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 T1100(E)(N19)T

NATIONAL CERTIFICATE

MECHANOTECHNICS N4
(8190194)

19 November 2018 (X-Paper)

09:00–12:00

This question paper consists of 5 pages and 3 formula sheets.

Copyright reserved Please turn over

(8190194) -2- T1100(E)(N19)T

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

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

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions.

2. Read ALL the questions carefully.

3. Number the answers according to the numbering system used in this question
paper.

4. Sketches must be large, neat and fully labelled.

5. Write neatly and legibly.

Copyright reserved Please turn over

(8190194) -3- T1100(E)(N19)T

QUESTION 1

1.1 Briefly explain what is meant when reference is made to the following
principles of a good workshop layout:

1.1.1 Clear transport rout

1.1.2 Optimum use of space

1.1.3 Flexible layout

1.1.4 Minimum handling of material

1.1.5 Pleasant working conditions

(5 × 2) (10)

1.2 Indicate the difference between air spray-painting and airless spray-painting
with the aid of labelled sketches. (10)

1.3 1.3.1 State FIVE ways in which roller bearings can be damaged.

1.3.2 State FIVE factors which may contribute to the failure of a journal
bearing.
(2 × 5) (10)
[30]

QUESTION 2

Calculate the quantity of rock in tonnes per hour which can be transported by a belt
conveyor with the following specifications:

Maximum tension in the belt = 35,3 kN

Contact angle of the belt on the driving pulley = 185°
Friction force = 2,5 kN
Belt speed = 95 m/min
Delivery height = 35 m
Coefficient of friction = 0,3 [14]

Copyright reserved Please turn over

(8190194) -4- T1100(E)(N19)T

QUESTION 3

3.1 A lathe is being driven by a motor providing a maximum input of 3 kW at

1 500 r/min. At the maximum power the machine efficiency is 80%.
The maximum and minimum velocities of the lathe spindle are 3 600 r/min
and 40 r/min respectively.

Find the torque of the maximum power at the:

3.1.1 Driving shaft of the motor (2)

3.1.2 Driving spindle of the lathe at maximum speed (4)

3.1.3 Driving spindle of the lathe at minimum speed (2)

3.2 Calculate the power in kW consumed by:

3.2.1 The operation of a shaping machine in which the cuffing force is

1 200 N and the stroke length which is 275 mm, takes 13 s to
complete

3.2.2 The operation of a lathe during which the cutting force applied to
the cutting tool is 1 000 N and the rotational speed of a workpiece
with a diameter of 350 mm is 350 r/min
(2 × 3) (6)
[14]

QUESTION 4

4.1 An ISO 150 screw thread of 3,5 mm pitch has an effective diameter of 30 mm.
The three-wire method is used for checking the effective diameter. The best
wire size method is used for the test wires.

Calculate the micrometer reading over the three wires. (6)

4.2 4.2.1 Explain step-by-step, how you would go about checking the
correctness of the teeth of a gear wheel, having a module of
10 mm and a pressure angle of 20°, using a gear tooth vernier
calliper and applying the constant-chord method of checking. (3)

4.2.2 Make the necessary calculations for the above test by using the
constant-chord method of checking. (5)
[14]

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(8190194) -5- T1100(E)(N19)T

QUESTION 5

A set of spur gears has a velocity ratio of 3:1 and a module of 8 mm if the pinion has
40 teeth.

Calculate:

5.1 The pitch-circle diameter of both gears (4)

5.2 The centre distance between the shafts (3)

5.3 The outside diameter of both gears (4)

5.4 The total depth that the milling cutter must be fed into the gear blank, in order
to cut the teeth (3)
[14]

QUESTION 6

6.1 A horizontal pipeline with a diameter of 90 mm conveys water at 20 ℓ/s with a

pressure drop of 50 kPa per 20 m of pipeline.

Calculate the value of the coefficient of friction (f) for the abovementioned
situation by using the Darcy formula. (5)

6.2 Use the Chezy formula for the abovementioned situation and calculate the
values of:

6.2.1 The hydraulic mean depth 'm'

6.2.2 The hydraulic gradient 'i'

6.2.3 The Chezi coefficient 'c'

(3 × 3) (9)
[14]

TOTAL: 100

Copyright reserved
(8190194) -1- T1100(E)(N19)T

FORMULA SHEET

Any other applicable formula may also be used.

