Mechanotechnics N4 2019 Combined

T1100(E)(A1)T
NATIONAL CERTIFICATE
MECHANOTECHNICS N4
(8190194)
1 April 2019 (X-Paper)

09:00–12:00
This question paper consists of 5 pages and a formula sheet of 3 pages.
Copyright reserved Please turn over

(8190194) -2- T1100(E)(A1)T
DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
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.

(8190194) -3- T1100(E)(A1)T
QUESTION 1
1.1 What is meant by individual production? (3)
1.2 Give TWO examples where the individual production method could be
applied. (2)
1.3 Name FIVE characteristics of individual production. (5)
1.4 Name FIVE ways in which a roller bearing can be damaged. (5)
1.5 Make a labelled sketch of a siphon wick lubricator which can be used for oil
lubrication of machine parts. (5)
1.6 Make a labelled drawing of the dip-painting method. (5)
1.7 State FIVE disadvantages of the dip-painting method. (5)

[30]
QUESTION 2
The driving pulley of a V-belt drive has an effective diameter of 250 mm and a speed of
1 800 r/min. The angle of the V-groove of the driving pulley is 46° and the contact
angle of the belt is 160°. The coefficient of friction is 0,3 and the mass of the belt is
0,5 kg/m length.
Calculate the number of V-belts required for this drive if the maximum allowable
tension per belt is 900 N and the belt has to transmit 30 kW. [14]
QUESTION 3
FIGURE 1 below shows the setup of a cutting tool held in the tool holder of a shaping
machine:
FIGURE 1

(8190194) -4- T1100(E)(A1)T
The ram of the shaping machine has a mass of 150 kg and is operating with a cutting
stroke length of 150 mm. The total work done during the cutting stroke is equal to
175 J and the coefficient of friction between the ram and the slides is 0,3.
Calculate the following:
3.1 The work done to overcome the friction between the ram and the slides (3)
3.2 The cutting force exerted on the cutting tool (3)
3.3 The forces exerted on the two contact points A and B if the clamping force in
the clamping screw is 2 000 N (8)
[14]
QUESTION 4
FIGURE 2 below shows a workpiece with a V-groove which has a 60° included angle
and a depth of 50 mm.
h
3
2 Ø 40 mm
50 mm
60°
FIGURE 2
4.1 Refer to FIGURE 2 above and name the numbered components. Write only
the answer next to the number (1–4) in the ANSWER BOOK. (4)
4.2 Use FIGURE 2 to calculate the distance 'h'. (6)
4.3 Describe how you would test the magnitude of the angle on the workpiece. (4)
[14]

(8190194) -5- T1100(E)(A1)T
QUESTION 5
An epicyclic gear train is shown in FIGURE 3 below. Gear wheel D rotates at

1 000r/min. Gear B and gear C are keyed to the same shaft.
TC=22 TA=100
Arm E
TB=16
TD=28 1000r/min
FIGURE 3
5.1 Determine the speed of gear wheel A if arm E is stationery. (10)
5.2 Determine the speed of arm E if gear wheel A is fixed. (4)

[14]
QUESTION 6
Water with a density of 1 000 kg/m3 is pumped through a vertical pipe that is
15 m long. The tapered pipe has a diameter of 180 mm at the upper end and 100 mm
at the lower end. When 90 l/s is pumped upwards through the pipe, a reading of
230 kPa is registered on the pressure gauge at the lower end.
Calculate the pressure gauge reading at the upper end of the pipe. [14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1100(E)(A1)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
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 
PCD
10. Fr = Ft × Tan 
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
28. Tg = m × g × sin  29. v = T × r

(8190194) -2- T1100(E)(A1)T
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
T1 1  Tan  
34.    Rr
T 2 1  Tan   35. Cos 
2 C
 Rr
36. Cos 
2 C 37. m = w × t × L × ρ
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   v 2 51. hf 
50. hf  3,026  d 5
2 g d
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

(8190194) -3- T1100(E)(A1)T
a 62. ω = 2 × N
60. T (acc drum) = I    mk 2 
R
work done
64. Ke 
efficiency
61. P = ω× T
66. (I1 + I2)ω3 = I1ω1 + I2ω2
1
63. Ke  I   2
2 Tan 
68.  
Tan (    )
65. P = Ke × operations/sec
  F  Re
70. T 
67. µ = Tan  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
T1100(E)(J26)T
MECHANOTECHNICS N4
(8190194)
26 July 2018 (X-Paper)

09:00–12:00

(8190194) -2- T1100(E)(J26)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1100(E)(J26)T
QUESTION 1
1.1 The layout of a workshop involves placing of the various machines and
related equipment in the different work areas, as well as arranging for storage
space or stores, staff facilities and administrative offices. The placing of
machines on the floor of a workshop must comply with important
requirements.
Name and briefly discuss FIVE requirements for the placing of machines on
the floor of a workshop. (5 × 2) (10)
1.2 State FIVE advantages for the use of ball and roller bearings in preference to
ordinary journal bearings. (5)
1.3 Ball and roller bearings sometimes overheat during use.
Give FIVE reasons for this occurrence. (5)
1.4 1.4.1 Make a labelled drawing of electrostatic spray painting. (6)
1.4.2 State TWO advantages of electrostatic spray painting. (2)
1.4.3 State TWO disadvantages of electrostatic spray painting. (2)

[30]
QUESTION 2
The following applies to a flat-belt drive:
The width is 250 mm

The thickness is 6 mm
The tension in the tight side of the belt is two and half times more than that in the slack
side.
The safe working stress is 350 kPa.
The centre distance between two shaft carrying pulleys with a diameter of 1 500 mm
and 500 mm respectively, is 2 m.
The larger pulley rotates at 150 r/min.
2.1 The power transmitted (10)
2.2 The length of the open belt drive (2)
2.3 The length of the belt if the drive is changed to crossed-belt drive (2)
[14]

(8190194) -4- T1100(E)(J26)T
QUESTION 3
3.1 A workpiece with a diameter of 250 mm is machined in a lathe at a spindle

speed of 200 r/min. The cutting depth is 5 mm and the feed of the cutting tool
is 0,5 mm per revolution of the workpiece. A cutting force of 2,5 kN is exerted
by the cutting tool on the workpiece.
3.1.1 The cutting pressure on the tool (N/mm2) (3)
3.1.2 The power required to machine the workpiece (kW) (3)
3.1.3 The motor power if the motor has an efficiency of 80% (2)
3.2 The belt drive from an electric motor transmits an effective driving force of
800 N to the 250 mm diameter driving pulley on a milling machine. The torque
to overcome friction on the driving parts of the machine can be assumed as
8 Nm.
Determine the following:
3.2.1 Torque transmitted to the machine pulley
3.2.2 Torque that is available at the milling cutter
3.2.3 The effective cutting force that can be executed by the 115 mm
diameter of the cutter
(3 × 2) (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 to check the
correctness of the teeth of a gear wheel with a module of 10 mm
and a pressure angle of 20. Use a gear tooth vernier caliper and
apply 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]

(8190194) -5- T1100(E)(J26)T
QUESTION 5
The epicyclic gear system shown in FIGURE 1 consists of a ring gear (annulus) (Ta)
with 100 teeth, a sun gear (Ts) with 40 teeth and a planetary gear (Tp) with
30 teeth mounted on an arm (D).
5.1 Determine the speed and direction of the sun gear (Ts) if the annulus (Ta) is
fixed and the arm (D) rotates at +30 r/min. (9)
5.2 Determine the speed and direction of the annulus (Ta) if the sun gear (Ts) is
fixed and the arm (D) rotates at +30 r/min.
FIGURE 1 (5)
[14]
QUESTION 6
6.1 Water flows through a pipe with a diameter of 25 mm and a length of 50 m at

a velocity of 2,5 m/s.
Use Darcy's formula to determine the loss of head due to friction. Assume
that the coefficient of friction has a value of 0,005. Test the answer by using
the Chezy formula. (9)
6.2 A horizontal pipeline with a diameter of 75 mm conveys water at a rate of

0,015 m/s with a pressure drop of 50 kPa for every 30 metres of pipe length.
Calculate the value of the coefficient of friction (ƒ) for the above-mentioned
circumstances by using Darcy's formula. (5)
[14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1100(E)(J26)T
FORMULA SHEET
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 f
PCD
11. Fn = Ft × Sec f
14. Ta = TA + +
13. T a = Ie × a A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
15. = = = 16. TOUTPUT = TINPUT ´ GR ´ η
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
= e mq
T1
23. 24. T1 = d × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -2- T1100(E)(J26)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
é m + Tan q ù é hTanq + b / 2 ù
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
ë h - b / 2 tan q û
T 1 é1 + mTan q ù
n
q R-r
=ê 35. Cos =
34. ú
T 2 ë1 - mTan q û 2 C
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
46. h = m ê1 - (sin q Cosq )ú
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
f ´ l ´ O2
4 ´ f ´ l ´v 2 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
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 ´ Cosq ) 55. Vol. bucket =
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3- T1100(E)(J26)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R 62. T = 2p × N
work done
64. Ke =
61. P = T × T efficiency
1 66. (I1 + I2) ω 3 = I1 ω 1 + I2 ω 2

63. Ke = I ´ w2
2
Tan q
65. P = Ke × operations/sec 68. h =
Tan ( q + f )
67. µ = Tan q m ´ F ´ Re
70. T =
sin q
72. Fc = m × ω 2 × g
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
75. Side thrust = FcCos q - mg Sinq
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh
Copyright reserved
T1100(E)(M29)T
MECHANOTECHNICS N4
(8190194)
29 March 2018 (X-Paper)

09:00–12:00
This question paper consists of 6 pages and 3 formula sheets.

(8190194) -2- T1100(E)(M29)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1100(E)(M29)T
QUESTION 1
1.1 Name and describe FIVE ways in which ball and roller bearings can be
damaged. (5 × 2) (10)
1.2 Corrosion can be defined as the destruction of a material as a result of

chemical, electrochemical or metallurgic interaction between the material and
the environment. The different forms corrosion can take on are based on the
appearance of the corrosion metal.
Name and briefly describe FIVE forms of corrosion. (5 × 2) (10)
1.3 There are certain factors that should be considered during the planning and
design of a good factory layout.
Name TEN of these important factors. (10)

[30]
QUESTION 2
The following information applies to a V-belt drive transmitting 35 kW:
Effective diameter of motor pulley = 35 mm

Speed of the motor pulley = 825 r/min
The V-groove angle of the pulley = 40°
Coefficient of friction = 0,3
Contact angle of the belt = 188°
Mass of the belt = 0,98 kg per metre length
Maximum allowable tension per belt = 740 N
Efficiency = 79%
Determine:
2.1 The belt speed (2)
2.2 The centrifugal tension (2)
2.3 The input power (2)
2.4 The tension in the tight and slack sides of the belt (6)
2.5 The number of V-belts (2)

[14]

(8190194) -4- T1100(E)(M29)T
QUESTION 3
FIGURE 1 shows the setup of a cutting tool held in the tool holder of a shaping
machine. The ram of the shaping machine has a mass of 100 kg and is in operation
with a cutting stroke length of 250 mm.
The total work done during one cutting stroke is equal to 125 J and the coefficient of
friction between the ram and the slides is 0,2.
FIGURE 1
Calculate:
3.1 The work done to overcome the friction between the ram and the slides (3)
3.2 The cutting force exerted on the cutting tool (3)
3.3 The forces exerted on the two contact points A and B, if the clamping force in
the clamping screw is 1 000 N (8)
[14]

(8190194) -5- T1100(E)(M29)T
QUESTION 4
FIGURE 2 shows a tapered ring gauge which is checked for accuracy by means of two
precision balls.
FIGURE 2
4.1 Explain step-by-step, how the precision balls are used to determine the
included angle of the ring gauge. (3)
4.2 Make a large, clear drawing of the diagram and show the included angle. (3)
4.3 Use the dimensions as given on the diagram and calculate the angle of the
ring gauge. (8)
[14]
QUESTION 5
The following specifications apply to a simple gear train with a pinion A and a gear
wheel B.
Module = 10 mm
Pressure angle = 20°
Gear ratio =3:2
PCD of pinion = 160 mm
Calculate:
5.1 The number of teeth on each gear wheel (4)
5.2 The addendum and dedendum of the gear teeth (2)

(8190194) -6- T1100(E)(M29)T
5.3 The outside diameters of both gears (2)
5.4 The pitch-circle diameter of the gear wheel (1)
5.5 The total depth of the teeth (1)
5.6 The tooth thickness at the pitch circle (4)

[14]
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. The horizontal distance of the water jet is 2,15 m and the jet falls 327 mm
vertically.
Determine:
6.1 The theoretical flow velocity of the water
6.2 The actual flow velocity of the water
6.3 The theoretical delivery of the water
6.4 The actual delivery of the water
6.5 The coefficient of delivery (cd)
6.6 The coefficient of velocity (cv)
6.7 The coefficient of contraction (cc)

(7 × 2) [14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1100(E)(M29)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
2
TA
TB 6. VR 
PCD of pinion
NB
7. VR  8. NA × TA = NB × TB
NA
2T
9. Ft 
PCD
10. Fr = Ft × Tan 
11. Fn = Ft × Sec 
14. T  TA  
13. T  = Ie ×  A ( NA ) 1 ( NA ) 1 2
NB B B IA
NA A A IB
  PCD
17. P  18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. 
21. v =  × (d + t) × N 22. P = Te × v
T1
23.  e  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
28. Tg = m × g × sin  29. v = T × r

(8190194) -2- T1100(E)(M29)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  
n
T1 1  Tan    Rr
34.  35. Cos 
 C
T 2 1  Tan   2
 Rr
36. Cos  37. m = w × t × L × ρ
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I  2  N T
40. t  41. P 
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
 m
44. do = de + 0,65P 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   v 2 51. hf 
50. hf  3,026  d 5
2 g d
Cd  A  a  ( 2 gh )
52. Q  ( 2 gh )
53. Q  Cd  A 
(A a )
2 2
( m2  1 )
ms
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

