONE COMPLETE TURN OF THE WORM IS
CALLED
ANS. LEAD
30. THE RADIAL DISTANCE THAT A GEAR TOOTH EXTENDS INTO THE SPACE BETWEEN TWO TEETH
ON A MATING GEAR IS CALLED
ANS. WORKING DEPTH
31. THE POSITION OF THE ROLLERS IN A ROLLER TYPE VARIABLE SPEED DRIVE IS SHIFTED WITH A
ANS. RACK AND PINION DEVICE
32. WHAT IS USED WITH A SHAFT-MOUNTED REDUCER TO PREVENT IT FROM ROTATING AND
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Industrial Mechanic / Millwright Study Notes and Review
PROVIDE MEANS OF ADJUSTING V BELT TENSION
ANS. TIE ROD
34. BEFORE INSTALLING A SHAFT MOUNTED REDUCER, THE SHAFT SHOULD BE CHECKED FOR
ANS. BENT SECTIONS, ROUNDNESS AND MISALIGNMENT
37. HOW IS TENTION MAINTAINED ON V BELTS WHEN USED WITH SHAFT-MOUNTED REDUCERS
ANS. TIE ROD
40. BOTH MECHANICAL AND ELECTRICAL PROTECTION AGAINS OVERLOADS ON THE SHAFT-
MOUNTED REDUCERS IS PROVIDED BY AN
ANS. OVERLOAD RELEASE
44. OVER-RUNNING CLUTCHES ARE DESIGNED TO PERMIT ROTATION OF THE DRIVING FORCE
ANS. IN THE FORWARD DIRECTION ONLY
46. REASON WHY SHAFT WILL NOT TURN IN THE REDUCTION UNIT
ANS. BEARING TOO TIGHT - - - INSTALL SHIMS
48. WHAT TYPE OF CHAIN CAN BE TAKEN APART WITHOUT DISCONNECTING LINKS OR PINS
ANS. DETACHABLE CHAIN
49. WHAT DOES WEAR ON THE SIDE OF A SPOCKET AND THE INSIDE OF A CHAIN LINK MEAN
56. WHAT TYPE OF FLEXIBLE COUPLING IS USED FOR HIGH TORQUE, LOW SPEED
ANS. SLIDER COUPLING
57. IN A THREE SHAFT REDUCTION UNIT WHICH SHAFT CAN HAVE BEARING FAILURE THAT IS NOT EASILY
DETECTED
ANS. INTERMEDIATE SHAFT
58. WHAT REDUCTION IS OBTAINED BY A 2 THREAD WORM DRIVING A WORM GEAR WITH 60 TEETH
ANS. 30: 1
60. ON A FLAT BELT DRIVE WITH VARIOUS PULLEY WIDTHS, THE BELT WIDTH IS DETERMINED BY
ANS. THE NARROWEST PULLEY
61. ON A SHAFT WITH THREE SPLIT ANTI-FRICTION PILLOW BLOCKS, HOW MANY BEARINGS SHOULD BE FIXED
ANS. ONE
62. A HEAVY LOADED DRIVE HAS TO BE REPEATEDLY STARTED, MOTOR OVERLOAD IS REDUCED BY USING
ANS. CENTRIFUGAL COUPLING
64. THE MECHANISM THAT CAN BE USED TO CHANGE DIRECTION OF MOTION AND INCREASE OR DECREASE
FORCE OR TRAVEL IS A
ANS. BELL CRANK
A = ARC OF CONTACT
D = LARGER DIAMETER OF SHEAVE (IN INCHES)
d = SMALLER DIAMETER OF SHEAVE ( IN INCHES )
C = CENTRE DISTANCE ( IN FEET )
NOTE: - - - LENGTH OF BELT BETWEEN PULLEYS CAN BE APPROXIMATED BY USING THIS FORMULA.
