NATIONAL

SENIOR CERTIFICATE

GRADE 12

MECHANICAL TECHNOLOGY
NOVEMBER 2011
MEMORANDUM

MARKS: 200

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NSC Memorandum

DBE/November 2011

ANSWER SHEET
QUESTION 1: MULTIPLE-CHOICE QUESTIONS
1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

D
[20]

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DBE/November 2011

QUESTION 2: TOOLS AND EQUIPMENT

2.1

Cylinder leakage test:

2.1.1

Cylinder Leakage Test 9

(1)

2.1.2

Procedure for cylinder leakage test:

Run the engine until normal operating temperature. 9

Remove the spark plug from cylinder number three. 9

Install cylinder leakage tester to the spark plug hole of

cylinder number three. 9

Remove the oil filler cap, radiator filler cap as well as the
air filter. 9

Turn the crankshaft pulley until piston number three is at

TDC (Power stroke) 9

Apply air pressure to cylinder. 9

Listen at the carburettor for a hissing noise. (Inlet valve is

leaking) 9

Listen at the exhaust pipe for a hissing noise. (exhaust

valve is leaking) 9

Listen at the dipstick for a hissing noise. (Piston rings are

worn) 9

Listen at the oil filler hole for a hissing noise. (Piston rings
are worn) 9

Look for bubbles in the radiator water, if so the cylinder

head gasket is blown or the cylinder block is cracked. 9

(11)

[50% (6 marks) will be credited for the steps related to any type of test other than that
mentioned in 2.1.1]
2.2

Spring tester:

Squareness/Roundness
pressure)

Correct tension9

2.3

Computer Numerical Control9

2.4

Metal arc gas shielded:

2.4.1

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9 or (specifications of length and

(2)

(1)

Advantages

Can weld in any position. 9

Higher disposition rate. 9

Less operator skill required. 9

Long welds can be made without stops and starts. 9

Minimal post-weld cleaning / no slag removal is required. 9

Causes less deformation 9

Gives better finish 9

Faster than arc welding 9

Easy operation 9
Any 3 X 1

(3)

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2.4.2

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Gasses

Argon 9 and CO 2 9

(2)
[20]

QUESTION 3: MATERIALS
3.1

3.2

3.3

Carbon fibre:

It gives a smooth finish9

Light in weight9

Resistant to corrosion9

Easy to mould9

Its tough9

Its strong 9

Stiffness of materials:
Material B is the stiffer9
Reason: Material B is more resistant to a bending deformation99

3.3.2

(3)

A non-ferrous alloy is a metal that has a combination of two or

more non-ferrous metals. 99

(2)

Examples:

Brass9

Bronze9

White metal9

Duralumin9

Solder9

Silver solder9

(3)

Any 3 X 1

Composite:
3.4.1

3.4.2

3.5

(2)

Non-ferrous alloys:
3.3.1

3.4

Any 2 X 1

Thermosetting plastics

Teflon9

Nylon9

(2)

Properties of Teflon and nylon to support choice:

High friction resistance9

Light in weight9

Easy to work with9

Provides a smooth finish9

Needs no lubrication 9

No/low maintenance 9

Corrosion free 9

Poor conductor of electricity 9 Any 4 X 1

(4)

Soft solder
Lead 9 and tin 9or Antimony

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Silver solder
High melting point 9
Resistant to corrosion9

(2)

good conductor
give a strong bead
used to join a variety of materials
[20]

QUESTION 4: SAFETY, TERMINOLOGY AND JOINING METHODS

4.1

4.2

4.3

Hydraulic press:
Make sure the object is firmly secured. 9
Make sure pins holding the beam is fitted properly. 9
Check pins for wear. 9
Check for oil leaks. 9
Make sure the area around the press is clean and free from oil. 9
Release pressure after operation 9
Personal safety 9
Safety guards 9
Any 4 X 1
Gas cylinders:
Store oxygen and acetylene separately.9
Store full and empty cylinders apart. 9
Keep cylinders in a cool place away from heat. 9
Place cylinders in an upright position. 9
Dont drop cylinders. 9
Cylinder heads must be on. 9
Keep cylinders away from oil or grease. 9
Dont hammer on cylinders. 9
Secure cylinders properly. 9
Do not transport in horizontal position 9

Any 4 X 1

(4)

(4)

Cutting feed:

V = DN
V
N=
D
100
N=
0,12
N = 265,258 2385 rpm
f = f1 T N
f = 0,1 40 265,258
f = 1061,03 mm / min
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9
9
9
9
9