(8190194) -3- T1100(E)(M29)T
a
60. T (acc drum) = I    mk 2 
R 62. ω = 2 × N
work done
64. Ke 
61. P = ω× T efficiency
1 66. (I1 + I2)ω3 = I1ω1 + I2ω2

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 

76.  
Copyright reserved
MARKING GUIDELINE
MECHANOTECHNICS N4
29 MARCH 2018
This marking guideline consists of 9 pages.

MARKING GUIDELINE -2- T1100(E)(M29)T
MECHANOTECHNICS N4
QUESTION 1
1.1 · FORCE APPLIED TO WRONG RING DURING MOUNTINGP
Care must be taken that the force required for mounting a bearing is exerted
correctly. Example: The force should be applied to the inner ring when the
bearing is mounted on a shaft, but applied to the outer ring when the bearing
is mounted in a housing.P
· MISALIGNMENT OF BEARINGS DURING MOUNTINGP
When a bearing is mounted with hydraulic or any other equipment, it must be

ensured that the bearing is placed absolutely square and aligned before it is
pressed and fitted into a shaft or into a housing. Misalignment during
mounting may cause damage to the races and rolling elements of the
bearing.P
· MOUNTING THE HOUSING END COVER INCORRECTLYP
If the housing and cover which normally pushes against the outer ring is
wrongly mounted, distortion of the bearing’s outer ring occurs. This leads to
bearing failure.P
· MOUNTING BEARINGS IN A DAMAGED HOUSING OR SHAFTP
Bearings should never be mounted on a damaged or worn shaft or worn

housing since this may cause the inner or outer ring to start creeping, thus
reducing the effectiveness of the bearings. Movement or creep can also
damage the bearings' seats.P
· MOUNTING BEARINGS THE WRONG WAY ROUNDP
Some bearings, for instance single-row angular contact bearings, can carry
loads in one direction only. If these bearings are mounted the wrong way
round, the bearing may be forced apart or the balls may be damaged, leading
to early bearing failure.P
· EXCESSIVE LUBRICATIONP
Too much grease forced between the rolling elements of bearings can cause
just as much damage as insufficient lubrication. Too much grease results in
rapid heating which will be detrimental to the effective working of the
bearings.P (Any 5 × 2) (10)
Copyright reserved
MECHANOTECHNICS N4
1.2 · SURFACE CORROSIONP
Surface corrosion is caused by either a chemical reaction or an

electrochemical process.P
· STRESS CORROSIONP
This type of corrosion usually occurs in metals subjected to welding, cold-

welding or forming.P
· GALVANIC CORROSIONP
Galvanic corrosion takes place when two dissimilar metals come into contact
with each other or when they are electrically joined.P
· INTERCRYSTALLINE CORROSIONP
Some alloys, especially stainless steel have an uneven structure caused by

the heating and cooling processes to which they are subjected.P
· PITTING CORROSIONP
This form of corrosion is recognised by the appearance of little holes or pitting

marks on the metal surface. It is an example of a non-uniform corrosion which
develops due to the unevenness in the structure of the metal.P (5 × 2) (10)
1.3 · Regulation of local authority

· The required volume of work
· Inspection requirements to be met
· The quantity of material required
· Volume of final product to be manufactured
· Sequence in which production has to take place
· Type and quantity of equipment needed
· By-products and waste products which may cause pollution
· The most effective flow routes for the proposed type of production
· Type of production required e.g. mass batch or individual production
· Available storage place
· Any additional services which are available, for example water, gas,
sewerage and electricity
· The types of handling equipment to be used
· The type and quantity of the available workforce and level of skill of these
workers (Any 10 × 1) (10)
[30]

MECHANOTECHNICS N4
QUESTION 2
2.1 p .D.N
v=
60
p ´ 0,035 ´ 825
= P
60
= 1,512 m / s P (2)
2.2 TC = mv 2
= 0,98(1,512) 2 P
= 2,24 N P (2)
2.3 Po
Pi =
h
35 ´ 10 3
Pi = P
0,79
= 44,304 kW P (2)
2.4 T1 - TC
= e mq cos eca
T2 - TC
740 - 2,24
= e 0,3 ´ 3, 281 ´ 2,924 P
T2 - 2,24
737,76
= 17,78 P
T2 - 2,24
737,76 = T2 17,78 - 39,827 P
777,587
T2 = P
17,78
\ T2 = 43,43734 N P \ T1 = 740 N P (6)
2.5 P
(T1 - T2 )n =
v
35 ´ 10 3
(740 - 43,734)n =
1,512
23148,148
n=
696,266
= 33,25
say n = 33 P
(2)
[14]

MECHANOTECHNICS N4
QUESTION 3
3.1 F f = mxmxg
F f = 0,2 ´ 100 ´ 9,81
= 196,2 N P
WD f = F f ´ S l
= 196,2 ´ 0,25 P
= 49,05 J P (3)
3.2 WDtotal = WDcutting + WD friction

WDcutting = WDtotal - WD friction
= 125 - 49,05
= 75,95 J P
WDcutting
Fcutting =
Sl
75,95
Fcutting = P
0,25
= 303,8 N P (3)

MECHANOTECHNICS N4
3.3 B
40
1 000 N
40
A
303,8 N 50
Take moments about B to find A
å CWM = å ACWM
A ´ 80 = (303,8 ´ 130) + (1 000 ´ 40) PP
79494
A= P
80
= 993,675 N P
Take moments about A to find B

å CWM = å ACWM
1 000 ´ 40 = (303,8 ´ 50) + ( B ´ 80) PP
24810
B= P
80
= 310,125 N P (8)
[14]
QUESTION 4
4.1 STEP 1
Draw up the arrangement on a sufficient large scale to show clearly all the
measurements.
STEP 2
Construct the right-angled triangle from the given measurements.
STEP 3
Calculate the angle from the right-angled triangle and then find the magnitude
of the included angle. (3)

MECHANOTECHNICS N4
4.2
4,25
36,75
30
20
Sketch = PPP (3)
4.3 B
BC = R - r
= 15 - 10 P
= 5 mm P
AB in ABC
AB = (36,75 + 10) - (15 + 4,25) P
= 46,75 - 19,25
= 27,5 mm P
BC
Sinq =
AB
5
q = Sin -1 P
27,5
= 10,476° P
\ included angle = 2q
= 2 ´ 10,476 P
= 20,952° P (8)
[14]
MECHANOTECHNICS N4
QUESTION 5
5.1 PCD A
TA =
m
160
= P
10
= 16 teeth P
TB 3
=
TA 2
3T
TB = A
2
3 ´ 16
TB = P
2
TB = 24 teeth P (4)
5.2 Addendum = m
= 10 mm P
Dedendum = 1,157 ´ m
= 1,157 ´ 10
= 11,57 mm P (2)
5.3 DOA = m(TA + 2)

= 10(16 + 2)
= 180 mm P
DOB = m(TB + 2)
= 10(24 + 2)
= 260 mm P (2)
5.4 PCD B = m ´ TB
= 10 ´ 24
= 240 mm P (1)
5.5 Totaldepth = Aaddendum + Ddedendum

= 10 + 11,57
= 21,57 mm P (1)
5.6 Cp = p ´ m
= p ´ 10 P
= 31,416 mm P
Cp
Tooththickness =
2
31,416
Tooththickness = P
2
= 15,708 mm P (4)
[14]
MECHANOTECHNICS N4
QUESTION 6
6.1 vt = 2 gh
= 2 ´ 9,81 ´ 4,5 P
= 9,396 m /s P
6.2 gx 2
va =
2y
9,81 ´ (2,15) 2
= P
2 ´ 0,327
= 8,327 m /s P
6.3 Qt = vt ´ At
p (0,052) 2
= 9,396 ´ P
4
= 0,02 m 3 / s P
6.4 Qa = v a ´ Aa
p (0,041) 2
= 8,327 ´ P
4
= 0,011 m 3 / s P
6.5 Qa
Cd =
Qt
0,011
= P
0,02
= 0,55 P
6.6 va
Cv =
vt
8,327
= P
9,396
= 0,866 P
6.7 Cd
Cc =
Cv
0,55
= P
0,866
= 0,635P
(7 × 2) [14]
TOTAL: 100
Copyright reserved
T1100(E)(N20)T
MECHANOTECHNICS N4
(8190194)
20 November 2017 (X-Paper)

09:00–12:00

(8190194) -2- T1100(E)(N20)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1100(E)(N20)T
QUESTION 1
1.1 Computer-aided design has replaced conventional drawings done by

draughtsman on the drawing board. Because of the tremendous advantages
of computers over the old conventional design methods, it has largely
revolutionised layout design.
Give SEVEN advantages and THREE disadvantages of using computers. (10)
1.2 State THREE possible causes for each of the following faults that can occur
during the spray process:
1.2.1 Uneven spray-painting
1.2.2 Sagging surface
1.2.3 Excessive paint spray
1.2.4 Speckle or orange-peel effect

(4 × 3) (12)
1.3 List EIGHT factors contributing to the failure of journal bearings. (8)
[30]
QUESTION 2
A conveyer belt drive placed at an inclination angle of 15° has a length of 120 m
between the loading point and discharge point. The belt speed is 2,5 m/s and
subjected to a friction force 9 kN. Assume the contact angle on the driving pulley to
be 225°. The coefficient of friction (µ) is 0,25 and the efficiency of the drive is 87%. The
maximum tension in the belt is 28 kN.
Calculate the quantity of rock transported in tonne per hour. [14]
QUESTION 3
3.1 The belt drive from the electric motor transmits an effective driving force of
800 N to the 300 mm diameter-driving pulley on a milling machine. The torque
to overcome friction on the driving parts of the machine can be assumed as
9 N.m.
3.1.1 Torque transmitted to the machine pulley
3.1.2 Torque available at the milling cutter
diameter-milling cutter
(3 × 2) (6)
(8190194) -4- T1100(E)(N20)T
3.2 Calculate the power consumed by the following:
3.2.1 Lathe operation during which the cutter force applied to the cutting
tool is 1 500 N and the rotational speed of the workpiece with a
diameter of 400 mm is 350 r/min
3.2.2 Shaper operation involving a cutting force by 750 N and a stroke

length of 130 mm long which takes 9 s to complete
(2 × 4) (8)
[14]
QUESTION 4
4.1 Calculate the distance X in FIGURE 1 below.
FIGURE 1 (8)
4.2 A gear with a module of 10 mm and a pressure angle of 20° is to be tested for
correctness by using the constant-chord method of testing.
Calculate the constant-chord width and height. (6)

[14]

(8190194) -5- T1100(E)(N20)T
QUESTION 5
The compound gear system of a reduction gearbox is shown in FIGURE 2 and

consists of an input gear A with 68 teeth rotating at 850 r/min and an intermediate shaft
on which two gears B and C are mounted having 136 and 70 teeth respectively and D
having 100 teeth.
If this gear system has a module of 6 mm, calculate the following:
5.1 The rotational speed of B, C and D (6)
5.3 The centre distance X (3)
5.4 The centre distance Y (3)
X
C
FIGURE 2
[14]

(8190194) -6- T1100(E)(N20)T
QUESTION 6
Water is in steady motion in a pipe that is inclined downwards. The diameter at the
upper end is 100 mm and the pressure is 55 kPa. The diameter at the lower end is 63
mm and the pressure is 35 kPa. The difference in vertical heights between the two
points is 3 m.
Determine the rate of flow in litres/seconds. Assume that there are NO losses because
of friction in the pipe. [14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1100(E)(N20)T
FORMULA SHEET
PCD
1. m 
T 2. DO = m × (T + 2)
m
3. C   ( TA  TB ) 1
2 4. Ke  mv 2
2
TA
TB 6. VR 
PCD of pinion
NB
7. VR 
NA 8. NA × TA = NB × TB
2T
9. Ft 
PCD
10. Fr = Ft × Tan 
11. Fn = Ft × Sec 
14. T  TA  
13. T  = Ie ×  A ( NA ) 1 ( NA ) 1 2
NB B B IA
NA A A IB
  PCD
17. P  18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. 
21. v =  × (d + t) × N 22. P = Te × v
T1
23.  e  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
28. Tg = m × g × sin  29. v = T × r

(8190194) -2- T1100(E)(N20)T
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
T1 1  Tan  
34.    Rr
T 2 1  Tan   35. Cos 
2 C
 Rr
36. Cos 
2 C 37. m = w × t × L × ρ
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   v 2 51. hf 
50. hf  3,026  d 5
2 g d
Cd  A  a  ( 2 gh )
52. Q  ( 2 gh )
53. Q  Cd  A 
(A a )
2 2
( m2  1 )
ms
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

(8190194) -3- T1100(E)(N20)T
a 62. ω = 2 × N
60. T (acc drum) = I    mk 2 
R
work done
64. Ke 
efficiency
61. P = ω× T
66. (I1 + I2)ω3 = I1ω1 + I2ω2
1
63. Ke  I   2
2 Tan 
68.  
Tan (    )
  F  Re
70. T 
67. µ = Tan  sin 
72. Fc = m × ω 2 × 
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc 

76.  
Copyright reserved
T1030(E)(J27)T
MECHANOTECHNICS N4
(8190194)
27 July 2017 (X-Paper)

09:00–12:00

(8190194) -2- T1030(E)(J27)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1030(E)(J27)T
QUESTION 1
1.1 Production methods generally used in the manufacturing industry include

mass production, batch production and individual production.
1.1.1 Explain individual production. (3)
1.1.2 List FIVE characteristics of individual production. (5)
1.2 Give TEN advantages of rolling bearings when compared to journal bearings. (10)
1.3 Give FIVE advantages of airless spray-painting. (5)
1.4 Make a labelled drawing of the air (conventional) spray-painting method. (7)
[30]
QUESTION 2
The following are particulars of an open flat-belt drive between a motor and a machine:
Belt speed = 900 m/min