THE DIFFERENCE OF ERROR INCREASES WITH THE VARIOUS CHANGES IN SIZES BETWEEN THE PULLEYS
L = LENGTH
D = DIAMETER IN INCHES
C = CENTRE DISTANCE IN INCHES
4. HOW CAN YOU SLIGHTLY INCREASE THE ARC OF CONTACT WITH TWO PULLEYS OF UNEQUAL DIAMETER
RPM OF DRIVEN GEAR = NUMBER OF TEETH OF DRIVEN GEAR X RPM OF DRIVEN GEAR
NUMBER OF TEETH OF DRIVER
NUMBER OF TEETH OF DRIVER GEAR = NUMBER OF TEETH OF DRIVEN GEAR X RPM OF DRIVEN GEAR
RPM OF DRIVER
CHAIN DEFINITIONS
DRIVE SPROCKET:
USUALLY, THE DRIVER SPROCKET IS THE SMALLER OF THE TWO SPROCKETS AND THE ONE HAVING THE
HIGHEST R.P.M.
DRIVEN SPROCKET:
THE DRIVEN SPROCKET IS USUALLY THE LARGER OF THE SPROCKETS AND THE ONE HAVING THE SLOWER
R.P.M.
CHAIN PITCH:
THIS IS THE DISTANCE ( IN INCHES ) FROM THE CENTRE OF ONE CONNECTING PIN TO THE CENTRE OF THE
NEXT.
CENTRE DISTANCE:
THE CENTRE DISTANCE IS THE DISTANCE ( IN INCHES ) BETWEEN THE CENTRES OF DRIVER AND DRIVEN
SHAFTS.
CHAIN LENGTH:
THE CHAIN LENGTH IS THE DISTANCE FROM CENTRE LINE OF THE CONNECTING PIN AT ONE END OF THE
STRAND TO THE EMPTY CONNECTING HOLE AT THE OPPOSITE END. CHAINS CAN BE MEASURED IN FEET
AND INCHES, OR IN PITCHES.
CHAIN RATING:
THE CHAIN RECOMMENDED WORKING LOAD, IS THE LOAD IN POUNDS THAT THE CHAIN WILL
SATISFACTORILY HANDLE OVER EXTENDED PERIODS OF TIME. MOST MANUFACTURERS RATE THEIR
CHAINS IN MAXIMUM OR AVERAGE WORKING LOAD.
ULTIMATE STRENGTH:
THIS IS THE STRENGHT OF THE CHAIN BEFORE IT WILL BREAK. THIS IS NOT A GOVERNING FACTOR IN THE
SELECTION OF THE CHAIN. HOWEVER, IT GIVES YOU THE SHOCK LOADING CAPACITY OF THE CHAIN.
PITCH DIAMETER:
THIS IS THE THEORETICAL CIRCLE DESCRIBED BY THE CENTRE LINE OF THE CHAIN AS IT PASSES OVER THE
SPROCKET. THE P. D. OF A SPROCKET IS USUALLY BELOW THE TOP OF THE TOOTH OR OUTSIDE DIAMETER
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(O. D.) OF THE SPROCKET. ON DRIVES THAT HAVE SHORTENED TEETH (SUCH AS SILENT CHAINS) THE PITCH
DIAMETER MAY BE LARGER THAN THE DIAMETER OF THE CIRCLE AT THE TOP OF THE TEETH.
STANDARD ROLLER CHAIN NUMBERS
THE RIGHT HAND FIGURE IN THE CHAIN NUMBER IS ZERO FOR ROLLER CHAINS OF THE USUAL PROPORTIONS, 1 FOR A
LIGHTWEIGHT CHAIN AND 5 FOR A ROLLERLESS BUSHING CHAIN.
THE NUMBER TO THE LEFT OF THE RIGHT-HAND FIGURE DENOTES THE NUMBER IF 1/8 INCH IN THE PITCH.