(6)
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Indexing:
4.4.1

4.4.2

40
A
9
40
=
9
70
4 4
4 6 4 7
=
or
or
74
7
7 6 7 9
28 9
24
16
or
or
=
49
42
28
9 or
16 holes on the 28 hole circle
24 holes on the 42 - hole circle or
28 holes on the 49 - hole circle
Indexing =

Dr
40
= ( A n)
Dv
A

Dr
40
= (70 67 )
Dv
70

Dr 120
=
Dv
70

Dr 12 4
=
Dv
7 4

Dr 48
=
Dv 28
No full turn , 16 holes on the 28 - hole circle
48
with change gears
or
28
No full turn , 24 holes on the 42 - hole circle
48
with change gears
or
28
No full turn , 28 holes on the 49 - hole circle
with change gears

48
28

4.4.3 Same direction/clockwise/positive 9

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(5)

(5)
(1)

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4.5

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Gear drives:
4.5.1

Driving gear /electrical motor gear9

(1)

4.5.2

Clockwise direction9

(1)

4.5.3

Output/final/driven gear/ washing machine gear9

(1)

4.5.4

Gear B
N A TA = N B TB
1200 30 = N D 22
NB

4.5.5

= 1636 rpm

Gear A
PCD = m T
= 3 30

= 90 mm
4.5.6

9
9
9
(3)

9
9

(2)

Outside diameter
Outside diameter (OD) = PCD + 2 Module

= 90 + (2 3)
= 96 mm
4.5.7

Dedendum
Dedendum = 1,157 m

= 1,157 3
= 3,471 mm

9
9

(2)

9
9

OR
Dedendum = 1,25 m
= 1,25 3
= 3,75 mm

4.6

9
9

(2)

Weld defects and testing:

4.6.1

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Causes porous weld:

Atmospheric contamination. 9
Surface contamination. 9
Dirty or wet electrodes. 9
Rusted MIG wire. 9
Type of welder 9
Current too high 9
Poor quality material 9
Incorrect method 9
Dirty welding rods 9

Any 2 X 1

(2)

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4.6.2

4.6.3

4.6.4

4.6.5

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Prevention:
Clean the workpiece. 9
Use clean, dry electrodes. 9
Use correct electrodes including low hydrogen electrodes
Any 1 X 1
9

(1)

Causes of poor fusion:

Welding current to low or too fast. 9
Welding pool too wide or too large9
Wrong joint preparation root gap & chamfering). 9
Welding electrode to thick. 9
Any 2 X 1

(2)

Prevention:
Use correct current. 9
Be sure to melt the sides of the groove. 9
Groove must be free of other metals. 9
Width of the electrode must be small enough to fit in
groove. 9
Any 1 X 1

(1)

Liquid dye penetration test:

Clean the weld that needs to be tested. 9
The dye is sprayed onto the welded surface.9
Allowed dye to penetrate all the cracks. 9
Excess dye is cleaned away with a cleaning agent. 9
Allowed surface to dry. 9
Spray a developer onto the surface to bring out the dye
trapped in cracks. 9
The dye will show all the surface defects 9

(7)
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QUESTION 5: MAINTENANCE AND TURBINES

5.1

Lubrication:
5.1.1

5.1.2

5.1.3

Properties

Viscosity must be correct. 9

It must resist oxidation. 9

It must avoid foaming. 9

Resist carbon forming. 9

It must prevent corrosion or rust9.

It must resist extreme pressures. 9

Pour point 9

Resistance to temperature change 9

Any 5 X 1

(5)

Viscosity of oil refers to the resistance of oil to flow./ thickness of

oil 99

(2)

EP Oils

Manual gearbox9

Final drive or differential9

Heavy duty machinery

(2)

Any 2 X 1

5.1.4

Society of Automotive Engineers 9

(1)

5.1.5

Cutting Fluid

Acts as lubricant 9

Prevents chips from sticking 9

Improves quality of finish 9

Keeps the work piece cool 9

Keeps the cutting tool cool 9

Gives the cutting tool a longer life span 9

Wash away/remove chips/swarfs

Any 4 x 1

(4)

5.1.6

Gear Lubrication
COLUMN A

5.1.7

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COLUMN B

Engine
Gearbox
Differential

SAE 20W50
Extreme pressure oil (EP 90)
Extreme pressure oil (EP 90)

Power steering

Hydraulic oil

Automatic transmission Fluid

Transmitting power via torque converter 9
Acting as hydraulic fluid via servo cylinder 9
Acts as a heat-transfer medium 9
Acts as lubricant for gears and bearings 9