Centre distance between shafts = 5m
Speed of the motor = 1 500 r/min
Contact angle on motor pulley = 180˚
Power = 15 kW
Speed of machine = 2 500 r/min
Contact angle on machine pulley = 175˚
Thickness of belt = 5 mm
Maximum allowable tension = 150 N per cm of belt width
Coefficient of friction = 0,25
2.1 The diameter of both pulleys (4)
2.2 The width of the belt in mm (7)
2.3 The length of the belt (3)

[14]
QUESTION 3
3.1 The electric motor of a drilling machine produces 950 W and has an efficiency
of 85%.
Calculate the cutting force on each cutting face edge of the drill if a hole of
30 mm in diameter has to be drilled with a drill rotating at 1 250 r/min. (6)

(8190194) -4- T1030(E)(J27)T
3.2 A grinding wheel with a diameter of 200 mm rotates at 3 000 r/min with a
tangential force of 40 N on the workpiece. The motor runs 1 500 r/min and the
efficiency of the machine is 72%.
3.2.1 The output power of the grinding wheel (3)
3.2.2 The input power of the motor (2)
3.2.3 The torque on the shaft of the motor (3)

[14]
QUESTION 4
4.1 The FIGURE below shows a 150 mm-deep V-groove with an included angle
of 65˚. This V-groove is checked with the aid of a 75 mm-diameter precision
roller, a set of gauge blocks and a straight edge.
65˚
150 mm
V-GROOVE
Calculate the thickness of the gauge blocks. (7)
4.2 An ISO 150 screw thread with a 4 mm pitch has an effective diameter of
35 mm. The three-wire method is used for checking the effective diameter. If
the best wire size is used for the test wires, calculate the micrometer reading
over the three wires. (7)
[14]

(8190194) -5- T1030(E)(J27)T
QUESTION 5
A set of spur gears, A and B, has a velocity ratio of 5 : 3 and a module of 6 mm.
If the pinion (A) has 30 teeth, calculate the following:
5.1 The pitch circle diameter of both gears (A and B) (4)
5.2 The centre distance between the two shafts (2)
5.3 The outside diameter of both gears (A and B) (4)
5.4 The total depth that the drilling cutter must be fed into the gear blank in order
to cut the teeth (4)
[14]
QUESTION 6
6.1 A 10 mm-diameter sharp-edged orifice is provided in the vertical side of a

water tank. The centre line of the orifice is 750 mm below the water level. The
set of water issuing in a horizontal direction reaches a horizontal distance
of 550 mm and falls 128 mm vertically. The set diameter of the vena contract
is 9 mm. Assume that the head of the water in the tank remains constant.
6.1.1 The coefficient of delivery (cd)
6.1.2 The coefficient of velocity (cv)
6.1.3 The coefficient of contraction (cc)
6.1.4 The time taken, in seconds, to discharge 50 litres of water from the
tank
(4 × 2) (8)
6.2 A venturi meter with a throat diameter of 160 mm is placed in a pipe with a
diameter of 260 mm. The discharge rate of the pipe is 135 litres per second.
Assume that the coefficient of delivery being used is 0,97 and that the venture
meter is equipped with a mercury manometer.
Calculate the mercury head in the manometer. (6)

[14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1030(E)(J27)T
FORMULA SHEET
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 =
PCD
10. Fr = Ft × Tan f
14. Ta = TA + +
13. T a = Ie × a A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = d × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -2- T1030(E)(J27)T
30. v = m ´ g ´ r g ´b´r
31. v =
2´h
é m + Tan q ù
32. v = gr ê ú
ë1 - mTan q û é hTanq + b / 2 ù
33. v = gr ê ú
n
T 1 é1 + mTan q ù
34. =ê ú q R-r
T 2 ë1 - mTan q û 35. Cos =
2 C
f R+r
36. Cos =
2 C 37. m = w × t × L × ρ
38. T1 = w × n × ft
39. P = Pg + Pµ
I ´w
40. t =
T 2´p ´ N ´T
41. P =
60
42. T = F × r
43. w = do + 3d - 1,5155P
44. do = de + 0,65P p ´m
45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3- T1030(E)(J27)T
a 62. ω = 2p × N
60. T (acc drum) = I ´ a = mk 2 ´
R
work done
64. Ke =
efficiency
61. P = ω× T
66. (I1 + I2)ω3 = I1ω1 + I2ω2
1
63. Ke = I ´ w 2
2 Tan q
68. h =
Tan ( q + f )
m ´ F ´ Re
70. T =
67. µ = Tan q sin q
72. Fc = m × ω 2 × g
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh
Copyright reserved
T1120(E)(M30)T
MECHANOTECHNICS N4
(8190194)
30 March 2017 (X-Paper)

09:00–12:00

(8190194) -2- T1120(E)(M30)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
4. ALL the work done in pencil (excluding sketches, drawings and diagrams) will
be regarded as rough work and will NOT be marked.

(8190194) -3- T1120(E)(M30)T
QUESTION 1
related equipment in different work areas, as well as arranging for storage
space or stores, staff facilities and administrative offices. The placing of the
machines on the floor of a workshop has to comply with certain important
requirements.
1.1.1 Name FIVE of these requirements. (5)
1.1.2 Briefly discuss the FIVE requirements named in

QUESTION 1.1.1. (5)
1.2 Journal bearings have certain advantages and disadvantages when

compared to roller bearings.
State TEN advantages of journal bearings. (10)
1.3 Electroplating is a process by which a metal is electrolytically deposited onto

another metal.
1.3.1 Explain the process of electroplating. (5)
1.3.2 Make a labelled drawing of electroplating. (5)

[30]
QUESTION 2
A conveyer belt-drive with an inclination angle of 17o has a capacity of 300 tons of rock
per hour. It is 125 m long between the loading point and the discharge point. The belt
speed is 1,5 m/s and a friction force of 10 kN applies. Assume that the contact angle
and the driving pulley is 230o, the coefficient of friction is 0,3 and the efficiency of the
drive is 80%.
Determine:
2.1 The input power needed from the driving motor (8)
2.2 The slack side belt tension T2 (4)
2.3 The tight side belt tension T1 (2)

[14]

(8190194) -4- T1120(E)(M30)T
QUESTION 3
3.1 A workpiece of 500 mm in diameter is being machined in a lathe. The spindle

speed of the lathe is 20 r/min and the efficiency of the drive is 85%. Take the
cutting pressure as 950 N/mm2 and the cutting depth of the cutting tool as
3,5 mm if the cutting feed of the cutting tool is 0,75 mm per revolution.
Calculate the output power at the cutting tool. (6)
3.2 In a cutting tooth operation on a milling machine, the horizontal force exerted
by the milling cutter is 1,5 kN. The milling cutter has a diameter of 125 mm
and rotates at 70 r/min. The feed of the milling cutter is 0,175 mm per tooth
and the cutter has 45 teeth.
Calculate the following if the average feed is equal to the tangential cutting
force:
3.2.1 The cutting speed of the milling cutter (2)
3.2.2 The power consumed during the cutting action of the milling cutter (2)
3.2.3 The power consumed for the feed of the milling machine (4)
[14]

(8190194) -5- T1120(E)(M30)T
QUESTION 4
FIGURE 1 below shows a V-groove with an included angle of 50º and a depth of
60 mm that is tested by means of a precision ball 45 mm in diameter.
FIGURE 1
4.1 Make a drawing in the ANSWER BOOK making use of a set of gauge blocks,
a straight edge and a precision roller of 45 mm diameter. (4)
4.2 Calculate the thickness of the gauge blocks used in QUESTION 4.1. (6)
4.3 Describe how the V-groove angle of 50° should be checked. (4)
[14]

(8190194) -6- T1120(E)(M30)T
QUESTION 5
The following specifications apply to a simple gear train with a pinion A and a gear
wheel B:
Module = 3,5 mm
Pressure angle = 20o
Gear ratio = 3 : 1
Pitch-circle diameter (PCD) of the pinion = 66,5 mm
Calculate:
5.4 The pitch circle diameter of the gear wheel (2)

[14]
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
(constriction) is 41 mm.
If the horizontal distance of the water jet is 2,15 m and the jet falls 327 mm vertically,
determine:
6.5 The coefficient of delivery (Cd)
6.6 The coefficient of velocity (Cv)
6.7 The coefficient of contraction (Cc)

(7 × 2) [14]
TOTAL: 100
Copyright reserved
(8190194) -1- T1120(E)(M30)T
MECHANOTECHNICS N4
FORMULAE
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T1 - TC
25. Tc = m × v2 26. = e mq cosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -2- T1120(E)(M30)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n q R-r
T1 é1 + mTan q ù 35. Cos =
34. =ê ú
T 2 ë1 - mTan q û 2 C
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2 ´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
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 )
52. Q = ( 2 gh )
53. Q = Cd ´ A ´
( A2 - a 2 )
( m2 - 1 )
m´s
r ´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3- T1120(E)(M30)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R
61. P = T × T 62. T = 2p × N
1 work done
63. Ke = I ´ w2 64. Ke =
2 efficiency
65. P = Ke × operations/sec 66. (I1 + I2)T3 = I1T1 + I2T2
Tan q
67. µ = Tan q 68. h =
Tan ( q + f )
m ´ F ´ Re
70. T =
69. T = µ × F × Re × n sin q
72. Fc = m × T 2 × g
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh
Copyright reserved
T960(E)(N29)T
NOVEMBER EXAMINATION
MECHANOTECHNICS N4
(8190194)

09:00–12:00
This question paper consists of 6 pages and 1 formula sheet of 3 pages.

(8190194) -2- T960(E)(N29)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
4. Candidates are advised to produce good sketches.

(8190194) -3- T960(E)(N29)T
QUESTION 1
1.1 The most common tests that are performed for corrosion are the salt, humidity
and the sulphur-dioxide tests.
1.1.1 Briefly explain the process of the salt-spray test. (5)
1.1.2 Make a labelled drawing of a salt-spray test. (5)
1.2 Since each workshop layout has its individual requirements and conditions
under which it has to function, the factors to be considered when designing a
particular layout would differ from one to another.
Name 10 important factors to be considered in the design of a workshop

layout. (10)
1.3 One of the first observable signs of imminent bearing failure is overheating.
Briefly describe how you would treat a journal bearing which overheats. (10)
[30]
QUESTION 2
2.1 The width of the belt in a flat-belt drive is 250 mm and the thickness of the belt
is 6 mm, the tension in the tight side of the belt is two and a half times greater
than that in the slack side of the belt and the safe working stress is 350 kPa;
the pulley has a diameter of 1 500 mm and rotates at 150 r/min.
Calculate the power transmitted by the belt. (8)
2.2 The following particulars apply to an incline belt conveyor:
Angle of incline of belt conveyor = 150

Incline length of the belt = 120 m
Speed at which belt moves = 2.5 m/s
Load conveyed = 450 tons of rock per hour
Force needed to overcome belt tension = 4 500 N
Calculate the power output needed from the motor to drive the system. (6)
[14]

(8190194) -4- T960(E)(N29)T
QUESTION 3
3.1 A shaft, 250 mm in diameter is revolving in a bearing and exerting a force of

75 kN on the bearing. The coefficient of friction between the shaft and the
bearing is 0,02 and the shaft rotates at 350 r/min.
Calculate the power lost due to friction. (6)
3.2 When a workpiece, 75 mm in diameter is machined on a lathe, the cutting

force applied to the cutting tool is 2 500 N. Assume that 15 N.m of torque is
lost due to friction in the bearings of the lathe spindle.
3.2.1 The torque needed at the driving pulley of the lathe. (3)
3.2.2 The driving force at the driving pulley of the lathe if it has an
effective diameter of 250 mm. (2)
3.2.3 The power needed at the driving pulley of the lathe if it rotates at
275 r/ min. (3)
[14]
QUESTION 4
FIGURE 1 below shows a taper of 1-in-5 on the diameter that must be tested for
correctness by using 18 mm diameter rollers. The centre distance between the top
and bottom rollers is 55 mm. The taper is 80 mm long. The top diameter of the taper
is 50 mm.
Calculate from a neat construction of drawings the distance across the top and bottom
rollers.
FIGURE 1 [14]
(8190194) -5- T960(E)(N29)T
QUESTION 5
An epicyclical gear train is shown in FIGURE 2.
The sun gear B, which is connected to the output shaft, rotates at 120 r/min in a
clockwise direction. Gears C and D are mounted on the same axis.
Number of teeth in gear A is 60, while gear D has 20 teeth, gear C 24 and gear B
16 teeth.
FIGURE 2
NO CONDITIONS A B C D ARM
E
1 Fix ARM E and rotates A = +1
1 0
2 Multiply by x and add y x+y y
3 NE = 0
NB = 120
4 NA = 0
NB = 120
Make use of the conditions given in the above table to calculate the following:
5.1 The velocity ratio of sun gear B (2)
5.2 The velocity ratio of planetary gear C (2)
5.3 The velocity ratio of gear D (2)
5.4 The speed and direction of the annulus A if arm E is fixed. (4)
5.5 The speed and direction of rotation of arm E, assuming the annulus A is fixed. (4)
[14]