THE LETTER H FOLLOWING THE CHAIN NUMBER DENOTES THE HEAVY SERIES, THUS THE NUMBER 80H DENOTES A 1
INCH PITCH HEAVY CHAIN.
THE HYPHENATED NUMBER 2 SUFFIXED TO THE CHAIN NUMBER DENOTES A DOUBLE STRAND, 3 A TRIPLE STRAND, 4
A QUADRUPLE STRAND AND SO ON.
HEAVY SERIES:
THESE CHAINS MADE IN INCH AND LARGER PITCHES HAVE THICKER LINK PLATES THAN THOSE OF THE REGULAR
STANDARD.
THIS CHAIN IS DESIGNATED AS NO. 41. IT IS INCH PITCH, INCH WIDE HAS 0.306 DIAMETER ROLLERS, 0.141 INCH
PIN DIAMETER AND SIDE PLATES 0.050 INCH THICK, MEASURING LOAD IS 18 POUNDS.
METALLURGY
BRITTLENESS -IS THE PROPERTY OF A METAL WHICH PERMITS NO PERMANENT DISTORTION BEFORE BREAKING. CAST
IRON, WHICH BREAKS EASILY, IS AN EXAPLE OF BRITTLE METAL.
DUCTILITY - IS THE ABILITY OF THE METAL TO BE PERMANENTLY DEFORMED WITHOUT BREAKING. METALS
SUCH AS MACHINE ( MILD ) STEEL, WHICH MAY BE DRAWN INTO WIRE IS A DUCTILE MATERIAL.
ELASTICITY - IS THE ABILITY OF A METAL TO RETURN TO ITS ORIGINAL SHAPE AFTER ANY FORCE, ACTING UPON
IT, HAS BEEN REMOVED. PROPERLY HEAT-TREATED SPRINGS ARE GOOD EXAMPLES OF ELASTIC MATERIALS.
MALLEABILTY -IS THAT PROPERTY OF A METAL, WHICH PERMITS IT TO BE HAMMERED OR ROLLED INTO OTHER SIZES
AND SHAPES.
TENSILE STRENGTH - IS THE MAXIMUM AMOUNT OF PULL THAT A MATERIAL WILL WITHSTAND BEFORE BREAKING. IT
IS EXPRESSED AS THE NUMBER OF POUNDS PER SQUARE INCH OF PULL THAT IS REQUIRED TO BREAK A BAR HAVING
A CROSS SECTION OF ONE SQUARE INCH.
ANNEALING -ANNEALING CONSISTS OF HEATING STEEL TO ABOVE ITS CRITICAL RANGE AND THEN ALLOWING IT TO
COOL SLOWLY.
NORMALIZING -IT CONSISTS OF HEATING SOMEWHAT ABOVE CRITICAL THE RANGE, FOLLOWED BY AIR-COOLING.
HARDENING -IS ACOMPLISHED BY HEATING THE STEEL BEYOND THE CRITICAL TEMPERATURE AND FOLLOWING BY
RELATIVELY FAST COOLING. IF HEATING FOR HARDENING IS BEING ACCOMPLISHED IN THE FORGE FIRE THE COLOR
SHOULD BE A FULL RED AND TO CHECK ON THE TEMPERATURE A MAGNET MAY BE USED, AS THE STEEL AT OR ABOVE
THE CRITICAL TEMPERATURE SHOULD BE NON-MAGNETIC. IF THE MAGNET IS BEING USED WHILE THE TEMPERATURE
IS BEING RAISED FROM THE ROOM TEMPERATURE, THE CORRECT POINT TO STOP HEATING IS WHERE THE STEEL NO
LONGER RESPONDS TO THE PULL OF THE MAGNET. IF A FURNACE IS BEING USED TO HEAT THE STEEL TO THE
HARDENING HEAT A PYROMETER AIDS GREATLY IN DETERMINING THE CRITICAL TEMPERATURE.