PCD
1. m  2. DO = m × (T + 2)
T

m
3. C   ( TA  TB ) 1
2 4. Ke  mv 2
2
TA
5. VR  PCD of gear
TB 6. VR 
PCD of pinion
NB
7. VR  8. NA × TA = NB × TB
NA

2T
9. Ft  10. Fr = Ft × Tan 
PCD

11. Fn = Ft × Sec 

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

( 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

  PCD
17. P  18. Ti + To + Th = 0
n
Input speed Teeth on driven gears
19. TA = TS + 2TP 20. 
Output speed Teeth on driving gears

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

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

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

Copyright reserved Please turn over

(8190194) -2- T1100(E)(N19)T

28. Tg = m × g × sin  29. v =  × r

30. v    g  r g br
31. v 
2h
   Tan  
32. v  gr  
1  Tan    hTan   b / 2 
33. v  gr  
 h  b / 2 tan  
n
T 1 1  Tan  
34.    Rr
T 2 1  Tan   35. Cos 
2 C
 Rr
36. Cos 
2 C 37. m = w × t × L × 

38. T1 = w × n × ft
39. P = Pg + Pµ
I 
40. t 
T 2  N T
41. P 
60
42. T = F × r
43. w = do + 3d - 1,5155P
44. do = de + 0,65P  m
45. w  (cos 2  )
2

  
46. h  m1  sin  Cos 
 4 

p1 ( v1 )2 p 2 ( v 2 )2
47.   gh1    gh2
Rho 2 Rho 2

gx 2
48. Vw ( Va )  49. v  C mi
2y

f    O2
4  f    v2 51. hf 
50. hf  3,026  d 5
2 g d

Cd  A  a  ( 2 gh ) 53. Q  Cd  A 
( 2 gh )
52. Q 
( A2  a 2 ) ( m2  1 )
ms
55. Vol. bucket =
54. V  ( g  R  Cos ) v
m1  g  S 2
56. L = 2C + D 57. Self-weight =
8 h
m2  g  S 59. T (acc load) = (T1 - T2)R
58. One load =
4h

Copyright reserved Please turn over

(8190194) -3- T1100(E)(N19)T

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

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

1 66. (I1 + I2) ω 3 = I1 ω 1 + I2 ω 2

63. Ke  I  2
2
Tan 
65. P = Ke × operations/sec 68.  
Tan (    )

67. µ = Tan    F  Re
70. T 
sin 

72. Fc = m × ω 2 × 
69. T = µ × F × Re × n

71. T = µ × n × (Fc - S)R

mv 2
73. Fc 


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

75. Side thrust = FcCos   mg Sin

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

77. Pl  CmgL  mgh

Copyright reserved
 MARKING GUIDELINE

NATIONAL CERTIFICATE

MECHANOTECHNICS N4

19 NOVEMBER 2018

This marking guideline consists of 8 pages.

Copyright reserved Please turn over

MARKING GUIDELINE -2- T1100(E)(N19)T
MECHANOTECNICS N4

QUESTION 1

1.1 1.1.1 You must design transport routes and aisles in your workshop to
be clearly visible. Clearly mark all routes so that the workers and
transport can easily move around.

1.1.2 Make sure that you use all available space in your workshop
whether it is horizontal or vertical space.

1.1.3 You must provide for future changes in layout and production. Plan
your workshop in such a way that it can be adapted for a change in
production.

1.1.4 Store material or equipment should be placed at a convenient

height so that minimum handling is needed.

1.1.5 Ensure that the working conditions are as pleasant as possible and
try to avoid any factor that may cause discomfort.
(5 × 2) (10)

1.2 Airless spray-painting

Air spray-painting

(2 × 5) (10)
Copyright reserved Please turn over
MARKING GUIDELINE -3- T1100(E)(N19)T
MECHANOTECNICS N4

1.3 1.3.1  Force applied to wrong ring during mounting

 Damage housing or shaft
 Excessive lubricants
 Bearing mounted the wrong way round
 Damage by misalignment during mounting
 Incorrect mounting of housing end cover (Any 5 × 1) (5)

1.3.2  Overloading
 Insufficient lubrication
 Extreme temperature
 Poor maintenance
 Fault in the design of the bearing
 Incorrect type of bearing
 Incorrect lubrication method
 Incorrect mounting of the bearing (Any 5 × 1) (5)
[30]