(8190194) -6- T960(E)(N29)T
QUESTION 6
6.1 A horizontal pipe line with a diameter of 90 mm conveys water at the rate of
20 Us with a pressure drop of 40 kPa for every 30 metres pipe line.
Calculate the value of the coefficient of friction (f) for the above mentioned
6.2 Use Chezi's formula for the circumstances in QUESTION 6.1 and calculate
the values of:
6.2.1 The hydraulic mean depth 'm' (2)
6.2.2 The hydraulic gradient 'I' (2)
6.2.3 The Chezi coefficient 'C' (3)
6.3 A pipe is 3,5 km long and connects two reservoirs. The difference in water
levels between the reservoirs is 40 m. The flow rate of the water in the pipe is
0,75 m3/s and the coefficient of friction is 0,005.
6.3.1 Diameter of the pipeline (2)
6.3.2 Hydraulic gradient (2)

l14]
TOTAL: 100
Copyright reserved
(8190194) -1- T960(E)(N29)T
MECHANOTECHNICS N4
FORMULAE
PCD
1. m  2. DO = m × (T + 2)
T
m 4. Ke 
1
mv 2
3. C   ( TA  TB )
2 2
TA PCD of gear
5. VR  6. VR 
TB PCD of pinion
NB 8. NA × TA = NB × TB
7. VR 
NA
2T
9. Ft  10. Fr = Ft × Tan 
PCD
11. Fn = Ft × Sec 
14. T  TA  
13. T = Ie × A ( NA ) 1 ( NA ) 1 2
NB B B IA
NA A A IB
  PCD
17. P  18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. 
21. v =  × (d + t) × N 22. P = Te × v
T1
23.  e  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
28. Tg = m × g × sin  29. v =  × r

(8190194) -2- T960(E)(N29)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  
n
T1 1  Tan    Rr
34.  35. Cos 
 C
T 2 1  Tan   2
 Rr
36. Cos  37. m = w × t × L × 
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I  2  N T
40. t  41. P 
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
 m
44. do = de + 0,65P 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   v 2 51. hf 
50. hf  3,026  d 5
2 g d
Cd  A  a  ( 2 gh )
52. Q  ( 2 gh )
53. Q  Cd  A 
(A a )
2 2
( m2  1 )
ms
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

(8190194) -3- T960(E)(N29)T
a
60. T (acc drum) = I    mk 2 
R
61. P =  × T 62.  = 2 × N
1 work done
63. Ke  I  2 64. Ke 
2 efficiency
65. P = Ke × operations/sec 66. (I1 + I2)3 = I11 + I22
Tan 
67. µ = Tan  68.  
Tan (    )
  F  Re
70. T 
69. T = µ × F × Re × n sin 
72. Fc = m ×  2 × 
71. T = µ × n × (Fc - S)R
mv 2
73. Fc 

76.  
Copyright reserved
MARKING GUIDELINE
MECHANOTECHNICS N4
29 NOVEMBER 2016

MARKING GUIDELINE -2- T960(E)(N29)T
MECHANOTECHNICS N4
QUESTION 1
1.1 1.1.1 The salt-spray test is done to test the porosity and resistance to
ocean-front corrosion of metals.ü These metals can be exposed to
the salt spray of the sea for a period by constructing a suitable
apparatus on the beach, however,ü this test is not always
practical. An alternative method is to expose the metal to a spray
of sodium chloride solution.
A metal workpiece is placed in a test chamber. Sodium chloride is
then atomised in a spray nozzle by means of compressed air to
form a fine salt mist (fog), before it is let into the test chamber,ü
where the temperature is thermostatically controlled. The salt mist
rises and settles on the test pieces.ü These test pieces are
suspended at an angle in the test chamber, so that the fog
concentrate which settles on them flows and is collected for
analysis.ü (5)
1.1.2 Test pieceü

Supply of salt
solutionü
Compressed air
supplyü
Spray nozzleü
Container for salt

solutionü
Heating elementü (5)

MECHANOTECHNICS N4
1.2 · Type of production required, e.g. mass production, batch production or

individual production.
· Inspection requirements to be met.
· The type of equipment needed, and the quantity thereof.
· The quantity of material required.
· Sequence in which production is to take place.
· Volume of final product to be manufactured.
workers
· Regulations of local authority
· Any additional services which are available, for example water, gas,
sewerage and electricity.
· The type and quantity of the available workforce and the level of skill of
these workers
· The storage space available
· The type of handling equipment to be used.
· The workshop by-products and waste products which might cause
pollution. (Any 10 x 1) (10)
1.3 Flood the bearing with oil. Do not under any circumstances pour cold water
onto the bearing.üü Examine the hot water by feeling it between the fingers
to establish whether grit is present. Keep flooding the bearing with oil until no
more grit is present.üü Pour oil on the shaft, next to the bearing. Reduce
the pressure on the bearing by reducing the load or, if possible reducing the
speed at which the bearing is operating.üü If the bearing remains hot,
slacken off the bearing-cap nuts.üü After the bearing has cooled down,
tighten the bearing and slowly restore the load.üü (10)
[30]

MECHANOTECHNICS N4
QUESTION 2
2.1 T1 = Stress ´ Area

= 350 ´ 0,06 ´ 0,25"
= 525N
T1 = 2.5T2
T1
T2 =
2,5
525
=
2,5
= 210 N
v = π(d + t ) ´ N
= π(1,5 + 0,006 ) ´ 2,5
= 11,828 ms -1
P = (T1 - T2 ) ´ v
= (525 - 210 ) ´ 11,829
= 3725,82 W (8)
2.2 Pg = mgh
( )
= 125 ´ 9,81 ´ 120 sin 15 0
= 38 085,222 W
Pf = F ´ v
= 4 500 ´ 2.5
= 11 250 W
P0 = Pg + Pf
= 38 085,222 + 1 1250
= 49 335,222 W (6)
[14]

MECHANOTECHNICS N4
QUESTION 3
3.1 Fi = μ ´ F
= 0,02 ´ 75 ´ 10 3
= 1 500 N
T = F´ r
1 500 ´ 0,25
=
2
= 187,5 Nm
2´p ´ N ´ T
P=
60
2 ´ p ´ 350 ´ 187,5
=
60
= 6 872,234 W (6)
3.2 3.2.1 T = F´ r
2 500 ´ 0,075
=
2
= 93.75 Nm
Tk = 93,75 + 15
= 108,75 N.m (3)
3.2.2 T
F=
r
108,75
=
0,125
= 870 N (2)
3.2.3 2´p ´ D ´ N
v=
60
2 ´ p ´ 0,25 ´ 275
=
60
= 7,2004 ms -1
P = F´ v
= 870 ´ 7,2004
= 6 264,3625W (3)
[14]

MECHANOTECHNICS N4
QUESTION 4
B
θ C 1
AC
tanθ =
BC
0.5
=
5
θ = tan -1 (0.1)
= 5.7110
Included angle = 2 ´ 5,7110

= 110 25 / (3)
50
B C
50-2BC
√

MECHANOTECHNICS N4
In D ABC
AB = 80
BC
tanθ =
AB
Þ BC = ABtanθ
= 80tan5.711
= 8 mm
Small diameter = 50 - 2BC

= 50 - 2 ´ 8
= 34 mm (3)
Bottom Roller X
A φ E
34 AE DE
√
X = 34 + 2AE + 2D
In ΔADE
1
j = (90 - 5,711)
2
= 42,145 0 (3)

MECHANOTECHNICS N4
G H
D
q
E f F
EF = AE = 9.944
HF = 80 - 55
= 25
GH
tanθ =
HF
Þ GH = HFtanθ
= 2,5tan5.711
= 2,5
Y = (50 - 2GH ) + 2 ´ 9 + 2 ´ 9,944

= (5 002 ´ 2,5) + 2 ´ 9 + 2 ´ 9,944
= 82,8 9 mm (5)
[14]

MECHANOTECHNICS N4
QUESTION 5
5.1 60 24
VB = ´
20 - 16
= -4.5 (2)
5.2 60
VC =
20
=3 (2)
5.3 60
VD =
20
=3 (2)
5.4 NA
NA = x + y
- 4,5x + y = 120
y=0
Þ -4,5x = 120
120
x=-
4,5
= -26,667
Þ NA = x + y
= -26,667 + 0
= -26,667 (4)
5.5 NE = y .........................(1)
x+y=0 .........................(2)
- 4,5 + y = 120 ..................(3)
eqn (2) - eqn (3)
5,5x = -120
- 120
x=
5.5
= -21.82
Þ y = 21,82 and
from (1) N E = y
= 21,82 r/min (4)
[14]

MECHANOTECHNICS N4
QUESTION 6
6.1 pressure
hf =
Rho ´ g
40 ´ 10 3
=
1000 ´ 9.81
= 4.077 m
h f ´ 3.026d 5
F=
L ´ Q2
4.077 ´ 3.026 ´ 0.09 5
=
30 ´ 0.02 2
= 0.006 (3)
6.2 6.2.1 d
m=
4
0.09
=
4
= 0.0225 (2)
6.2.2 hf
i=
L
4.077
=
30
= 0.1365 (2)
6.2.3 Q
v=
A
0.02 ´ 4
=
π ´ 0.09 2
= 3.144 ms -1
v
C=
mi
3.144
=
0.0225 ´ 0.136
= 56.215 (3)

MECHANOTECHNICS N4
6.3 6.3.1 f ´ l ´ Q2
d=5
3,026h f
0,005 ´ 3,5 ´ 10 3 ´ 0,75 2
=5
3,026 ´ 40
= 0,604 m
= 604 mm (2)
6.3.2 hf
i=
l
40
=
3,5 ´ 10 3
= 0,011 (2)
l14]
TOTAL: 100

T960(E)(A10)T
AUGUST EXAMINATION
MECHANOTECHNICS N4
(8190194)
August 2016 (X-Paper)

9:00–12:00

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

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
4. All sketches must be clear, neat and labelled.

(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:
1.2.1 Electroplating
1.2.2 Electrostatic spray-painting

(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.
1.3.1 Describe the product layout. (2)
1.3.2 Name FOUR requirements for the product layout. (4)
1.3.3 State FOUR disadvantages of the product layout. (4)

[30]
QUESTION 2
An open flat-belt drive is used to transmit 25 kW. The driving pulley has a diameter of
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:
2.1 The belt speed (2)
2.2 Ratio of belt tension (2)
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]

(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)
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)
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.
Calculate:
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.
3.2.2 The power consumed by the cutting process if the bar of steel
rotates at 650 r/min.
(2 x 3) (6)
FIGURE 1 [14]

(8190194) -5- T960(E)(A10)T
QUESTION 4
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)
FIGURE 2
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.
4.2.2 Use the given dimensions and calculate distance 'X'. (5)
FIGURE 3 [14]

(8190194) -6- T960(E)(A10)T
QUESTION 5
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)
FIGURE 4
5.2 A simple spur-gear train made of a gear wheel A and a pinion B has a module
of 5 mm.
The velocity ratio of the two gears is 3,1 and the pinion has 24 teeth.
Calculate:
5.2.1 The pitch-circle diameter of gear wheel A. (3)
5.2.2 The pitch-circle diameter of pinion B. (1)
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]

(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:
6.5 The coefficient of delivery (Cd)
6.6 The coefficient of velocity (Cv)
6.7 The coefficient of contraction (Cc)

(7 x 2) [14]
TOTAL: 100
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
2
TA
TB 6. VR 
PCD of pinion
NB
7. VR  8. NA × TA = NB × TB
NA
2T
9. Ft 
PCD
10. Fr = Ft × Tan 
11. Fn = Ft × Sec 
14. T  TA  
13. T = Ie × A ( NA ) 1 ( NA ) 1 2
NB B B IA
NA A A IB
  PCD
17. P  18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. 
21. v =  × (d + t) × N 22. P = Te × v
T1
23.  e  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
28. Tg = m × g × sin  29. v =  × r

(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  
n
T1 1  Tan    Rr
34.  35. Cos 
 C
T 2 1  Tan   2
 Rr
36. Cos  37. m = w × t × L × 
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I  2  N T
40. t  41. P 
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
 m
44. do = de + 0,65P 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   v 2 51. hf 
50. hf  3,026  d 5
2 g d
Cd  A  a  ( 2 gh )
52. Q  ( 2 gh )
53. Q  Cd  A 
(A a )
2 2
( m2  1 )
ms
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

(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
Tan 
65. P = Ke × operations/sec 68.  
Tan (    )
67. µ = Tan    F  Re
70. T 
sin 
72. Fc = m ×  2 × 
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc 

76.  