TEMPERING -TEMPERING IS THE APPLICATION OF HEAT AFTER HARDENING. THE PURPOSE IS TO RELIEVE SOME OF
THE HARDENING STRAINS AND ALSO TO SOFTEN THE STEEL. TEMPERING IS ACCOMPLISHED BY HEATING TO SOME
PREDETERMINED TEMPERATURE AND FOLLOWED BY ANY RATE OF COOLING.
5. SCRAP STEEL, LIMESTONE AND MOLTEN PIG IRON ARE THE BASIC CHARGE FOR
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ANS. OPEN HEARTH FURNACE
12. WHICH IS NOT A FERROUS METAL COPPER, CAST IRON, STEEL OR WROUGHT IRON.
ANS. COPPER
14. WHICH OF THE FOLLOWING FERROUS METALS IS SO BRITTLE THAT IT CAN BE EASILY BROKEN
ANS. CAST IRON
23. THE UPPER LIMIT OR STRENGTH OF STEEL BEYONG WHICH IT WILL NOT RETURN TO ITS ORIGINAL
SHAPE IS CALLED
ANS. ELASTIC LIMIT
24. THE FURNACES WHICH HAVE THEIR HEARTH OPEN TO THE FLAMES WHICH MELT THE CHARGE IS
CALLED
ANS. OPEN HEARTH
26. IDENTIFYING METALS BY OBSERVING THE SPARKS WHEN THE METAL IS HELD TO A GRINDING
WHEEL IS CALLED
ANS. SPARK TEST
28. IN A BLAST FURNACE THE FIRST STEP IN THE MANUFACTURING OF CAST IRON OR STEEL IS THE
PRODUCTION OF
ANS. PIG IRON
31. WHAT IS THE CHIEF RAW MATERIAL USED TO MAKE IROM STEEL
ANS. IRON ORE
6. HOW IS OIL KEPT FROM RUNNING OUT THE SHAFTS OF A GEAR BOX
ANS. BY USING AN OIL SEAL
7. PARALLEL SHAFT REDUCERS HAVING SPLASH LUBRICATION REQUIRE THE REDUCER TO HAVE
ANS. OIL TROUGHS OR DAMS
8. WHAT IS USED WITH OIL WHEN USING THE OIL MIST LUBRICATION SYSTEM
ANS. CLEAN DRY AIR
FABRICATION
3. SHEET METAL IS A FLAT METAL 12 OR MORE INCHES WIDE WITH A THICHNESS LESS THAN
ANS. 0.25
5. BENDS ARE MADE WHEN FORMING SHEET METAL, OVER DIFFERENT TYPES OF STEEL ANVILS
CALLED
ANS. BENCH STAKES
8. REMOVING THE BURRS AND JAGGED AREAS ON CUT SHEET METAL IS KNOWN AS
ANS. DRESSING
9. THE CURVED SLIVERS OF METAL THAT SOMETIMES REMAIN ON THE EDGE OF CUT SHEET METAL
IS CALLED
ANS. FISH HOOKS
10. WHAT MATERIALS MAY THE FACE OF SOFT- FACED HAMMERS BE MADE OF
ANS. PLASTIC, COPPER AND LEAD
8. THE JOINING OF TWO OR MORE PIECES OF METAL BY MELTING THEM AD CAUSING THEM TO FLOW
TOGETHER IS KNOWN AS
ANS. FUSION WELDING
10. THE ACETYLENE REGULATOR MAY BE DISTINGUISHED FROM THE OXYGEN REGULATOR BY
ANS. THE GRUVE CUT IN THE CIRCUMFERENCE OF THE REGULATOR CONNECTING THE NUT
3. WHEN USING A OPEN END WRENCH DOUBLE HEAD ( DOUBLE ENDED WRENCH ) HOW CAN YOU LOOSEN
A NUT IN A RECTRICTED PLACE
