T960(E)(A10)T

AUGUST EXAMINATION

NATIONAL CERTIFICATE

MECHANOTECHNICS N4
(8190194)

August 2016 (X-Paper)

9:00–12:00

This question paper consists of 7 pages and 1 formula sheet of 3 pages.

Copyright reserved Please turn over

(8190194) -2- T960(E)(A10)T

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
NATIONAL CERTIFICATE
MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100

za
INSTRUCTIONS AND INFORMATION

o.
1. Answer ALL the questions.

2. Read ALL the questions carefully.

.c
3. Number the answers according to the numbering system used in this question
paper. rs
4. All sketches must be clear, neat and labelled.

5. ALL the work done in pencil (excluding sketches, drawings and diagrams) will
be regarded as rough work and will NOT be marked.
pe

6. Write neatly and legibly.

Pa
et
Tv

Copyright reserved Please turn over

(8190194) -3- T960(E)(A10)T

QUESTION 1

1.1 Various faults can occur in a ball-and-roller bearing.

1.1.1 Name FIVE faults that can occur in a ball-and-roller bearing.

1.1.2 Describe the FIVE faults named in QUESTION 1.1.1.

(2 x 5) (10)

1.2 Briefly explain the following processes:

za
1.2.1 Electroplating

1.2.2 Electrostatic spray-painting

o.
(2 x 5) (10)

1.3 Three production methods which are generally used in the manufacturing
industry are mass production, batch production and individual production.

.c
1.3.1 Describe the product layout. rs (2)

1.3.2 Name FOUR requirements for the product layout. (4)

1.3.3 State FOUR disadvantages of the product layout. (4)

[30]
pe

QUESTION 2

An open flat-belt drive is used to transmit 25 kW. The driving pulley has a diameter of
Pa

200 mm and rotates at 4,445 r/sec, while the driven pulley rotates at 3,333 r/sec. The
contact angle on the driven pulley is 176 0 and the centre distance between the pulley
shafts is 1,5 m. Assume the coefficient of friction of 0,37.

Determine:
et

2.1 The belt speed (2)

2.2 Ratio of belt tension (2)

Tv

2.3 Tension in the slack side of the belt (3)

2.4 Tension in the tight side of the belt (2)

2.5 Length of belt for the drive (3)

2.6 Length of belt if the drive is changed to a crossed-belt drive. (2)

[14]

Copyright reserved Please turn over

(8190194) -4- T960(E)(A10)T

QUESTION 3

3.1 A lathe is being driven by a motor providing a maximum input of 2,5 kW at

1 500 r/min. At maximum power the machine efficiency is 85%. The
maximum and minimum velocities of the lathe spindle are 3 500 r/min and
30 r/min respectively.

Determine the torque at maximum power:

3.1.1 At the driving shaft of the motor (2)

za
3.1.2 At the driving spindle of the lathe at maximum speed (4)

3.1.3 At the driving spindle of the lathe at minimum speed (2)

o.
3.2 FIGURE 1 below shows a set-up of the cutting tool in a post of a lathe
machine. A round steel bar with a diameter of 85 mm is being machined in the
lathe.

.c
Calculate: rs
3.2.1 The minimum clamping force which clamping screw B has to be
tightened if a cutting force of 1 000 N is applied at the tip of the
cutting tool.
pe
3.2.2 The power consumed by the cutting process if the bar of steel
rotates at 650 r/min.
(2 x 3) (6)
Pa
et
Tv

FIGURE 1 [14]

QUESTION 4

Copyright reserved Please turn over

(8190194) -5- T960(E)(A10)T
4.1 FIGURE 2 shows an internal dovetail to be checked for accuracy with two
25 mm diameter precision rollers.

4.1.1 Duplicate the diagram in the ANSWER BOOK. (2)

4.1.2 Use the diagram drawn in QUESTION 4.1 to calculate the distance
'X' between the inside faces of the rollers if the two angles of 45 0
were correctly machined. (5)

za
o.
.c
FIGURE 2
rs
4.2 An external dovetail is machined to an angle of 450 as shown in FIGURE 3.
The angles are tested for correctness by means of two precision rollers of
15 mm diameters each.
pe

4.2.1 Duplicate the diagram in the ANSWER BOOK. (2)

4.2.2 Use the given dimensions and calculate distance 'X'. (5)
Pa
et
Tv

FIGURE 3 [14]

QUESTION 5

Copyright reserved Please turn over

(8190194) -6- T960(E)(A10)T
5.1 FIGURE 4 shows a pinion (B) with 30 teeth meshing internally with a ring gear
(A). The centre distance between the shafts is 45 mm and the teeth have a
module of 1,5 mm.

Calculate:

5.1.1 The number of teeth on the ring gear 'A'.

5.1.2 The pitch-circle diameter of the ring gear.

(2 x 2) (4)

za
o.
.c
rs
pe

FIGURE 4

5.2 A simple spur-gear train made of a gear wheel A and a pinion B has a module
Pa

of 5 mm.
The velocity ratio of the two gears is 3,1 and the pinion has 24 teeth.

