MARKING GUIDELINE

NATIONAL CERTIFICATE

FITTING AND MACHINING THEORY N2

9 APRIL 2021

This marking guideline consists of 9 pages.

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MARKING GUIDELINE -2-
FITTING AND MACHINING THEORY N2

SECTION A

QUESTION 1: OCCUPATIONAL SAFETY

NOTE: Candidates need answer only QUESTION 1.1 or QUESTION 1.2.

1.1 1.1.1 False

1.1.2 False
1.1.3 True
1.1.4 True
1.1.5 False
(5 × 1) [5]

OR

1.2. 1.2.1 True

1.2.2 False
1.2.3 True
1.2.4 False
1.2.5 True
(5 × 1) [5]

QUESTION 2: COUPLINGS

2.1 2.1.1 Metal disc coupling

2.1.2 Flexible couplings

2.1.3 Floating disc

(3 × 1) (3)

2.2 2.2.1 Permanent coupling

2.2.2 Flexible coupling

2.2.3 Self-aligning coupling

(3 × 1) (3)
[6]

QUESTION 3: LIMITS AND FITS

3.1 3.1.1 Push fit – parts will move relative to each other when slight hand
pressure is applied to move the two parts.

3.1.2 Running fit – The two mating parts fit into each other smoothly but
not loosely.

3.1.3 Sliding fit – The two parts slide freely relative to each other.

3.1.4 Press fit – Pressure is applied mechanically or hydraulically to fit the

one part tightly into the other.
(4 × 1) (4)
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FITTING AND MACHINING THEORY N2

3.2 3.2.1 Bilateral tolerance – The limits of a dimension are on both sides of
the basic size.

3.2.2 Unilateral tolerance –The limits of a dimension are only on one side
of the basic size.

3.2.3 High limit – Is the maximum permissible size allowed relative to the
basic size of the work-piece.
(3 × 1) (3)
[7]

QUESTION 4: BEARINGS

4.1 • Insufficient lubrication

• Contamination in the bearing
• Bearing slipping in the housing or on the shaft
• Flattened roller or ball
• Different sizes of rollers or balls
• Indentation of races
(Any 3 × 1) (3)

4.2 • They cannot be repaired

• They are noisy in operation at high speeds
• Less capacity to withstand shock
• High initial costs
(Any 2 × 1) (2)
[5]

QUESTION 5: LUBRICATION AND VALVES

5.1 5.1.1 Rubbing speed – It is the speed at which a shaft turns inside a
bearing.

5.1.2 Adhesion – It is the ability a substance has to cling to another

material or substance.

5.1.3 Viscosity – The speed of flow or resistance to flow or thickness of

the liquid.
(3 × 1) (3)

5.2 When the pressure in a system exceeds the spring tension of the valve,  the
valve opens and allows fluid to flow. When the pressure drops below the
spring tension, the valve closes  and stops the flow of fluid. (3)
[6]

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FITTING AND MACHINING THEORY N2

QUESTION 6: PACKING, STUFFING BOXES, JOINTS AND WATER PIPE

SYSTEMS

6.1 • To prevent heat loss due to radiation

• To prevent or minimise condensation in the pipelines
• To minimise hammer shocks in the system
• To have more accurate gauge readings
• To prevent water entering reciprocating machines
• Saves energy
• Prevents water pipes from freezing in winter (Any 5 × 1) (5)

6.2 • Bell-and-spigot
• Welded
• Soldered or brazed
• Screwed (threaded)
• Flanged
• Butt-and-strap
• Fillet welding (Any 4 × 1) (4)
[9]

QUESTION 7: PUMPS

7.1 7.1.1 A – Piston pump

B – Plunger pump (2)

7.1.2 Reciprocating pumps (1)

7.1.3 Positive displacement (1)

7.2 • To slow the liquid down

• To increase the pressure energy
• To prevent overloading of the impeller motor (Any 2 × 1) (2)
[6]

QUESTION 8: COMPRESSORS

8.1 Air filter – It prevents dust and foreign matter in the air from entering the
cylinder.

8.2 High pressure cylinder – It compresses the air to the required pressure.

8.3 Drain valve – It is used to drain all the water in the air receiver.

8.4 Cotter – It tightens up the bearing holes as wear takes place between the
bearing halves and the crank.
(4 × 1) [4]

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FITTING AND MACHINING THEORY N2

QUESTION 9: V-BELTS, GEAR DRIVES, CHAIN DRIVES AND REDUCTION

GEARBOXES

9.1 The main function of a V-belt is to transfer driving motion from one shaft to
another. (1)

9.2 9.2.1 Arc of contact – It is the portion of the pulley that is in contact with
the V-belt along its circumference.

9.2.2 Driven pulley – It is the pulley that is attached to the working part of
the machine.
(2 × 1) (2)

9.3 • They are expensive to manufacture

• They are not repairable
• They require constant lubrication
• The drive and driven shafts need to be close together
• If anything goes wrong, slippage does not occur to prevent damage to the
machine (Any 3 × 1) (3)

9.4 9.4.1 To transmit power from one shaft to another when the distance
between shafts is too large to use gears.

9.4.2 Used when positive transmission is desired (i.e., no slippage).

(2 × 1) (2)

9.5 • They are relatively noisy

• Wear causes elongation of the chain
• The sprockets need replacing due to wear
• They have speed limitations
• They break without warning (Any 2 ×1) (2)

9.6 • Ensure bearings are lubricated with grease.