ANS. TURN THE WRENCH OVER
4. WHEN USING A OPEN END WRENCH, WHY IS IT BEST TO PULL THE WRENCH IN THE CORRECT DIRECTION
ANS. TO AVOID SPREADING THE WRENCH OPENING
10. WHEN SMALL PARTICALS OF THE MATERIAL BEING FILLED BECOMES CLOGGED IN THE TEETH OF THE FILE IT
IS CALLED
ANS. PINNING
12. WHAT IS THE LEAST NUMBER OF TEETHWHICH SHOULD CONTACT THE MATERIAL BEING SAWED
ANS. TWO TEETH
13. THE THIN SECTION BETWEEN THE FLUTES ON A DRILL GIVES RIGIDITY AND STRENGTH WHICH IS CALLED
THE
ANS. WEB
5. THE TOOL HOLDER RECOMMENDED FOR MACHINING WORK CLOSE TO THE LATHE CHUCK JAWS
IS THE
ANS. LEFT HAND
8. A DRILL DRIFT IS
ANS. A TAPERED WEDGE USED FOR REMOVING DRILLS
11. WHAT TWO ATTACHMENTS COULD BE USED ON THE LATHE TO SUPPORTA CYLINDRICAL SHAFT
DURING MACHINING
ANS. STEADY REST AND FOLLOW REST
12. USING TWO SIDE MILLING CUTTERSTO MACHINE THE OPPOSITE SIDES OF A
WORKPIECEPARALLEL IN ONE CUT IS CALLED
ANS. SRTADDLE MILLING
13. WHAT IS THE NAME OF THE MILLING MACHINE ATTACHMENT, WHICH CONVERTS THE ROTARY
MOTION OF THE SPINDIL INTO RECIPROCATING MOTION FOR CUTTING KEYWAYS, SPLINES ETC.
ANS. SLOTTING ATTACHMENT
16. WHEN TURNING A SHAFT IN A LATHE WITH TAIL STOCK OFF CENTRE
ANS. SHAFT WILL BE TAPERED
17. TO TURN DOWN A SQUARE SHAFT IN A LATHE WHAT TYPE OF CHUCK IS USED
ANS. FOUR JAW INDIPENDAN CHUCK
B. JARNO: 6 PER FOOT RANGE IN SIZE FROM #2 TO #20 (SOME VERTICAL MILLING MACHINE
SPINDLES)
C. BROWN AND SHARPE TAPER 5 PER FOOT RANGE IN SIZE FROM #1 TO #18
D. STANDARD TAPER PIN PER FOOT USED FOR THE ASSEMBLY AND ALIGNMENT OF MACHINERY
E. AMERICAN STANDARD STEEP MACHINE TAPER 3 PER FOOT RANGE IN SIZE FROM #5 TO #60
(#40 AND #50 TAPERS ARE SIZES USED FOR MILLING MACHINES)
FASTENING TECHNIQUES
1. IF YOU HAVE A TRIPLE STAR SHREAD WITH A PITCH OF .0833, HOW FAR WILL A NUT MOVE ALONG THE
SHAFTIN ONE COMPLETE REVOLUTION.
ANS. 0.2499
4. WHICH OF THE FOLLOWING KEYS REQUIRE A SPECIAL SHAPE MILLING CUTTER TO PRODUCE THE KEYSEAT
ANS. WOODRUFF KEY
10. STANDARD TAPER PINS HAVE THE FOLLOWING TAPER PER FOOT
ANS. INCH
16. THE DISTANCE FROM A POINT ON A THREAD TO THE CORRESPONDING POINT ON THE NEXT THREAD IS
CALLED
ANS. PITCH
THREAD TERMINOLOGY
MAJOR DIAMETER - OR OUTSIDE DIAMETER IS THE LARGEST DIAMETER OF A SCRWE THREAD OF NUT
MINOR DIAMETER IS THE SMALLEST DIAMETER ACROSS THE BOTTOM. THIS WAS FORMERLY KNOWN AS THE ROOT
DIAMETER.