Calculate:
et

5.2.1 The pitch-circle diameter of gear wheel A. (3)

5.2.2 The pitch-circle diameter of pinion B. (1)

Tv

5.2.3 The exact centre distance between the two shafts. (2)

5.2.4 The outside diameter of gear wheel A. (2)

5.2.5 The outside diameter of pinion B. (2)

[14]

Copyright reserved Please turn over

(8190194) -7- T960(E)(A10)T

QUESTION 6

A sharp-edge orifice 52 mm in diameter in the side of a large tank, is discharging water

under a constant pressure head of 4,5 m. The diameter of the vena contracta is
41 mm. If the horizontal distance of the water jet is 2,15 m and the jet falls 327 mm
vertically, determine the following:

6.1 The theoretical flow velocity of the water

6.2 The actual flow velocity of the water

za
6.3 The theoretical delivery of the water

6.4 The actual delivery of the water

o.
6.5 The coefficient of delivery (Cd)

6.6 The coefficient of velocity (Cv)

.c
6.7 The coefficient of contraction (Cc)
(7 x 2) [14]
rs
TOTAL: 100
pe
Pa
et
Tv

Copyright reserved
(8190194) -1- T960(E)(A10)T

MECHANOTECHNICS N4
FORMULA SHEET

PCD
1. m  2. DO = m × (T + 2)
T

m
3. C   ( TA  TB ) 1
2 4. Ke  mv 2

za
2
TA
5. VR  PCD of gear
TB 6. VR 
PCD of pinion

o.
NB
7. VR  8. NA × TA = NB × TB
NA

2T

.c
9. Ft 
PCD
10. Fr = Ft × Tan 
rs
11. Fn = Ft × Sec 

12. Ie = IA + (VR)2 IB + (VR)2 IC + (VR)2 ID

pe
( NB ) TBC ( ND ) TD
14. T  TA  
13. T = Ie × A ( NA ) 1 ( NA ) 1 2

NB B B IA
15.    16. TOUTPUT  TINPUT  GR  η
NA A A IB
Pa

  PCD
17. P  18. Ti + To + Th = 0
n
Input speed Teeth on driven gears
et

19. TA = TS + 2TP 20. 

Output speed Teeth on driving gears

21. v =  × (d + t) × N 22. P = Te × v
Tv

 e 
T1
23. 24. T1 =  × A
T2
T 1  TC
25. Tc = m × v2 26.  e cosec 
T 2  TC

27. L 

 D  d  
 D  d 2
 2C
2 4C

28. Tg = m × g × sin  29. v =  × r

Copyright reserved Please turn over

(8190194) -2- T960(E)(A10)T

g br
30. v    g  r 31. v 
2h

   Tan    hTan  b / 2 
32. v  gr   33. v  gr 
1  Tan   
 h  b / 2 tan  

T1 1  Tan  
n  Rr
 35. Cos 
34. 
T 2 1  Tan   2 C

za
 Rr
36. Cos  37. m = w × t × L × 
2 C

o.
38. T1 = w × n × ft 39. P = Pg + Pµ
I  2  N T
40. t 

.c
T 41. P 
60
42. T = F × r 43. w = do + 3d - 1,5155P
rs
 m
44. do = de + 0,65P 45. w  (cos 2  )
2
 
pe

46. h  m 1  sin  Cos 
 4 

p1 ( v1 )2 p 2 ( v2 )2
47.   gh1    gh2
Pa

Rho 2 Rho 2

gx2
48. Vw ( Va )  49. v  C mi
2y
et

f    O2
4  f   v 2 51. hf 
50. hf  3,026  d 5
2 g d
Tv

Cd  A  a  ( 2 gh )
52. Q  ( 2 gh )
2 2 53. Q  Cd  A 
(A a )
( m2  1 )
ms
54. V  ( g  R  Cos ) 55. Vol. bucket =
v
56. L = 2C + D m1  g  S 2
57. Self-weight =
8 h
m2  g  S
58. One load =
4h 59. T (acc load) = (T1 - T2)R

Copyright reserved Please turn over

(8190194) -3- T960(E)(A10)T

a
60. T (acc drum) = I    mk 2 
R 62.  = 2 × N

work done
64. Ke 
61. P =  × T efficiency

63. Ke 
1
I  2 66. (I1 + I2)3 = I11 + I22
2

za
Tan 
65. P = Ke × operations/sec 68.  
Tan (    )

67. µ = Tan    F  Re

o.
70. T 
sin 

72. Fc = m ×  2 × 

.c
69. T = µ × F × Re × n

71. T = µ × n × (Fc - S)R

rs
mv 2
73. Fc 

pe

74. Tractive effort = mass on driving wheels × µ × g

75. Side thrust = FcCos   mg Sin

Pa

FcCos  mgSin
76.  
mgCos  FcSin

77. Pl  CmgL  mgh

et
Tv

Copyright reserved Please turn over