MARKING GUIDELINE
AUGUST EXAMINATION
MECHANOTECHNICS N4
10 AUGUST 2016

MARKING GUIDELINE -2- T960(E)(A10)T
MECHANOTECHNICS N4
QUESTION 1
1.1 1.1.1 · Rust or corrosionü

· Cage failureü
· Indentation of the elementsü
· Flakingü
· Abnormal noiseü
· Cracks and fracture (Any 5 x 1) (5)
1.1.2 Rust or corrosion

This fault can be caused by using the wrong lubricant, or by water
or moisture entering the bearing.ü
Cage failure
The cage which spaces the rollers or balls is placed under light
strain during the operation of the bearing. Because they are very
sensitive to poor lubrication, the places where they touch the rolling
elements will begin to show wear and will later even give and
break.ü
Indentation of the elements

When lubrication is ineffective or the bearing is not protected
against the entry of impurities or dust, the small particles will
damage the raceway as well as the balls and rollers by being
pressed between the rolling elements and the raceway.ü
Flaking
If the bearing is used incorrectly, small fatigue cracks may appear
on the rolling elements and raceways. These cracks cause very
small fragments to break off and flake. Although the flaking
fragments are very small, continuous use of the bearing causes the
flaking to spread over the entire loaded zone, with the result that
the bearing eventually becomes completely useless.ü
Abnormal noise
Abnormal noise can be caused by wear or damage to the bearing
and rolling elements, dust or dirt entering the rolling elements, or
poor or insufficient lubricants.ü
Cracks and fractures

Cracks and fractures may be the result of incorrect mounting,
where the inner race is fitted to the shaft or the outer race fits too
tight in the sleeve. Cracks and fracture can also be caused by
loads on the bearing which are too heavy or the use of the wrong
type of bearing for a specific application. (Any 5 x 1) (5)

MECHANOTECHNICS N4
1.2 1.2.1 The metal to be plated called the cathode, is connected to the
negative pole of a low-voltage direct current source while a plating
metal, the anode, is connected to the positive pole of the direct
current source.ü When the two electrodes are placed in the
electrolyte, electron and ion movement occurs in the electrolyte,
from the anode to the cathode. As this electron and ion movement
takes place the anode starts corroding and a metal deposit forms
on the cathode.ü When two copper wires are connected to the
negative and positive poles of a low-voltage direct current source
and placed in a diluted solution of copper sulphate, a plating
process will start.ü The anode gradually gets thinner, while the
cathode gradually gets thicker. üThe loss in mass of the anode will
be exactly equal to the gain in mass of the cathode. The copper-
sulphate solution in the plating bath undergoes no change.ü
1.2.2 With electrostatic spray-painting we create a positive and negative

electrostatic field to deposit the paint on the metal.ü We
adequately earth the metal to be painted.üMetals have a positive
charge; so we negatively charge the paint in the nozzle. When the
paint then leaves the nozzle, the positive metal automatically
attracts it.ü The metal part attracts the paint spray leaving the
nozzle by electrostatic force, and so the work can even attract
overspray. üThis gives the so-called ‘wrap-around effect', with an
accompanying reduction in paint loss through overspray.ü
(2 x 5) (10)
1.3 1.3.1 With product layout the machines are arranged in the order in
which you wish the workers to process the product. Processing of
the raw material starts at the first machine.ü The material passes
without interruption to the next machine in the line, until the final
product emerges from the last machine.ü (2)
1.3.2 The manufacture of sufficiently larger volumesü

Sufficient spares for the maintenance of machinesü
A sufficient supply of raw materials to prevent interruptionü
The minimum number of changes in the design of the productü
Careful production planning
The setting of strict inspection requirements (Any 4 x 1) (4)
1.3.3 There is lack of flexibility due to specialised machinery and

methods.ü
If one machine breaks down, the whole production line stops.ü
Large volumes must be maintained.ü
Faulty parts that are found during inspection are rejected, due to
lack of specialised adjustment on the production line.ü
There is a high capital outlay because of specialised machines or
duplication of machines. (Any 4 x 1) (4)
[30]

MECHANOTECHNICS N4
QUESTION 2
2.1 Belt Speed

V = πDN
= π ´ 0,2 ´ 4,445ü
= 2,793 m/s ü (2)
2.2 Ratio of belt tension

θ ´μ
T1
=e 57.3
T2
0.37´176 0ü
= e 57.3
T1 = 3,1155T2ü (2)
2.3 Tension in the slack side

P = (T1 - T2 )V
25 000 = (3,1155T2 - T2 ) ´ 2,793 ü
25 000
2,1155T2 =
2,094
25 000 ü
T2 =
5,9083
ü
= 4 232,127 N (3)
2.4 Tension in the tight side

T1 = 3,1155T2
= 3,1155 ´ 4 232,127 ü
= 13 183,076 N ü (2)
2.5 Length of open belt

D´ N =dń
200 ´ 4,445 = dx3,333
200 ´ 4.445
D=
3,333
ü
= 266,727 mm
= 267 mm
π
L= (D + d ) + 1 (D - d )2 + 2C
2 4C
π 1
= (267 + 200) + (267 - 200)2 + 2 ´ 1 500 ü
2 4 ´ 1 500
= 3 734,408 mmü
= 3,734 m (3)

MECHANOTECHNICS N4
2.6 Length for crossed belt

π 1
L = (D + d ) + (D + d )2 + 2C
2 4C ü
π 1
= (267 + 200) + (200 + 200)2 + 2 ´ 1 500 ü
2 4 ´ 1,5
= 3 770,005 mm ü
= 3,77 m (2)
[14]
QUESTION 3
3.1 3.1.1 Pi
T=
2π ´ N motor
2 500
= ü
2π ´ 1 500
ü (2)
= 15,915 N
3.1.2 P0 = η ´ Pi
= 0,85 ´ 2 500 ü
= 2 125 W ü
P ´ 60 ü
T=
2π ´ 3500
ü (4)
= 5,798 Nm
3.1.3 P0 ´ 60
T= ü
2π ´ 30
= 676,409 Nmü (2)

MECHANOTECHNICS N4
3.2 3.2.1
1000 N
F
B A
135 60
ACM = CWM
F ´ 135 = 1 000 ´ 60
1 000 ´ 60 ü
F=
135
= 444,444 N ü
3.2.2 T = F´ r
= 1 000 ´ 0,0425
= 42,5 Nm ü
2ππN
P=
60
2π ´ 650 ´ 42,5 ü
=
60
= 2 892,88 W ü
(2 x 3) (6)
[14]

MECHANOTECHNICS N4
QUESTION 4
4.1 4.1.1
X mm
125 mm
A B
0
65
f 25 mm
E 35 mm
C D
(2)
4.1.2 In ΔABC
AB
= tan 25 0
35
AB = 35 tan 25 0
= 16,32 ü
In ΔCDE
12,5
tan 32,5 0 =
CD
12,5
CD =
tan 32,5 0
ü
= 19,62
Distance X = 125 - 2AB + 2CD + 2R

= 125 - 2AB + 2CD + 25 ü
ü
= 125 - 2 ´ 16,32 + 2 ´ 19,62 + 25
ü
= 156,78 mm
ALTERNATIVE METHOD:
X= 2R + 2CD + DE
= 25 + (2 x 19,62) + 92,36
= 156,6 mm (5)

MECHANOTECHNICS N4
4.2 4.2.1
(2)
4.2.2 In ΔABC
7,5ü
tan 22,5 0 =
AB
7,5
AB =
tan 22,5 0 ü
= 18,106 mm ü
Distance X = 125 - 2AB - 2R

= 125 - 2 ´ 18,106 - 2 ´ 7,5ü
= 73,786 mm ü (5)
[14]

MECHANOTECHNICS N4
QUESTION 5
5.1 5.1.1 Number of teeth
m
C= (TA - TB )
2
1,5
45 = (TA - 30) ü
2
90
TA - 30 =
1,5
TA = 30 + 60 ü
= 90
5.1.2 PCD = m ´ TA
= 1,5 ´ 90ü
= 135 mmü
(2 x 2) (4)
5.2 5.2.1 PCD of A
TA = 3 ´ TB
= 3 ´ 24 ü
= 72 teeth ü
PCD = m ´ TA
= 5 ´ 72
= 360 mmü (3)
5.2.2 PCD of B
PCD = m ´ TB
= 5 ´ 24 ü
= 120 mm ü (1)
5.2.3 5
C= (72 - 24) ü
2
= 120 mm ü (2)
5.2.4 D 0 of A
D 0 = m(TA + 2 ) ü
= 5 ´ (72 + 2 )
= 370 mm ü (2)

MECHANOTECHNICS N4
5.2.5 D 0 of B
D 0 = m(TB + 2 )
= 5 ´ (24 + 2) ü
= 130 mm ü (2)
[14]
QUESTION 6
6.1 v t = 2 gh
= 2 ´ 9,81 ´ 4,5 ü
= 9,396 m/s ü
6.2 gx 2
va =
2y
9,81 ´ 2,15 2 ü
=
2 ´ 0,327
ü
= 8,327 m/s
6.3 Qt = vt ´ At
p ´ 0,052 2
= 9,396 ´ ü
4
= 0,01989 m /s ü
3
6.4 Qa = va ´ Aa
p ´ 0,0412 ü
= 8,327 ´
4
3
= 0,01098 m /s ü
6.5 Qa
Cd =
Qc
0,01098
= ü
0,01989
= 0,55 ü
6.6 va
Cv =
vt
8,327 ü
=
9,396
= 0,886 ü

MECHANOTECHNICS N4
6.7 Aa
Cc =
At
0,00132ü
=
0,002123
= 0,62 ü (7 x 2) [14]
TOTAL: 100
Copyright reserved
T1040(E)(A11)T
APRIL EXAMINATION
MECHANOTECHNICS N4
(8190194)
11 April 2016 (X-Paper)

9:00–12:00

(8190194) -2- T1040(E)(A11)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
4. Candidates are hereby advised to produce good sketches.
5. ALL the work done in pencil excluding sketches, drawings and diagrams will

(8190194) -3- T1040(E)(A11)T
QUESTION 1
1.1 State TEN principles for good workshop layout. (10)
1.2 State THREE possible causes for each of the following faults that can happen
in the spray process:
1.2.1 Excessive paint spray
1.2.2 Uneven spray-painting
1.2.3 Sagging surface
1.2.4 Speckle or orange-peel effect

(4 × 3) (12)
1.3 Name THREE general methods of lubrication (3)
1.4 Make a labeled drawing of a siphon and wick lubricator which can be used for
lubricating machine parts. (5)
[30]
QUESTION 2
The thickness of a 4-ply leather belt is 13 mm, it transmits 45 kW from a pulley that is
1,3 m in diameter and the speed of this pulley is 255 r/min. The contact angle is 172°
and the coefficient of friction between the belt and the pulley is 0,27. The mass of the
belt is 9,75 kg/m and the maximum allowable tension is 8 kN/m width per ply.
2.1 Belt speed (2)
2.2 Centrifugal tension in the belt (2)
2.3 Tension in the tight side per width (2)
2.4 Tension in the slack side (4)
2.5 Power transmitted by 1 m belt width (2)
2.6 Belt width
GIVEN: w = total power/power per width (2)

[14]

(8190194) -4- T1040(E)(A11)T
QUESTION 3
FIGURE 1 shows the setup of the cutting tool that is held in the tool holder of a shaping
machine.
The ram of the shaping machine has a mass of 150 kg and is operating with a cutting
stroke length of 150 mm. The total work done during one cutting stroke is equal to
3.1 The work done to overcome the friction between the ram and the slides. (3)
3.2 The cutting force exerted on the cutting tool. (3)
the clamping screw is 2 000 N. (8)
[14]
FIGURE 1
QUESTION 4
4.1 An ISO screw thread with a 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.

(8190194) -5- T1040(E)(A11)T
4.2 4.2.1 Explain step-by-step how you would go about checking the
correctness of the teeth of a gear wheel that has a module of
10 mm and a pressure angle of 20°. Use a gear tooth vernier
calliper and apply the constant-chord method of checking. (4)
4.2.2 Make the necessary calculations for the test explained in

QUESTION 4.2.1 by using the constant-chord method of checking. (5)
[14]
QUESTION 5
5.1 An epicyclical gear train shown in FIGURE 2 consists of an annulus A having

130 teeth, a sun gear B having 40 teeth and a planetary gear C having
50 teeth that are mounted on arm D.
NR CONDITIONS A B C ARM D
1 Fix arm D and
rotates A = + 1 rev 0
2 Multiply by x and
add y x+y y
Make use of the conditions given in the table above to calculate the following:
5.1.1 The velocity ratio of sun gear B (1)
5.1.2 The velocity ratio of planetary gear C (1)
5.1.3 The speed of planetary gear C when annulus A is fixed and arm D
rotated at 50 r/min (4)
5.1.4 The speed of annulus A when sun gear B is fixed and arm D
rotates at 30 r/min (4)
FIGURE 2

(8190194) -6- T1040(E)(A11)T
5.2 A set of spur gears have a velocity ratio of 5 : 3 and a module of 6 mm if the
pinion has 30 teeth.
Calculate the pitch diameter of both gears. (4)

[14]
QUESTION 6
6.1 Determine the flow rate of water in litres per second (ℓ/s) flowing through a
200 mm diameter pipe equipped with a Venturi meter that has a throat
diameter of 130 mm. The coefficient of delivery is 0,97 and the mercury
manometer shows a reading of 880 mm. (7)
6.2 Water with a density of 1 000 kg/m3 flows through a tapered pipe which has a
large diameter of 0,4 m and a small diameter of 0,2 m. The pressure gauge at
the small diameter of the pipe is 16 kPa and the velocity of flow at the small
diameter is 20 m/s.
Calculate the pressure at the larger diameter of the pipe (7)

[14]
TOTAL: 100
Copyright reserved
(8190194) -1-
-7- T1040(E)(A11)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
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
( D ± d )2
+ 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -2-
-8- T1040(E)(A11)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
T 1 é1 + mTan q ù q R-r
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3-
-9- T1040(E)(A11)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R 62. T = 2p × N
work done
64. Ke =
1 66. (I1 + I2)T3 = I1T1 + I2T2

63. Ke = I ´ w2
2
Tan q
Tan ( q + f )
67. µ = Tan q m ´ F ´ Re
70. T =
sin q
72. Fc = m × T 2 × g
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
APRIL EXAMINATION
MECHANOTECHNICS N4
11 APRIL 2016

MECHANOTECHNICS N4
QUESTION1
1.1 · Flexibility of layout

· Coordination of services
· Accessibility of service and maintenance points
· Transport routes
· Optimal use of space
· Minimising travelling distances of staff and material
· Minimum handling of material
· One-way flow of material and products
· Pleasant working conditions
· Safety of workers and security of equipment (10 × 1) (10)
1.2 1.2.1 · Viscosity of the paint is too low

· Atomising air pressure is too high
· Distance between the spray gun and the work piece is too great
1.2.2 · Insufficient air pressure

· Blocked pipes reduce paint supply
· Spray nozzle is no longer effective
1.2.3 · Spray gun moves too slow

· Applying too much paint to the surface
· Paint is too thin
· Holding the spray gun too close to the surface (Any 3)
1.2.4 · We use the wrong thinners or solvents.