INCLUDE ANGEL OF A THREAD IS THE ANGEL BETWEEN EACH SIDE OF THE THREAD. FOR EXAMPLE, THE INCLUDED
ANGEL OF A AMERICAN NATIONAL FORM THREAD IS 608
PITCH (P) IS THE DISTANCE FROM ANYONE ONE POINT ON ONE THREAD TO THE CORRESPONDING POINT ON THE
NEXT THREAD MEASURED ALONG THE LENGTH OF THE WORK, OR P = .1/TPI (THREAD PER INCH )
LEAD IS THE DISTANCE THREAD ADVANCES IN ONE COMPLETE TURN ALONG ITS AXIS. FOR EXAMPLE ON A SINGEL
THREAD THE LEAD IS EQUAL TO THE PITCH; ON A DOUBLE THREAD (THE THREAD WITH TWO STARTS) THE LEAD IS
EQUAL TO TWICE THE PITCH
DEPTH OF THREAD IS THE VERTICAL DISTANCE FROM THE ROOT TO THE CREST OF THE THREAD
PITCH DIAMETER IS THE DIAMETER OF AN IMAGINARY CYLINDER EQUAL TO HALF THE DEPTH OF THE THREAD, IT IS
THE BASIC DIAMETER FOR ROLLING THREADS
HELIX ANGLE IS THE ANGLE DEVILOPED BY THE CIRCUMFRENCE OF THE OUTSIDE DIAMETEROF THE THREAD AND
THE PITCH, THE HELIX ANGLE IS REQUIRED FOR THREAD ROLLING DIES OR FOR THREAD MILLING
TOLERANCE IS THE AMOUNT OF VARIATION PERMITED IN THE SIZE OF A PART, FOR EXAMPLE, A TOLERANCE OF
.002 IMPLIES A VARIATION OF + OR - .001
7/8 9 UN C 2 A-B
7/8= DIAMETER OF THREADS
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9= NUMBER OF THREADS PER INCH
UN= UNIFIED NATIONAL FORM THREADS
C= THREAD SERIES
2= CLASS OF FIT
A-B= EXTERNAL OR INTERNAL THREADS
SCREW THREAD CLASSES TO FIT HAVE BEEN ESTABLISHED FOR THE PURPOSE OF ASSURING THE
MANUFACTURE OF INTERCHANGABLE SCREW THREAD PARTS.
THESE CLASSES INCLUDE 1A, 2A, AND 3A AS APPLIED TO EXTERNAL THREADS, AND 1B, 2B, AND 3B
APPLIED TO INTERNAL THREADS.
THE REQUIREMENTS FOR A SCREW THREAD FITFOR SPECIAL APLICATIONS CAN BE MET BY SPECIFYING
THE PROPER COMBINATION OF CLASSES FOR THE COMPONENTS. MOST REQUIREMENTS, HOWEVER,
WILL BE SATISFIED BY SELECTING ONE OF THE FOLLOWING COMBINATIONS; ANY VARIATION IN THESE
THREAD ELEMENTS MUST BE DEDUCTED FROM THE PITCH DIAMETER TOLERENCE .
CLASS 1A AND 1B --- THESE CLASSES 1A EXTERNAL AND 1B INTERNAL ARE USED ON THREDED
COMPONENTS WHERE QUICK AND EASY ASSEMBLY IS NECESSARY,AND WHERE A LIBERAL ALLOWANCE IS
REQUIRED TO PERMIT READY ASSEMBLY, EVEN WITH SLIGHTLY BRUISED OR DIRT CLOGGED THREADS
CLASSES 2A AND 2B --- THESE CLASSES 2A EXTERNAL AND 2B INTERNAL, ARE DESIGNED FOR SCREWS,
BOLTS, AND NUTS. THEY ARE ALSO SUITED FOR A WIDE VARIETY OF OTHER APPLICATIONS.AN
ALLOWENCE IS PROVIDED WHICH MINIMIZES GALLING AND SEIZURE AS ENCOUNTERED IN ASSEMBLY
AND USE. TO A LIMITED EXTENT, IT ALSO ACCOMODATES PLATING, FINISHES, OR COATINGS.