B9
D9
D9
A9

Any 2 X 1

(4)

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5.2

5.4

5.5

5.6

DBE/November 2011

Blower:
5.2.1

Roots blower 9

(1)

5.2.2

1. Inlet 9
2. Outlet 9
3. Rotors 9

(3)

Operation

The engine drives the rotors by means of gears or chain 9

Air is trapped between the rotor and aluminium casing. 9

This air is carried around the outside of the rotor and is

pushed into a decreasing volume. 9

This raises the pressure of the air with the rotational speed
of the rotors. 9

The air is forced into the inlet manifold and then fed into the
cylinders. 9

(5)

5.2.3

5.3

10
NSC Memorandum

Superchargers

To fill the cylinder with air pressure higher than atmospheric

pressure. 9

To increase the compression pressure in the cylinder. 9

To increase volumetric efficiency of the engine. 9

No lag in relation to turbo charger 9

Obtain more power 9

Any 3 X 1

Superchargers and turbochargers

Supercharger is mechanically driven by gears or a belt. 9

Turbocharger is driven by the exhaust gases. 9

Steam turbine uses

To drive generators to generate electricity. 9

To operate ships. 9

To operate pumps 9

(2)

Any 2 X 1

Advantages of steam turbines

It is compact. 9
No lubrication is required. 9
Steam turbine speeds can be more accurately regulated. 9
A variety of fuels can be used to obtain steam. 9
Steam turbines are more economical. 9
Higher speeds can be obtained as compared to internal
combustion engines. 9
Low maintenance 9
Any 4 X 1

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(3)

(2)

(4)
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QUESTION 6: FORCES AND SYSTEMS AND CONTROL

6.1

Hydraulics:
6.1.1

Fluid pressure:
D 2
AB =
4
(0,2)2
AB =
4
AB = 31,41593 10 3 m 2
P=

9
9
9

FB
AB

15 10
31,41593 10 3
= 477464,8293 Pa
3

P=

9
9

= 0,48 MPa

6.1.2

Force F on piston A:
D 2
AA =
4
2
(0,075 )
AA =
4
AA = 4,4178 10 3 m 2

(6)

9
9
9

PA = PB
PA =

FA
AA

FA = PA AA

)(

FA = 0,48 10 6 4,42 10 3

FA = 2,10935 kN
= 2,11 kN
F
F
or 1 = 2
A1
A2

F1 =

F2 A1
A2

15 10 3 4,4178 10 3
31,41593 10 3
= 2,1093 kN
= 2,11 kN
=

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9
9

99
9
9
9
9
(6)

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6.1.3

DBE/November 2011

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Distance 'X':
VB = VA

9
9

AB = AA LA
X=

AA LA
AB

(4,42 10 )(0,12)
X=
3

6.2

31,41 10 3
X = 16,87499773 mm / stroke
X = 16,87499773 16

X = 269,99 mm
= 270 mm

(6)

Stress and strain:

6.2.1

Side length:
F
A
F

=
A=

9
9

30 10 3
A=
6 10 6
A = 5 10 3 m 2
A = L2
L=

L = 5 10 3 m 2

9
9
9
9
9

L = 0,0707106 m
L = 70,71 mm

9
(8)

6.2.2

Strain:

6 10 6
=
90 10 9
= 0,06667 10 3
=

= 6,67 10 5
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9
9
9
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DBE/November 2011

Change in length:
l
l
l = l

l = 6,67 10 5 200 9
9
= 0, 013 mm

6.3

9
(3)

Belt drives:
6.3.1

Rotational frequency of the driven pulley

( DDN + t ) N DN = (DDR + t ) N DR
9
(DDR + t ) N DR
N DN =
9
( DDN + t )

(475 + 12)1440
(180 + 12)

487 1440
192
= 3652,5 rpm
=

9
9
9

Or
9

N 1 D1 = N 2 D 2
N2 =

9
9

N 1 D1
D2

475 1440
180
= 3800 rpm

6.3.2

Belt speed:
V=

(D + t) N

60
(0.475 + 0,012) 1440
=
60
1
= 36,72 m.s

6.4

(5)

9
9
9

(3)

Clutches:
6.4.1

The maximum torque transmitted:

T = WnR
0,28
2
3
= 0,3 4 10 2 0,14

= 336 Nm

9
9

T = 0,3 4 10 3 2

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DBE/November 2011

Power transmitted at 3500 rpm in kW:

2NT
9
P=
60
2 3500 336
P=
99
60
9
P = 123,15 kW

(4)
[50]
TOTAL:

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200