· We do not mix the paint properly before use.
· The air pressure is wrong.
· We prepare the surface incorrectly.
(Any 3)
(3 × 4) (12)
1.3 · Gravity feed

· Grease lubrication
· Splash lubrication
· Forced lubrication
· Pressure-feed lubrication (Any 3 × 1) (3)

MECHANOTECHNICS N4
1.4
NOTE: TWO marks for the drawing

THREE marks for any three appropriate labels (5)
[30]
QUESTION 2
2.1
V=π
(D + t ) N
60
= π´
(1,3 + 0,013) ´ 255 ü
60
= 17,53 m/s ü (2)
2.2 TC = Mv 2
= 9,75 ´ 17,53 2 ü
= 2996,183 kg/m ü
= 2 996,2 kg/m (2)
2.3 T1 = w ´ n ´ f t
= 1 ´ 4 ´ 8 ´ 1 000 ü
= 32 000 N ü (2)

MECHANOTECHNICS N4
2.4 T1 - TC
θ´μ
= e 57.3
T2 - TC
0.25´1720
32 000 - 2 996,2 ü
=e 57.3
T2 - 2 996,2
29 003,8 = 2,2479(T2 - 2 996,2 ) ü
T2 = 15 898,82 N üü (4)
2.5 P = (T1 - T2 )V
= (32 000 - 15 898,82 ) ´ 17,53
ü
= 16 101,18 x 17,53 ü
= 282 253,685 W
= 282, 254 KW (2)
2.6 Total power

w=
power per width
45
= ü
282,254
= 0,15943 mm
= 159,43 m ü
= 160 m (2)
[10]
QUESTION 3
3.1 Ff = μmg
= 0,3 ´ 150 ´ 9,81
= 441,45 N ü
work done = Force ´ Distance

= 441,45 ´ 0,15 ü
= 66,218 J ü (3)
3.2 Work done = 175 - 66,218

= 108,783 J ü
Work done
Force =
Distance
108,783 ü
=
0,15
= 725,213 N ü (3)

MECHANOTECHNICS N4
3.3 725.213 N 2000 N

ü
75 65 65
A B
Calculate A, Take moments about point B:
CWN = ACWN
A ´ 130 = 2 000 ´ 65 + 725,213 ´ 205 ü
2 000 ´ 65 + 725,213 ´ 205 ü
A=
130
= 2143,605 N ü
Calculate B, Take moments about A
CWN = ACWN
2 000 ´ 65 = 725,213 ´ 75 + B ´ 130 ü
2 000 ´ 65 - 725,213 ´ 75
B= ü
130
= 581,6079 N ü
ALTERNATIVE METHOD:
Upwards = Downwards
A+B = 725,213 + 2 000
2 143,605 + B = 2 725,213
B = 2 725,213 – 2 143,605
B = 581,608 N (8)
[14]

MECHANOTECHNICS N4
QUESTION 4
4.1 Micrometer reading:
d = 0,577 p ü
= 0,577 ´ 3,5 ü
= 2,02 mm ü
w = D + 3 d + 1,516 p
= 30 + 3 ´ 2,02 + 1,516 ´ 3,5 ü
= 41,366 mm ü (5)
4.2 4.2.1 · Calculate the chord height

· Set the vertical scale of the gear tooth vernier calliper
· Measure the chord width and compare it
· Compare the chord width with the calculation and measure it (4)
4.2.2 æ π ö
h = mç1 - sinθ cos θ ÷ ü
è 4 ø
æ π ö
= 10 ´ ç1 - sin20 0 cos20 0 ÷ ü
è 4 ø
= 7,476 mm ü
πm
w= cos 2 θ
2
π ´ 10
= cos 2 20 0 ü
2
= 13,872 mm ü (5)
[14]

MECHANOTECHNICS N4
QUESTION 5
5.1 5.1.1 TA
VR =
TB
130
=
40
= 3,25 ü (1)
5.1.2 TA TB
VR = ´
TB TC
130
=-
50
= -2,6 ü (1)
5.1.3 y = 50 ü
x+y =0
x = -y
= -50 ü
N C = -2,6x + y
= -2,6 ´ (- 50 ) + 50 ü
= 180 r/min ü
Nc rotates 180 r/min in the clockwise/positive direction (4)
5.1.4 y = 50
- 2,6x + 50 = 0 ü
- 50
x=
- 2,6
= 19,231 ü
NA = x + y
= 19,231 + 50 ü
= 69,231 r/min ü
Nc rotates 69,23 r/min in the clockwise/positive direction (4)

MECHANOTECHNICS N4
5.2 5
TB = TA
3
5
= ´ 30 ü
3
= 50 teethü
PCDA = m ´ TA
= 6 ´ 30
= 180 mm ü
PCDB = m ´ TB
= 6 ´ 50
= 300 mm ü (4)
[14]
QUESTION 6
6.1 πD 2
A=
4
π ´ 0,2 2
=
4
= 0,031 m 2 ü
D4
m2 =
d4
0,2 4
=
0,13 4
= 5,59 ü
h = 12,6 L
= 12,6 ´ 0,88
= 11,09 m ü
2gh
Q = Cd ´ A ´ ü
m2 -1
2 ´ 9,81 ´ 11,09
= 0,97 ´ 0,031 ´ ü
5,59 - 1
= 0,207 m 3 s -1 ü
= 207 Ls -1 ü (7)

MECHANOTECHNICS N4
6.2 πD 2
A1 =
4
π ´ 0,2 2
=
4
= 0,0314 m 2 ü
πD 2
A2 =
4
π ´ 0,4 2
=
4
= 0,1256 m 2 ü
Q1 = Q 2
A1
V2 = ´ V1
A2
20
= ´ 0,0314
0,1256
= 5 ms -1 ü
P1 V2 P2 V2
+ 1 + h1 = + 2 + h2
Rh 0 ´ g 2 g Rh 0 ´ g 2 g
ü ü
16 ´ 10 3
20 2
P2 52
+ +0= + + 1,274
1 000 ´ 9,81 2 ´ 9,81 1 000 ´ 9,81 2 ´ 9,81
1,631 + 20,387 = 102 ´ 10 -6 P2 + 1,274
1,631 + 20,387 - 1,274

P2 = ü
102 ´ 10 -6
= 203 284,314 Pa ü
= 203,284 kPa (7)
[14]
TOTAL: 100
Copyright reserved
T1030(E)(D1)T
MECHANOTECHNICS N4
(8190194)
1 December 2015 (X-Paper)

9:00–12:00
Copyright reserved
(8190194) -2- T1030(E)(D1)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1030(E)(D1)T
QUESTION 1
1.1 Workshop layout is highly specialised. To be successful in this regard, you

need exceptional knowledge and experience. Your ideal should be for the raw
material to enter one end of the workshop and pass through the workshop in
the manufacturing process. The finished product should leave the workshop
at the other end.
1.1.1 Name FIVE symptoms of a poor workshop layout.
1.1.2 State FIVE advantages of a good workshop layout.

(5 x 2) (10)
1.2 Briefly explain what is meant when reference is made to the following different
forms of corrosion:
1.2.1 Galvanic corrosion
1.2.2 Inter-crystalline corrosion
1.2.3 Stress corrosion
1.2.4 Surface corrosion
1.2.5 Pitting corrosion (5 x 2) (10)
1.3 We apply a lubricant to separate the peaks and valleys in surfaces from each
other. In this way we reduce friction between surfaces.
1.3.1 Define the following terms of adhesion and cohesion as they apply
lubricants. (4)
1.3.2 Make a labelled drawing of the needle lubricator. (6)

[30]

(8190194) -4- T1030(E)(D1)T
QUESTION 2
The following information regarding a V-belt is given:
Safe belt tension = 6.5 MPa per belt

Mass of the belt = 0,8625 kg/metre length
Sectional area of the belt = 750 mm2
Coefficient of friction =0.25
Angle of contact on small pulley =165,780
V-groove angle = 440
Driving pulley diameter = 845 mm
Driving speed = 920 r/min
Number of belts =2
2.1 Belt speed (2)
2.2 Centrifugal tension in the belt (2)
2.3 Tension in the tight side (2)
2.5 Total power transmitted by the drive (2)

[14]
QUESTION 3
3.1 Shaping machine

The ram of a shaper has a mass of 200 kg and is moving in slides. The
coefficient of friction between the ram and the slides may be taken as 0.08.
3.1.1 The horizontal force needed to move the ram. (2)
3.1.2 The coefficient of friction if the force which is moving the ram is
reduced by 25% (4)
3.2 Lathe machine.

A work piece of 500 mm in diameter is being machined in a lathe. The spindle
speed of the lathe is 20 r/min and the efficiency of the drive is 85%. Take the
cutting pressure as 950 N/ mm2 and the cutting depth of the cutting tool as
3.5 mm.
If the cutting feed of the cutting tool is 0.75 mm per revolution calculate:
3.2.1 The output power at the cutting tool (6)
3.2.2 The input power from the motor (2)

[14]

(8190194) -5- T1030(E)(D1)T
QUESTION 4
4.1 FIGURE 1 shows a roller with two sets of gauge blocks of 12,75 mm each.
The distance from the bottom of the groove to the top face is 70 mm; the
included angle of the groove is 600.
4.1.1 Make a clear labeled drawing of the set-up in the ANSWER BOOK. (6)
4.1.2 Calculate the diameter of the roller. (6)
4.1.3 What is the set-up in FIGURE 1 used for? (2)
FIGURE 1 [14]

(8190194) -6- T1030(E)(D1)T
QUESTION 5
An epicyclical gear train shown in FIGURE 2 consists of an annulus (A) having 100
teeth, a sun gear (B) having 40 teeth and a planetary gear (C) having 30 teeth that are
mounted on arm (D).
5.1 Develop a table for calculations of epicyclic gear drives. (8)
5.2 If arm (D) rotated at 30 r/min, calculate the speed of sun gear (B) when
annulus (A) is fixed. (3)
5.3 Determine the speed of annulus (A) when the sun gear (B) is fixed and arm
(D) rotates at 30 r/min. (3)
[14]
FIGURE 2

(8190194) -7- T1030(E)(D1)T
QUESTION 6
6.1 Determine the flow rate of water in litres per second, flowing through a
200 mm diameter pipe equipped with a Venturi meter having a throat
diameter of 130 mm. The coefficient of delivery is 0.97 and the mercury
manometer shows a reading of 880 mm. (6)
6.2 Water flows through a pipe with a diameter of 25 mm and a length of 50 m at

a velocity of 2,5 m/s.
6.2.1 Use Darcy's formula to determine the loss of head due to friction. (2)
6.2.2 Assume the coefficient of friction has a value of 0,005.
Test the answer obtained in QUESTION 6.2.1 by using Chezy's

formula. (6)
[14]
TOTAL: 100
Copyright reserved
-1-
(8190194) -8- T1030(E)(D1)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
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA 16. TOUTPUT = TINPUT ´ GR ´ η

15. = = =
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -9--2- T1030(E)(D1)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh ) ( 2 gh )
52. Q = 53. Q = Cd ´ A ´
2 2
(A -a ) ( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -10-
-3- T1030(E)(D1)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R 62. T = 2p × N
work done
64. Ke =
1 66. (I1 + I2)T3 = I1T1 + I2T2

63. Ke = I ´ w2
2
Tan q
Tan ( q + f )
67. µ = Tan q m ´ F ´ Re
70. T =
sin q
72. Fc = m × T 2 × g
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh
Copyright reserved
MARKING GUIDELINE
MECHANOTECHNICS N4
1 DECEMBER 2015

MARKING GUIDELINE -2- T1030(E)(D1)T
MECHANOTECHNICS N4
QUESTION 1
1.1 1.1.1 · Inadequate control: there is not enough control or proper control
of the workshop.ü
· Transport routes are too long.ü
· Congestion of workers and material: there is not enough
working space for people and material to move about freely.ü
· Frequent accidents: accidents occurred often.ü
· Bottlenecks in the production line: somewhere along the
production line there are delays.ü
· Unnecessary handling of material and equipment. ü
· Low worker performance.ü (Any 5 x 1) (5)
1.1.2 · You keep production costs and production time to a minimum. ü

· The workshop produces products of better quality faster and
more efficiency through better use of machines, labour, time
and space.ü
· It is easier to control and supervise the labour force.ü
· Workers have greater job satisfaction because working
conditions are safer and more pleasant.ü
· You can make programme and production changes easily.ü
(5 x 1) (5)
1.2 1.2.1 Galvanic corrosion. It takes place between two dissimilar metals
when they come into contact with each other or are electrically
joined.üIf the metals are exposed to a humid atmosphere or to
liquid which serves as an electrolyte, the cycle is then completed.
ü Corrosion then takes place in one of the metals.
1.2.2 Inter-crystalline corrosion. Some alloys, especially stainless

steel, have an uneven structure, caused by the heating and cooling
processes to which the metal is subjected.üThese also cause the
grain of the metal to be uneven. The boundaries within which the
grain is found, known as the grain boundaries, are anodic, while
the grains are cathodic.ü
1.2.3 Stress corrosion. This type of corrosion usually occurs in metals

subjected to welding, cold welding or forming.ü Internal stresses
develop in the structure of metal due to the operation and, if these
stresses are not relieved by normalising the process, cracks will
develop in the grain structure of the metal.ü
1.2.4 Surface corrosion. Chemical or electrochemical processes can

cause surface corrosion. When we expose a metal to a humid
atmosphere, corrosion in the form of an even layer of rust on the
surface of the metal will occur.ü This is caused by the anode and
cathode areas or spots on the metal surface constantly changing
position. ü

MECHANOTECHNICS N4
1.2.5 Pitting corrosion. We recognise this type of corrosion by the

appearance of little holes or pitting marks on the metal surface.üIt
is an example of non-uniform corrosion which develops due to
unevenness in the structure of the metal. The unevenness in the
structure of metal causes a potential difference at localised areas
(the anodic and cathodic areas), which can lead to little holes in
the surface of the metal due to electrochemical corrosion.ü
(5 x 2) (10)
1.3 1.3.1 Adhesion is the ability of more of one material or substance to

cling to another.üFor example, oil adheres strongly to steel, while
water does not adhere to steel at al,l so the adhesive strength of oil
to steel is higher than the adhesive strength of water to steel.ü
Cohesion is the force in substance or material which holds or

binds it togetherü. For an example, thick grease has a much
higher cohesive strength than oil or water.ü (4)
1.3.2
(6)
[30]