• Check bearings for wear by listening for excessive noise. (2)
[12]

TOTAL SECTION A: 60

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FITTING AND MACHINING THEORY N2

SECTION B

NOTE: Candidates need answer only TWO of the following questions

QUESTION 10: HYDRAULICS AND PNEUMATICS

10.1 10.1.1 C
10.1.2 A
10.1.3 E
10.1.4 B
10.1.5 D
(5 × 1) (5)

10.2 10.2.1 Double acting cylinder or cylinder

10.2.2 Spring loaded non-return valve or non-return valve
10.2.3 Throttle valve
10.2.4 Sequence valve
10.2.5 Air receiver
(5 × 1) (5)

10.3
HYDRAULIC SYSTEM PNEUMATIC SYSTEM
Uses hydraulic oil Uses air
Uses a pump to generate power Uses a compressor to generate
power
Closed circuit – oil returns to the Open circuit – air is released to the
tank atmosphere
Higher system pressure Lower system pressure
Slower operation Faster operation
Minimum power loss Power loss occurs over long
distances
Higher operating costs Lower operating costs
Self-lubricating Requires lubrication
(Any 3 × 2) (6)

10.4 Positive displacement pumps are used in hydraulics. (1)

10.5 • Power transmission

• Lubrication
• Cooling (3)
[20]

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FITTING AND MACHINING THEORY N2

QUESTION 11: CENTRE LATHES

11.1 • Plain or solid mandrels

• Cone mandrels
• Screw mandrels
• Expanding mandrels (4)

11.2 • Only external tapers can be turned

• Due to centres being misaligned, uneven wear takes place on the centres
and centre holes (2)

11.3 𝑆𝑆 = 𝜋𝜋DN

𝑆𝑆
𝑁𝑁 =
𝜋𝜋D

45
= 
𝜋𝜋×0.085

𝑁𝑁 = 168.517 𝑟𝑟/𝑚𝑚𝑚𝑚𝑚𝑚 

𝐿𝐿 = 𝑓𝑓 × 𝑁𝑁 × 𝑡𝑡
= 0.8 × 168.517 × 5 
𝐿𝐿 = 674.068 𝑚𝑚𝑚𝑚  (4)

11.4 11.4.1 𝐷𝐷 − 𝑑𝑑 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ 𝑜𝑜𝑜𝑜 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤

𝑆𝑆𝑆𝑆𝑆𝑆 − 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = ×
2 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

95−60 500
= × 
2 330

= 17.5 × 1.52
𝑆𝑆𝑆𝑆𝑆𝑆 − 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 26.515 mm  (2)

11.4.2 𝜃𝜃 𝑋𝑋
𝑡𝑡𝑡𝑡𝑡𝑡 =
2 𝐿𝐿

𝜃𝜃 17.5
𝑡𝑡𝑡𝑡𝑡𝑡 =
2 330

𝜃𝜃
𝑡𝑡𝑡𝑡𝑡𝑡 2
= 0.053 

𝜃𝜃 = 𝑡𝑡𝑡𝑡𝑡𝑡−1 0.053 × 2 
𝜃𝜃 = 6.068°
𝜃𝜃 = 6° 04′  (3)

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MARKING GUIDELINE -8-
FITTING AND MACHINING THEORY N2

11.5 • Material type

• Tooling required
• Dwell time
• Stock length
• Coolant application
• Cutting speed
• Information from a drawing
• Operating sequence
• Sizes according to dimensioning sizes
(Any 5 × 1) (5)
[20]

QUESTION 12: MILLING MACHINES AND SURFACE GRINDERS

12.1 12.1.1 Dovetail cutter – Is used to manufacture dovetail slides that are used
on various machines.

12.1.2 Slotting cutter – It is used only for cutting slots, grooves and keyways.

12.1.3 End mill cutter – It is used for milling slots, cutting profiles and facing
narrow surfaces.

12.1.4 Slot drill – It is used to cut keyways and blind slots

(4 × 1) (4)

12.2 • It prevents the continuous forming of shavings

• It reduces chattering
• It helps in the removal of shavings
• It gives a better cutting action
• It is more economical in terms of power consumption
• It allows an easier flow of coolant
• It improves the finish on the work-piece
(Any 3 × 1) (3)

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FITTING AND MACHINING THEORY N2

12.3 𝑁𝑁
𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 =
9°
37
= 9


1
= 4
9
1 2
= 4� × � 
9 2
2
= 4 
18
𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼
= 4 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎  𝑎𝑎𝑎𝑎𝑎𝑎 2 ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑖𝑖𝑖𝑖 𝑎𝑎 18 ℎ𝑜𝑜𝑜𝑜𝑜𝑜 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 
(5)

12.4 90
𝐷𝐷 =
1000
𝐷𝐷 = 0.09 𝑚𝑚

𝑆𝑆 = 𝜋𝜋𝜋𝜋𝜋𝜋
𝑆𝑆
𝑁𝑁 = 
𝜋𝜋𝜋𝜋
23
= 
𝜋𝜋×0.09

𝑁𝑁 = 81.346 𝑟𝑟/𝑚𝑚𝑚𝑚𝑚𝑚  (3)

12.5 12.5.1 Grit size – It is the actual size of the abrasive particles on a grinding
wheel.

12.5.2 Grade – It is the hardness of the wheel or the strength of the bond
holding the abrasive particles in place.

12.5.3 Structure – It is the spacing of the grit in the wheel.

(3 × 1) (3)

12.6 • Use coarser grit wheels

• Use an open structure wheel
• Use a softer grade wheel
• Increase work speed
(Any 2 × 1) (2)
[20]

TOTAL SECTION B: 40
GRAND TOTAL: 100

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