QUESTION 2

Pf  F f xv
 2,5  103  1,583
 3 957,5W 

T1
= e μθ
T2
35 500
 e 0,33, 228 
T2
35 500
T2  
2,633
 13,289 N 

Pt  (T1  T2 )v
 (35 500  13289,152)1,583 
 35159,772 W 
 35,160 kW 

Pt  Pg  Pf
Pg  Pt  Pf
 35159,772  39 57,5 
 31202,272W 

Copyright reserved Please turn over

MARKING GUIDELINE -4- T1100(E)(N19)T
MECHANOTECNICS N4

Pg  mgh
31202,272
m 
9,81 35
= 90,876 kg/s 
90,876 × 3 600
= 
1 000
= 327,154t / h  [14]

QUESTION 3

3.1 3.1.1 2πNT

P=
60
P × 60
T=
2πN
3000 × 60
= 
2π × 1500
= 19099 Nm  (2)

3.1.2 Po

Pi
Po = 3000 × 0,8 
 2400W 
2NT
P
60
P × 60
T=
2πN
2400 × 60
= 
2π × 3600
= 6,366 Nm  (4)

3.1.3 2NT
P
60
P × 60
T=
2πN
2400 × 60
= 
2π × 40
= 572,957 Nm  (2)

Copyright reserved Please turn over

MARKING GUIDELINE -5- T1100(E)(N19)T
MECHANOTECNICS N4

3.2 3.2.1 W
P
t
Fxs

t
1200 × 0,275
= 
13
= 25,385 W 
= 0,025 kW  (3)

3.2.2 T  Fxr OR DN

v
 1 000  0,175 60
= 175 Nm   (0,35)  (350)
v
2NT 60
P
60  6,414 m /s 
2  350  175 P = F ×v
 
60  1 000  6,414 
= 6414,085 W  6414 W
 6,414 kW   6,414 kW  (3)
[14]

QUESTION 4

4.1 wirediameter  0,577 p

= 0,577 × 3,5 
 2,0195 mm 
d o  d e  0,65 p
= 30 + (0,65 × 3,5) 
 32,275 mm 

w  d o  3d  1,516 p
 32,275  3(2,0195)  1,516(3,5) 
 33,0275 mm  (6)

4.2 4.2.1 Step 1: Calculate the chordal height.

Step 2: Set the vertical scale of the gear tooth vernier calliper to
the above value.

Step 3: Measure the chordal width and compare it with the

calculated value. Compare the calculated and the
measured value of the chordal width and if they
correspond, the gear tooth has been correctly machined.
(3 × 1) (3)

Copyright reserved Please turn over

MARKING GUIDELINE -6- T1100(E)(N19)T
MECHANOTECNICS N4

4.2.2 m
w (cos 2  )
2
π × 10
= (cos 20) 2 
2
 13,87mm 
π
h = m [1 (sin θ. cos θ )] 
4
π
h = 10 [1 (sin 20°.co20°)] 
4
 7,476 mm  (5)
[14]

QUESTION 5

5.1 3
VR 
1
TA 3

TB 1
TA  3TB
 3 40 
TB  120 teeth 

PCD A  m  T A
 8 120
 960mm 

PCD B  m  TB
 8 40
 320 mm  (4)

5.2 m
C (TA  TB )
2
8
 (120  40) 
2
 640 mm  (3)

Copyright reserved Please turn over

MARKING GUIDELINE -7- T1100(E)(N19)T
MECHANOTECNICS N4

5.3 DOA  m(TA  2)

 8(120  2) 
 976 mm 

DOB  m(TB  2)
 8(40  2) 
 336 mm  (4)

5.4 Totaldepth  Addendum  Dedendum

 8  (1,157  8) 
 17,256 mm  (3)
[14]

QUESTION 6

6.1 f  l  Q2 h f  3,026  d 5
hf  f 
3,026  d 5 l  Q2
p 5,096  3,026  (0,09) 5
hf   
Rho  g 20  (0,02) 2
50  10 3
hf    0,0114 
1 000  9,81
 5,096 m  (5)

6.2 6.2.1 d
m
4
0,09

4
 0,023 (3)

6.2.2 hf
i
l
5,096
 
20
 0,255  (3)

Copyright reserved Please turn over

MARKING GUIDELINE -8- T1100(E)(N19)T
MECHANOTECNICS N4

6.2.3 v d 2
c A
mi 4
Q  (0,09) 2
v 
A 4
0,02
  6,361 103 m 2 
6,361 103
 3,144 m/s 
v
c
mi
3,144

0,023  0255
 41,053  (3)
[14]

TOTAL: 100

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