CLASSES 3A AND 3B --- THESE CLASSES 3A EXTERNAL AND 3B INTERNAL, ARE PROVIDED FOR THOSE
APPLICATIONS WHERE CLOSENESS TO FIT AND ACCURACY OF LEAD ARE IMPORTANT. THESE THREADS ARE
CONTAINED CONSISTANCLY ONLY THROUGH THE USE OF HIGH QUALITY PRODUCTION SUPPORTED BY A
VERY EFFICIENT SYSTEM OF GAUGING AND INSPECTION.
THE PITCH DIAMETER FOR CLASSES 1, 2, ANS 3 FOR EACH STANDARD DIAMETER AND NUMBER OF
THREADS PER INCH MAY BE FOUND IN MOST MECHANICAL ENGINEERING HANDBOOKS.
KEYS
BLUEPRINT
1. A BLUE PRINT WITH 3 VIEWS IS CALLED
ANS. ORTHOGRAPHIC
9. A STRIGHT LINE GOINING ANY TWO POINTS ON THE CIRCUMFRENCE OF A CIRCLE IS CALLED A/AN
ANS. CHORD
10. A LINE THAT TOUCHES BUT DOES NOT CUT THE CIRCUMFRENCE OF A CIRCLE IS CALLED A
ANS. TANGENT
MEASUREMENT
1. A LARGE CIRCLE MAY BE MADE WITH A TOOL CALLED
ANS. TRAMMEL
3. THE DIVICE THAT COMPRESSES THREE INTERCHANGEABLE TOOS ( SQUARE , CENTER HEAD, AND
PROTRACTOR ) IS
ANS. COMBINATION SET
10. TO ENSURE A DIAMETER WILL BE MEASURED CORRECTLY WHEN A CALIPER IS USED, THE
CALAPER SHOULD BE
ANS. SLIPED OVER WITH A DELICAT TOUCH
12. A TOOL THAT CAN BE USED TO MAKE ACCURATE MEASUREMENTS BUT MUST BE USED WITH A
MICRO METER
ANS. TELESCOPING GAUGE
13. THE VERNIER CALIPER HAS AN ADVANRAGE OVER THE VERNER MICROMETER IN THAT IT
ANS. CAN BE USED TO MAKE BOTH INSIDE AND OUTSIDE MEASUREMENTS OVER THE RANGE OF SIZE
15. PRECISION MEASURING TOOLS ARE DIVIDED INTO CATEGORIES WHICH ARE
1. FOR OUTSIDE MEASUREMENT
2. FOR INSIDE MEASUREMENT
3. FOR DEPTH MEASUREMENT
4. FOR THREAD MEASUREMENT
ANS. ALL THE ABOVE
20. WHEN READING THE GRADUATIONS OF A MICROMETER DEPTH GUAGE, HOW ARE THEY
COMPAIRED TO A STANDARD MICROMETER
ANS. THEY ARE REVERSED
LAYOUT
6. IN THE PROCESS OF LAYING OUT, FINE ADJUSTMENTS IN POSITIONING A WORK PIECE ON A SURFACE PLATE
SHOULD BEST BE DONE WITH
ANS. SMALL JACKS
8. NAME TWO SUBSTANCES WHICH IS USED ON ROUGH CASTINGS AND TO SHOW UP THE SCRIBED LINES
ANS. (1) CHALK AND (2) A MIXTURE OF LIME AND ALCOHOL
9. TO MAKE LAY OUT LINES EASIER TO SEE ON THE SHINY FLASH OF METAL WE CAN USE.
ANS. LAYOUT DYE (BLUING)
10. THE BEST METHOD OF SCRIBING ARCS FROM AN EXISTING HOLE WOULD BE TO USE
ANS. A FALSE CENTRE
