Secondary Integrated

Tests
MECHANICAL TECHNOLOGY
PAPER: WRITTEN
MAY/JUNE 2019
TIME: 2hours 30minutes

INSTRUCTIONS
• This paper consists of six questions in four sections. Answer all questions.
• Show all working where necessary.
• All sketches and diagrams should be done in pencil.
• You may use a silent non-programmable calculator.
• All dimensions are given in mm unless stated otherwise.
• It is not necessary to convert to SI units on this paper.

Student’s Candidate Number:

Student’s Full Name:
Student’s Date of birth:
Date of Examination:
Name of School:
 SECTION A: METALLURGY AND MATERIALS
Answer all questions

1. In order to obtain Iron (Fe) in its pure form a series of steps must be taken
to extract iron ore from raw materials. A blast furnace, as shown below, is
used in the extraction process.

a).

Figure 1

Label the following parts:

A_________________________________________________________
B_________________________________________________________
C_________________________________________________________
D_________________________________________________________
[4]
b). Name at least three ores in which iron could be extracted from.
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[3]
 c). Name the by product formed from the reactions in the blast furnace.
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[1]
d). State at least two uses of the by-product listed above.
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[2]
e). When the pure Iron has been extracted the metal on its own does not
have much use until it has been treated to gain the desirable properties. The
metal is subjected to certain heat treatment methods such as Annealing,
tempering, normalizing, etc.
Distinguish between Annealing and Tempering.
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[4]
f). State one property of metals that are annealed.
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[1]

[15 MARKS]
2. Define the following terms:
a). Polymers
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b). Thermoplastics
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c). Thermosetting plastics
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[3]

d). State two plastics that is either thermoplastics or a thermosetting plastics

and state one use of each plastic.
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[4]
e). One of the thermoplastics of length 100mm by 34mm were subjected to
various loads in order to determine its yield point. The results were placed and a
graph was generated from it.
Figure 2: Graph of Load versus Extension
 f). Explain the term ‘yield point’.
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[1]
g). Using the graph above determine the yield point of the thermoplastic.
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[1]
h). Calculate the strain of the material.
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[2]
i). Hence calculate the Young’s Modulus of the material.
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[3]
j). State one effect of a large Young’s Modulus on a material.
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[1]

[15 MARKS]
 SECTION B: ENGINEERING DESIGN
Answer all questions

3. A housing company in New England manufactures sliding windows for homes.

After installing these windows in different houses customers have made
complains about the difficulties in opening these windows. The build up of dust
and residue caused friction between the groove and the window. Therefore, you
have been proposed with the task of designing a mechanism for the window to
slide without friction. Your design may be freehand or ruler assisted.
[20 MARKS]
Figure 3: Sliding Window

Scale: 1:8
 SECTION C: SIMPLE MACHINES
Answer all questions

4. a). Define the term ‘Mechanical Advantage’.

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[2]
b). The diagram below shows a standard pulley system used in the
automotive industry to lift an engine.

Figure 4

c). Calculate the force, F needed to lift the engine.

[Gravity = 9.8kg ms-2]
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[5]
 d). Explain why a user can apply less force to the pulley system to raise the
engine that weighs more than the user’s input force.
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[2]

e). Determine the mechanical advantage of the system.

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[3]

f). Fasteners are another example of simple machines and their main purpose is
to join objects together either permanently or temporarily. Therefore, complete
the following table.

Fastener Use

Rivets

Used to assemble parts

in appliances.
[2]

e). State one way in which a nut can be locked.

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[1]

[15 MARKS]
 SECTION D: INDUSTRIAL PROCESSES
Answer all questions

5. The figure below shows a shaft for manufactured for an automobile using the
center lathe machine. The shaft is made from a piece of mild steel bar of length
100mm by dia. 25mm.

Figure 5

a). State the difference between a ‘rake’ and ‘clearance angle’ used on a lathe
cutting tool.
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[2]

b). Briefly explain the procedure for producing the shaft above using a center
lathe.
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[6]
 c). Sketch the cutting tool that would be used to produce the threaded portion.

[3]

d). Calculate the spindle speed that is to be used to produce the 14 mm diameter
if the cutting speed for mild steel is given as 24 m/min.
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[4]

[15 MARKS]
6. a). State the reason for why coated electrodes are used in electric arc
welding
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[1]
b). Explain how an electrode is able to easily penetrate metal in the electric arc
welding process.
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[3]

c). Draw a labeled diagram to illustrate the process of the electrode

penetrating a piece of metal in the electric arc welding process.

[4]
 d). State ONE factor that contributes to proper penetration in the electric arc
welding processes.
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[1]
e). List ONE precaution to be taken when doing electric arc welding.
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[1]

[10 MARKS]

[TOTAL: 90 MARKS]
END OF EXAMINATION