MECHANOTECHNICS N4
QUESTION 2
2.1 Belt Speed
πDN
V=
60
π ´ 0.845 ´ 920
=
60
= 40,704 ms -1 (2)
2.2 Centrifugal force
TC = mv 2
= 0.8625 ´ (40.704 )
2
= 1429 N (2)
2.3 T1 = safe stress ´ Area

= 6.5 ´ 106 ´ 750 ´ 10- 6
= 4875 N (2)
2.4 Tension in the Slack side
0.25´165,780
T1 - TC
= 2.718 57.3´sin22
0
T2 - TC
4875 - 1429
= 2.7181.931
T2 - 1429
3446 = 6.895(T2 - 1429 )
T2 = 499.782 + 1429
= 1928.78 N (6)
2.5 Power Transmitted
Power = Effective power ´ Velocity

= (T1 - T2 ) ´ V ´ 2
= (4875 - 1928.78) ´ 40.702 ´ 2
= 239.85 kW (2)
[14]

MECHANOTECHNICS N4
QUESTION 3
3.1 3.1.1 F = μ ´ FN
= 0.08 ´ 200 ´ 9.81
= 156.96 N (2)
3.1.2 156.96 ´ 75
F=
100
= 117.72 N
F
m=
Normal reaction
117.72
=
200 ´ 9.81
= 0.06 (4)
ALTERNATIVE METHOD
F = 156, 96 X 25/100
= 39,188 N
F = 156.96 – 39.188
= 117,72 N
3.2 3.2.1 πDN

V=
60
π ´ 500 ´ 20
=
60
= 0.524 ms -1
FO = Cutting pressure ´ Cutting Area

= 950 ´ 10 6 ´ 0.0035 ´ 0.00075
= 2 493.75 N
PO = FO ´ V
= 2 493.75 ´ 0.524
= 1 305.724 W (6)
3.2.2 Efficieny = Output Power/Input Power

Output power
Input power =
Efficiency
1305.724
=
0.85
= 1536.145 W (2)
[14]
MECHANOTECHNICS N4
QUESTION 4
4.1 4.1.1
√
Precision ball
Straight edge √
or roller
mm
75 mm
12..75
A
12
B
B
D
√
Gauge of
blocks
E
mm
70 mm
70
600
V Block √
NB:Two marks for sketch and four for labelling (6) (6)
4.1.2 AB
tanθ =
82.75
AB = 82.75 ´ tan30 0
= 47.776 mm
ΔABD
AD
tan30 0 =
47.776
AD = 47.776tan30 0
= 27.583 mm
Diameter = 2AD
= 2 ´ 27.583
= 55.167 mm (6)

MECHANOTECHNICS N4
ALTERNATIVE METHOD
ΔEDC
AC = DC + AD(R) R = RADIUS OF THE ROLLER

AC = DC + R
DC = AC – R = 82,5 - R
BUT DE = R
ΔEDC
Sin 30º = DE(R)/(82.75 – R)

0,5(82.5 –R) = R
41,375 – 0.5R = 1R
41,375 = 1.5R
R = 27,586
Diameter = 2 X R
= 2 X 27.586
= 55,172 mm
4.1.3 The set up in figure 1 is used to check the V-groove angleüü (2)
QUESTION 5
5.1 NR Conditions A B C ARMD

1 Fix Arm D and
rotates A = +1
1 100 30 100 0
´ = -2.5 = 3.33
30 - 40 30
2 Multiply by x and
add y
x+y - 2.5x + y 3.33x + y y
3 NA = 0
N D = 30 0 NB 30
4 NB = 0
N D = 30 0 30
NA = ? NB = 0
(8)

MECHANOTECHNICS N4
5.2 X+Y=0
-2,5X + Y = NB
Y = 30
X +Y = 0
X +30 = 0
X = -30
Determine N B
N B = -2,5x + y
= -2,5 ´ (- 30 ) + 30
= 105 r/min (3)
5.3 Determine N A
y = 30
- 2.5x + y = 0
- 2.5x + 30 = 0
- 30
x=
- 2.5
= 12
NA = x + y
= 12 + 30
= 42 r/min (3)
[14]

MECHANOTECHNICS N4
QUESTION 6
6.1 Calculate the flow rate
π
A= ´ d2
4
π
= ´ 0.2 2
4
A = 0.031 m 2
2 D4
m = 4
d
0.2 4
=
0.13 4
m 2 = 5.59
Find the head of water h
h = 12.6h 1
h = 12.6 ´ 0.88
= 11.09 m
Find Q
2gh
Q = Cd ´ A ´
m2 -1
2 ´ 9.81 ´ 11.09
= 0.97 ´ 0.031 ´
5.59 - 1
= 0.207 m 3 s -1
= 207 Ls -1 (6)

MECHANOTECHNICS N4
6.2 6.2.1 Find h f (Darcy)
4 ´ f ´ l ´ v2
hf =
2´g´d
4 ´ 0.005 ´ 50 ´ 2.5 2
=
2 ´ 9.81 ´ 0.025
h f = 12.742 m (2)
6.2.2 Find h f (Chezy)
2´g
v = C mi and C =
f
2 ´ 9.81
C=
0.005
= 62.64
d
m=
4
0.0025
=
4
= 0.00625 m
v 2 0.00625h f
=
C2 l
2.5 2 ´ 50
hf =
62.64 2 ´ 0.00625
= 12.742 m (6)
[14]
TOTAL: 100
Copyright reserved
T1040(E)(J27)T
AUGUST EXAMINATION
MECHANOTECHNICS N4
(8190194)
27 July 2015 (Y-Paper)

13:00–16:00

(8190194) -2- T1040(E)(J27)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
4. Candidates will be penalised for poor drawings.
be regarded as rough work and will not be marked.

(8190194) -3- T1040(E)(J27)T
QUESTION 1
1.1 Explain briefly what is meant when reference is made to the following
principles of a good workshop:
1.1.1 Safety of workers and security of equipment
1.1.2 Minimum handling of material
1.1.3 Flexibility of a layout
1.1.4 Minimum traveling distances for material and staff
1.1.5 Optimum use of space

(5 x 2) (10)
1.2 After completion of corrosion tests carried out on metals to determine and
prevent the effect of corrosion on the metals, the test results have to be
evaluated.
1.2.1 State THREE different corrosion tests which can be carried out. (3)
1.2.2 Name SEVEN factors which have to be considered when

evaluating test results. (7)
1.3 Lubrication devices are used to provide a regulated quantity of a lubricant to

machine parts.
1.3.1 Name FIVE general methods of lubrication.
1.3.2 Make a labeled drawing of the siphon wick lubricator.

(5 x 2) (10)
[30]
QUESTION 2
A conveyor belt running at a speed of 90 m/min has an effective width of 900 mm and
transports stone at the rate of 250 tons per hour up an incline with a vertical rise of
30 m. The belt forms a contact angle of 190° on the driving pulley and the coefficient
of friction between the belt and the driving pulley is 0,25. Assume that a force of 3 kN
is required to overcome the belt friction.
2.1 Power to overcome friction (2)
2.2 Power to overcome gravity (2)
2.3 The ratio of the two tensions (2)

(8190194) -4- T1040(E)(J27)T
2.5 Tension in the tight side (2)
2.6 Number of pliers required in the thickness of the belt if allowable tension in
the belt is 7,2 kN width per layer
[n = T1/width x allowable tension] (2)

[14]
QUESTION 3
3.1 The tangential cutting force exerted on the bar held in the lathe chuck is
2 400 N. The bar is 50 mm in diameter and a torque of 12 Nm is required to
overcome friction of the lathe spindle in its bearings.
Calculate:
3.1.1 Torque required at the driving pulley on the machine
3.1.2 Driving force required on the machine pulley if it has an effective

diameter of 240 mm
3.1.3 The minimum power required at the machine pulley if it has to

revolve at 200 r/min
(3 x 2) (6)
3.2 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.

[14]

(8190194) -5- T1040(E)(J27)T
QUESTION 4
A tapered hole of 30° included angle is machined in a work piece and has to be
checked for accuracy by means of a12 mm diameter steel ball as shown in FIGURE 1
below.
FIGURE1
4.1.1 Duplicate drawing of the set-up in the ANSWER BOOK. (2)
4.1.2 Calculate distance X to determine if the angle is accurately

machined, making use of the sketch drawn in QUESTION 4.1.1. (6)
4.2 An ISO 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.

[14]

(8190194) -6- T1040(E)(J27)T
QUESTION 5
The epicyclic gear train in FIGURE 2 below, consists of an annulus with 80 teeth, a sun
gear with 40 teeth and three planetary gears each having 20 teeth. The output shaft is
connected to the arm carrying the planetary gears, while the input shaft is connected to
the sun gear which is rotating at 450 r/min in a clockwise direction.
FIGURE 1
5.1 Develop a table for calculations of epicyclic gear drives. (8)
5.2 Use the data obtained from the table developed in the QUESTION 5.1 to
calculate the speed of rotation of the output shaft if the annulus is fixed. (3)
5.3 Make use of the data obtained from the table in QUESTION 5.1, to calculate
the speed of the annulus if the output shaft rotates at 10 r/min, in the opposite
direction from the sun gear, which is rotating clockwise at 300 r/min. (3)
[14]

(8190194) -7- T1040(E)(J27)T
QUESTION 6
The centre line of a tapered pipe that is 10,5 m long is at an incline of 35° to the
horizontal. The taper decreases from 350 mm, at the larger diameter, which is at the
upper end of the pipe, to a diameter 300mm at the lower end of the pipe. Water with a
density of 1 000 kg/m3 flows from the lower end to the upper end at 130 ℓ/s, and the
pressure gauge at the lower end registers a reading of 125 kPa.
6.1 The pressure at the upper end of the pipe. (12)
6.2 The change in the kinetic energy per unit mass over the length of the pipe. (2)
[14]
TOTAL: 100
Copyright reserved
(8190194) -8-
-1- T1040(E)(J27)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
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -9-
-2- T1040(E)(J27)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3-
-10- T1040(E)(J27)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R 62. T = 2p × N
work done
64. Ke =
1 66. (I1 + I2)T3 = I1T1 + I2T2

63. Ke = I ´ w2
2
Tan q
Tan ( q + f )
67. µ = Tan q m ´ F ´ Re
70. T =
sin q
72. Fc = m × T 2 × g
69. T = µ × F × Re × n
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
AUGUST EXAMINATION
MECHANOTECHNICS N4
27 JULY 2015

MARKING GUIDELINE -2- T1040(E)(J27)T
MECHANOTECHNICS N4
QUESTION 1
1.1 1.1.1 Safety of your workers takes priority over all other considerations,
no worker must be exposed to any dangerü. You need to comply
with all safety regulationsü
1.1.2 You need to limit the handling of material, by making use of

conveyor belts, chutes, overhead cranes and other such means.ü
Store and place material and other equipment at a convenient
height so that it needs minimum handling.ü
1.1.3 You must provide for future changes in layout and production.ü
Plan your workshop so that it can be adapted for a change in
production or expanded for the manufacture of new products.ü
1.1.4 You must plan for only direct and essential movement to occur.ü
You need to eliminate unnecessary movement by making use of
the shortest distances and routes.ü
1.1.5 It is important that you use all available space in your workshop.ü
You should use overhead transport systems such as cranes and
conveyor belts.ü
(5 x 2) (12)
1.2 1.2.1 · The salt-spray testü

· The humility testü
· The sulphur-dioxide testü (3 x 1) (3)
1.2.2 · The change in the mass of the test piece when the corrosion
matter or layer of rust has been removed.ü
· Changes in the appearance of the work piece surface.ü
· Changes in structure.ü
· Changes in the mechanical properties of metal.ü
· The depth of corrosive attack.ü
· The type and nature of corrosive matter.ü
· Changes in the corrosive medium.ü (7 x 1) (7)
1.3 1.3.1 · Gravity feedü

· Grease lubricationü
· Splash lubricationü
· Forced lubricationü
· Pressure-feed lubricationü (5 x 1) (5)

MECHANOTECHNICS N4
1.3.2
(3 marks for labeling and 2 marks for the drawing) (5)

[30]
QUESTION 2
2.1 Power to overcome friction
P = F´ V
90
= 3 000 ´
60
= 4 500 W (2)
2.2 Power to overcome gravity
P = mgh
= 69,444 ´ 9,81 ´ 30
= 20 437,5 W (2)
2.3 Ratio of the two tensions

0.25´190 0
T1
= 2,718 57.3
T2
= 2,29
T1 = 2,29T2 (2)

MECHANOTECHNICS N4
2.4 Tension in the slack side
Pt = (T1 - T2 )V
90
4500 + 20437.5 = (2.29T2 - T2 ) ´
60
24937,5 = 1,29T2 ´ 1.5
24 937,5
T2 =
1,29 ´ 1,5
\ T2 = 12887,6 N (4)
2.5 Tension in the tight side
T1 = 2,29T2
= 2,29 ´ 12 887,7
\ T1 = 29 512,604 N (2)
2.6 Number of pliers
T1
=
ω ´ Tension
29 512,6
No. of pliers =
7 200 ´ 0,9
= 4,55
@5 (2)
[14]
QUESTION 3
3.1 3.1.1 T = Tf + TC
= 12 + 2 400 ´ 0,025
= 72 Nm
3.1.2 T
F=
R
72
=
0,12
= 600 N
3.1.3 P = F´ V
π ´ 0,24 ´ 200
= 600 ´
60
= 1 800 W
(3 x 2) (6)

MECHANOTECHNICS N4
3.2 3.2.1 Pi ´ 60
T=
2π ´ N Motor
2.5 ´ 10 3 ´ 60
=
2π ´ 1500
= 15.915 Nm (2)
3.2.2 P0 ´ 60
T=
2π ´ 3 500
P0 = η ´ Pi
= 0,85 ´ 2500
= 2 125 W
2 125 ´ 60
T=
2π ´ 3 500
= 5,798 Nm (4)
3.2.3 2125 ´ 60
T=
2π ´ 30
= 676.409 Nm (2)
[14]

