higher education & training Department: Higher Education and Training REPUBLIC OF SOUTH AFRICA T700(E)(M22)T APRIL 2011 NATIONAL CERTIFICATE FITTING AND MACHINING THEORY N2 (11022032) 22 March (X-Paper) 09:00 — 12:00 Calculators may be used. Candidates will require drawing instruments, pens and a ruler. This question paper consists of 6 pages, a 1-page formula sheet and 1 diagram sheet.ee ee ee eee eS SG 2 TTOO(E\(M22)T DEPARTMENT OF HIGHER EDUCATION AND TRAINING REPUBLIC OF SOUTH AFRICA NATIONAL CERTIFICATE FITTING AND MACHINING THEORY N2 TIME: 3 HOURS MARKS: 100 NOTE: If you answer more than the required number of questions, only the required number of questions will be marked. All work you do not want to be marked, must be clearly crossed out. INSTRUCTIONS AND INFORMATION 1 Answer ALL the questions in SECTION A 2. Answer ONLY TWO questions in SECTION B. 3 Answer either QUESTION 1.1 or 1.2 of QUESTION 1 4 Read ALL the questions carefully. 5 Number the answers correctly according to the numbering system used in this, question paper 6 Write neatly and legibly. PTO3 T700(E)(M22)T SECTION A QUESTION 1: OCCUPATIONAL SAFETY NOTE 1.4 12 Answer either QUESTION 1.1 or QUESTION 1.2. Explain, in your own words, FIVE basic safety measures to for the use and ‘lock-out' electrical equipment, which apply to mechanical fitters when working on machinery. OR Explain, in your own words, FIVE regulations associated with First Aid certification for workers above or below the surface with regard to mining industry. QUESTION 2: COUPLINGS FIGURE 1 (DIAGRAM SHEET 1 attached) shows a sketch of a type of coupling. Answer the following questions with reference to FIGURE 1. 24 22 23 Name the type of coupling Describe the construction of this coupling with special reference to the material used for the different parts. State TWO types of misalignment associated with couplings. QUESTION 3: LIMITS AND FITS 3.1 3.2 Explain, in your own words, what is meant by the following terms: 3.1.1 Tolerance 3.1.2 Interchange-ability 3.1.3 Allowance Indicate under which classification of fit, the following types of fit are categorised: 3.21 Drive fit 3.22 Push fit Slide fit Shrink fit Running fit PTO 15] [5] (1) (2) (2) [5] (1) (1) (1) (1) (1) (1) (1) (1) [8] re ee eeT700(E)(M22)T I QUESTION 4: BEARINGS I 44 Give THREE reasons why bearings are important in industry. 42 State FOUR properties of the material used for plain bearings. 43 Give FOUR reasons for the failure of anti-friction bearings. QUESTION 5: LUBRICATION AND VALVES TH 51 Lubvcants are classied into Solid; Semi-solid; and Liquid types. Give the classification of lubricant used in the following lubricators: le 44 Grease applicator gun 1.2 Bottle oiler 1.3 Splash feed lubricator ; 1.4 Stauffer cup I 5.2 Name THREE types of shut-off valves. QUESTION 6: PACKING, STUFFING BOXES, JOINTS AND WATER PIPE SYSTEMS I 61 Give FIVE important guidelines to ensure the proper fitting of O-rings and seals in hydraulic systems to prevent leakage. I 6.2 Name TWO types of thermo-plastic pipes and give ONE example applicable to each. I QUESTION 7: PUMPS 7.1 Explain, in your own words, the function of a plunger when working with I reciprocating pumps. 72 FIGURE 2 (DIAGRAM SHEET 1 attached) shows a sketch of a vane-pump. Name the FOUR parts of the pump that are indicated by the letters A — D. PTO (3) (4) (4) [11] (1) (1) (1) (1) (3) (5) (4) 9] (1) (4) [5]5 T7OO(E)(M22)T QUESTION 8: COMPRESSORS Explain in your own words, the function of each of the following compressor components: 81 Safety valve 82 Belt transmission guard 83 Drain valve 84 Receiver 85 Pressure regulator switch QUESTION 8: V-BELT, GEAR AND CHAIN DRIVES 9.1 Explain the principle of velocity ratios and mechanical advantage when using different gears in gear drives. 9.2 State THREE advantages that belt drives have over gear drives. TOTAL SECTION A: SECTION B ‘Answer only TWO of the questions in SECTION B QUESTION 10: HYDRAULICS AND PNEUMATICS 10.1 Name the hydraulic components (A — E) associated with the ISO symbols in FIGURE 3, (DIAGRAM SHEET 1 attached). 10.2 State the main differences between a pneumatic system and a hydraulic system when referring to the recycling of oil as opposed to how pneumatics deal with the same phenomenon? 10.3 State THREE ways by which directional control valves can be actuated 10.4 Give the function of the following pneumatic components 10.4.1 Vacuum pump 10.4.2 Pressure regulator 10.4.3 Double-acting cylinder 10.5 State the TWO most important scientific factors which affect the speed of an actuator in a pneumatic system, 10.6 State FIVE advantages pneumatic systems have over hydraulic systems PTO (2) (3) [5] 6) (2) (3) a) a) a) 2) (5) [20]14 11.2 11.3 11.4 neat 12.2 12.3 12.4 12.5 12.6 & T700(E)(M22)T QUESTION 11: CENTRE LATHES State FOUR advantages of the use of mandrels. State TWO advantages and TWO disadvantages of using the tailstock set- over method for taper -turning. Calculate the amount of tailstock set-over required for a shaft, 240 mm in length with a taper of 6°. A round shaft with an outside diameter of 75 mm must be provided with a three-start thread with a lead of 30 mm. 11.4.1 Calculate the helix angle of the thread (8) as well as the leading and clearance angles. Assume that the clearance angle of 3°. 11.4.2 Calculate the leading angle. 11.4.3 Calculate the clearance angle 11.4.4 Give the names of the square thread terms listed in FIGURE 4 (DIAGRAM SHEET 1 attached) between A — D. QUESTION 12: MILLING MACHINES AND SURFACE GRINDERS Identify the milling cutter types in FIGURE 5 (DIAGRAM SHEET 1 attached) and write the answers next to the letters A - C. State FOUR methods of indexing on a milling machine. State THREE possible factors which cause the loading of a grinding wheel. Calculate the cutting speed of the cutter in meters per minute, when using a cutter of 35 mm in diameter at a speed of 360 r/min. State TWO advantages and TWO disadvantages of upcut milling, Give THREE reasons why it is more desirable to use a milling cutter with coarse teeth. TOTAL SECTION B: GRAND TOTAL: (4) (4) (3) (3) (1) (1) (4) [20] (3) (4) (3) (3) (4) (3) [20] 100FITTING AND MACHINING THEORY N2 FORMULA SHEET Saf xTXN aDN 60 Ss= D~d__ length of workpiece length of taper e tan === 204 90° - (Helix angle + clearance angle) 90° + (Helix angle - clearance angle) Lead = No.of starts * pitch T700(E)(M22)TS26 SSeS = ee oe ee ee ee T7OO(E)\(M22)T DIAGRAM SHEET / DIAGRAMVEL 1 : Figure 1/Figuur 1 Figure 2/ Figur 2 Zr Sea Cooyrgnt sese-ved Please turn over