1 PART CEMENT
2 PARTS SAND
2 PARTS STONE ( MAX)
ADD WATER AS REQUIRED
NOTE TO FIND THE NUMBER OF CU. YDS. OF CONCRETE NEEDED MULTIPLY THE NUMBER OF SQUARE FEET BY
THE BEPTH IN INCHES THEN DIVIDE THE RESULT BY 324 (L X W X D 4 324)
LOOK FOR SLIVERS, NAILS, AND SHARPE ENDS ETC. WHEN HANDELING MATERIALS OR PACKAGES, IF POSSIBLE
REMOVE THEM
MAKE CERTAIN OF GOOD BALANCE. FEET SHOULDER WIDTH APART; ONE FOOT BESIDE AND ONE FOOT BEHIND THE
ARTICLE TO BE LIFTED.
BEND THE KNEES, DO NOT STOOP. KEEP THE BACK STRAIGHT, NOT VERTICAL; THERE IS A DIFFERENCE. TUCKING IN
THE CHIN TO MAKE CERTAIN THE BACK IS STRAIGHT
GRIP THE LOAD WITH PALMS OF THE HANDS AND THE FINGERS. THE PALM GRIP IS MUCH MORE SECURE. WITH GRIP
TAKEN, TUCK IN THE CHIN TO MAKE SURE THE BACK IS STRAIGHT
USE BODY WEIGHT TO START THE LOAD MOVING AND THEN LIFT BY PUSHING UP WITH THE LEGS, MAKING FULL USE
OF THE STRONGEST SET OF MUSCLES.
LENGTH WEIGHT
10 MILLILITERS 1 CENTILITER
10 CENTILITERS 1 DECILITER
10 DECILITERS 1 LITER
10 LITERS 1DECALEITERS
10 DECILITERS 1HECTOLEITER
10 HECTOLITERS 1 KILOLEITER
COMBINATION SET
COMBINATION SET CONSISTS OF A STEEL RULE, SQUARE HEAD, CENTER HEAD AND PROTRACTOR
THE STEEL RULE OR BLADE IS MARKED IN 1/8, 1/16, 1/32 ANS 1/64. IT IS A VERY GOOD AND USEFUL
MEASURING TOOL BUT ONLY ACCURATE TO 1/64 OF AN INCH. THE SAME APPLIES IF YOU ARE
MEASURING OVER THE LENGTH OF THE RULE. EG, IF YOU ARE MEASURING A 4 FT, SHAFT YOU WOULD
NOT PLACE THE 12 INCH RULE ON THE SHAFT AND MARKE OFF 12 INCHES, THEN MARK OFF 24 INCHES.
ETC. WHAT YOU WOULD USE IS A RULE THAT WOULD BE FOUR FEET OR OVER.
SQUARE HEAD SLIDES ON THE STEEL RULE AND CAN BE POSITIONED AS REQUIRED. THE SQUARE HEAD
HAS AN ACCURATLY GROUND 90( FACE PLUS A 45( MITER FACE. THERE IS A SPIRIT LEVEL INCORPORATED
IN THE HEAD WHICH IS VERY USEFULL IN LEVELING.
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PROTRACTOR HEAD SLIDES ON THE STEEL RULE. MOST PROTRACTOR HEADS WILL TURN FROM 0( TO
180( IN OPPOSITE DIRECTIONS. THIS IS A VERY GOOD TOOL FOR CHECKING AND MARKING OFF THE
ANGLE DESIRED.
CENTER HEAD THIS HEAD ALSO SLIDES ON THE STEEL RULE AND IS USED FOR MARKING OF SHAFTS ETC.
TO CHANGE TO MULTIPLY BY