MECHANOTECHNICS N4
QUESTION 4
4.1 4.1.1
A B
G
20 mm
B
x
12 mm
F
30 0
C
(2)
4.1.2 In D ABC
AB
= tan15 0
BC
AB
BC =
tan15 0
\ BC = 37,321 mm
In D CDE
DE
= sin15 0
CE
6
CE =
sin15 0
\ CE = 23,1822 mm
X = BC - CE - EF
= 37,321 - 23,1822 - 6
= 8,139 mm (6)
MECHANOTECHNICS N4
4.2 d = 0,577P
= 0,577 ´ 3,5
= 2,019
= 2,02
W = D + 3d - 1.516P
= 30 + 3 ´ 2,02 - 1,516 ´ 3,5
= 30,754mm (6)
[14]
QUESTION 5
5.1 NR Conditions A B C Arm D

1 Fix Arm D
and rotates A
= +1 +1 + 80 + 80 + 20 0
= +4 ´ = -2
+ 20 + 20 - 40
2 Multiply by x
and add y
x+y 4x + y - 2x + y +y
3
NA = 0 NA = 0 N S = +300 ND = ?
N S = +300
4
N S = +300 N S = +300 N D = -10
N D = -10 NA = ?
(8)
5.2 x+y=0
- 2x + y = 300
3x = -300
300
x=-
3
x = -100
y = +100
ND = y
= 100
\ N D = +100 r/min (3)

MECHANOTECHNICS N4
5.3
- 2x + y = 300
y = -10
- 2.x = 310
310
x=
-2
= -155
y = -10
NA = x + y
= -155 + (- 10 )
\ N A = -165 r/min (3)
[14]

MECHANOTECHNICS N4
QUESTION 6
6.1 Determine P2
πD 2
A1 =
4
π ´ 0,3 2
=
4
= 0,07 068 m 2
πD 2
A2 =
4
π ´ 0,35 2
=
4
= 0,09 621 m 2
Q1 = Q 2
Q1
V1 =
A1
0.13
=
0,0 707
= 1,839 ms -1
Q2
V2 =
A2
0.13
=
0,0 962
= 1,351 ms -1
h1 = 0
h 2 = 10,5 ´ sin35 0
= 6,023 m
P1 V2 P2 V2
+ 1 + h1 = + 2 + h2
Rh 0 ´ g 2g Rh 0 ´ g 2g
125 000 1,839 2 P2 1.3512

+ +0= + + 6,023
1 000 ´ 9,81 2 ´ 9,81 1 000 ´ 9,81 2 ´ 9,81
12,742 + 0,127 = 0,0001P2 + 0,093 + 6,023
0.0001P2 = 6,799
P2 = 67 984 Pa
= 67,984 KPa (12)

MECHANOTECHNICS N4
6.2 Find change ine K e

V12 V22
Ke = -
2 2
2
1,839 1,3512
= -
2 2
= 1,391 - 0,913
= 0,778 J (2)
[14]
TOTAL: 100
Copyright reserved
T1040(E)(A9)T
BACKUP EXAMINATION
MECHANOTECHNICS N4
(8190194)
9 April 2015 (Y-Paper)

13:00–16:00

(8190194) 2 T1040(E)(A9)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
5. ALL work done in pencil (excluding sketches, drawings and diagrams) will be
regarded as rough work and will NOT be marked.

(8190194) 3 T1040(E)(A9)T
QUESTION 1
particular layout would differ from one layout to another.
Name TEN important factors to be considered in the design of a workshop

layout. (10)
1.2 Corrosion can be defined as the destruction of a material as a result of

chemical, electrochemical or metallurgic interaction between the material and
the environment. The different forms corrosion can take on are based on the
appearance of the corroded metal.
Name and briefly describe FIVE forms of corrosion. (10)
1.3 Rolling bearings have certain advantages as well as disadvantages when

compared to journal bearings.
State TEN advantages of rolling bearings in contrast with journal bearings. (10)
[30]
QUESTION 2
The driving pulley of a V-belt drive has an effective diameter of 250 mm and a speed of
1 800 r/min. The angle of the V-groove of the driving pulley is 400 and the contact
angle of the belt is 1400. The coefficient of friction is 0,25 and the mass of the belt is
0,5 kg/m length.
Calculate the number of V-belts required for this drive if the maximum allowable
tension per belt is 900 N and the belt has to transmit 30 kW. [14]
QUESTION 3
3.1 A workpiece of 250 mm diameter is machined in a lathe at a spindle speed of

200 r/min. The cutting depth is 5 mm and the feed of the cutting tool is
0,5 mm per revolution of the workpiece. If a cutting force of 2,5 kN is exerted
by the cutting tool on the workpiece, calculate the following:
3.1.1 The cutting pressure on the tool (N/mm2 ) (3)
3.1.2 The power required to machine the workpiece (kW) (3)
3.1.3 The motor power if the motor has an efficiency of 80% (2)

(8190194) 4 T1040(E)(A9)T
3.2 The belt drive from an electric motor transmits an effective driving force of
800 N to the 250 mm diameter driving pulley on a milling machine.
The torque to overcome friction on the driving parts of the machine can be
assumed as 8 Nm.
3.2.1 Torque transmitted to the machine pulley (2)
3.2.2 The torque that is available at the milling cutter (2)
diameter of the cutter (2)
[14]
QUESTION 4
FIGURE 1 (below) show a tapered ring gauge which is checked for accuracy by means
of two precision balls.
4.1 Explain, step by step, how you would use the precision balls to determine the
included angle of the ring gauge. (3)
4.2 Make a large, clear drawing of the diagram in the ANSWER BOOK. (3)
4.3 Use the dimensions as given on the diagram and calculate the angle of the
ring gauge. (8)
FIGURE 1 [14]

(8190194) 5 T1040(E)(A9)T
QUESTION 5
An epicyclic gear train shown in FIGURE 2 consists of an annulus (A) having 60 teeth,
a sun gear (B) which is connected to the output shaft having 16 teeth and rotates at
120 r/min in a clockwise direction, and a planetary gear (D) having 20 teeth and
gear (C) having 24 teeth are mounted on the same axis.
5.1 If arm (E) is fixed, calculate the speed and direction of annulus (A). (8)
5.2 Determine the speed and direction of the arm (E), assuming the annulus (A)
is fixed. (2 × 3) (6)
FIGURE 2 [14]
QUESTION 6
The following particulars apply to an orifice provided in the side of a tank:
Diameter of the orifice = 30 mm

Delivery of water = 0,75 m3/min
Diameter of vena contracta = 25 mm
Pressure head = 34,5 m
6.1 The coefficient of delivery (Cd) (8)
6.2 The coefficient of contraction (Cc) (3)
6.3 The coefficient of velocity (Cv) (3)

[14]
TOTAL: 100

(8190194) -1-6 T1040(E)(A9)T
MECHANOTECHNICS N5
FORMULAE
PCD
1. m = 2. DO = m × (T + 2)
T
m 1
3. C = ´ ( TA + TB ) 4. Ke = mv 2
2 2
TA PCD of gear
5. VR = 6. VR =
TB PCD of pinion
NB
7. VR = 8. NA × TA = NB × TB
NA
2´T
9. Ft = 10. Fr = Ft × Tan f
PCD
14. Ta = TA + +
13. T a = Ie × a A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = d ×A
T2
25. Tc = m × v2 T 1 - TC
26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć

(8190194) -2-7 T1040(E)(A9)T
28. Tg = m × g × sin f 29. v = w × r
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × r
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w
40. t = 2´p ´ N ´T
T 41. P =
60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù p1 ( v1 )2 p 2 ( v 2 )2
46. h = m ê1 - (sin q Cosq )ú 47. + + gh1 = + + gh 2
ë 4 û Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3-8 T1040(E)(A9)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R
61. P = w × T 62. w = 2p × N
1 work done
63. Ke = I ´ w2 64. Ke =
2 efficiency
65. P = Ke × operations/sec 66. (I1 + I2) w 3 = I1 w 1 + I2 w 2
Tan q
67. µ = Tan q 68. h =
Tan ( q + f )
m ´ F ´ Re
70. T =
69. T = µ × F × Re × n sin q
72. Fc = m × w 2 × g
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
APRIL EXAMINATION
MECHANOTECHNICS N4
9 APRIL 2015

MECHANOTECHNICS N4
QUESTION 1
1.1 Important factors in the design of a workshop layout
· Type of production required, e.g. mass production, batch production or

individual production.
· The most effective flow routes for the proposed type of production.
· The required volume of work.
· Inspection requirements to be met.
· The type of equipment needed, and the quantity thereof.
· The quantity of material required.
· Sequence in which production is to take place.
· Volume of final product to be manufactured.
· The type and quantity of the available workforce and level of skill of
these workers.
· Regulation of local authority. (10 x 1) (10)
1.2 Different forms of corrosion
Surface corrosion
Surface corrosion is caused by either the chemical or electrochemical

process. When metal is exposed to a humid atmosphere, corrosion in the
form of an even layer of rust on the surface of the metal will occur. This is
caused by the anode and cathode areas or spots on the metal surface
constantly changing position, thus causing the corrosion to spread over the
entire surface of the metal. (2)
Stress corrosion
This type of corrosion usually occurs in metals subjected to welding, cold

welding or forming. Internal stresses develop in the structure of the metal due
to the operation and if these stresses are not relieved by a normalising
process cracks will develop in the grain structure of the metal. (2)
Galvanic corrosion
Galvanic corrosion takes place between two dissimilar metals when they
come into contact with each other or are electrically joined. If the metals are
exposed to a humid or to liquid which serves as an electrolyte, the cycle is
completed. Corrosion then takes place in one of the metals. (2)
Intercrystalline corrosion
Some alloys, especially stainless steel, have an uneven structure, caused by

the heating and cooling processes to which the metal is subjected. This also
causes the grain of the metal to be uneven. The boundaries within which the
grain is found are anodic, while the grains are cathodic. Because of the
potential difference between the grain boundaries and the grains, corrosion
takes place in the structure of the metal. (2)

MECHANOTECHNICS N4
Putting corrosion
This form of corrosion is recognised by the appearance of little holes or pitting

marks on the metal surface. It is an example of a non-uniform corrosion which
develops due to the unevenness in the structure of the metal. In contrast to
surface where the anodic and cathodic areas or spots change position, the
areas remain static during pitting. Thus corrosion develops in one place. (2)
1.3 Bearings
Advantages of rolling bearing
· They have lower toque resistance

· They require less lubrication
· Some rolling bearings can support both radial and axial loads
· They require little axial space
· The bearings are easily to replace
· The bearings require very little maintenance
· They can take heavy overloads for short periods
· They give a warning, by becoming noisy, when they begin to fail
· They can maintain high rotational speeds
· The bearings can be pre-packed and sealed with a lubricant (10)
[30]
QUESTION 2
V = πDN
= π ´ 0.25 ´ 30
= 23.5619 m/s
(2)
TC = m ´ v 2
= 0.5 ´ 23.562 2
= 277.584 N (2)
140´0.25
T1 - TC
= e 57.3sin 20
0
T2 - TC
900 - 277.584
= 5.965
T2 - 277.584
622.416 = (T2 - 277.584 ) ´ 5.965
622.416
T2 = + 277.584
5.965
= 381.929 N (6)

MECHANOTECHNICS N4
P = (T1 - T2 ) ´ V
= (900 - 381.929 ) ´ 23.562
= 12207 W (2)
Power
n=
Power per belt
30000
=
12207
= 2.458
» 3 belts (2)
[14]
QUESTION 3
3.1 3.1.1 F0
Pressure =
Area
2500
=
0.5 ´ 5
= 1000 N/mm 2 (3)
3.1.2 pDN
V=
60
p ´ 0.25 ´ 200
=
60
= 2.618 m/s
P = F´V
= 2500 ´ 2.618
= 6545 watt
= 6.545 kW (3)
3.1.3 P0
Pi =
z
6245
=
0.8
= 8181.25 watt (2)
3.2 3.2.1 T = F´R

= 800 ´ 0.125
(2)
= 100 N.m

MECHANOTECHNICS N4
3.2.2 Toque = Torque Pulley - Torque Friction

= 100 - 8
= 92 N.m (2)
3.2.3 T = F´R
92 = F ´ 0.0575
92
F=
0.0575
= 1600 N (2)
[14]
QUESTION 4
4.1 Method
· Draw up the arrangement on a sufficiently large scale to clearly

indicate all the measurements.
· Construct the right angle triangle from the given measurements.
· Calculate the angle from the right-angled triangle and then determine
the magnitude of the inclined angle. (3)
4.2 5mm
C
4.25 mm B
36.75 mm
φ = 30 mm
27.5 mm
φ = 20 mm θ
A
(5)
MECHANOTECHNICS N4
4.3 AC = (X + r ) - (Y + R )
= (36.75 + 10) - (4.25 + 15)
= 27.5 mm
BC = R - r
= 15 - 10
= 5 mm
BC
sinθ =
AC
5
=
27.5
= 0.182
θ = sin -1 0.182
= 10.4750
Inclined angle = 2θ
= 2 ´ 10.475
= 20.950
= 20 0 51' (8)
[16]
Question 5
5.1 NO. Conditions Gear A Gear B Gear C Gear D Gear E

1 Fix arm E and +1 + 60 + 24
´ + 60 + 60
= +3
0
+ 20 - 16
= +3
rotates A+1 + 20 + 20
revolution = -4.5
2 Multiply by x x+y -4.5x+y 3x+y 3x+y +y
and add y
3 NE = 0 NA = ? N B = 120 0
N B = +120
4 NA = ? NA = 0 N E = 120 NE = ?
NB = 0
N C = 100
(8)

MECHANOTECHNICS N4
- 4.5x + y = 120 ..........................(1)

+ y = 0 .................................(2)
- 4.5x = 120
120
x=-
4.5
= -26.666
and y = 0
NA = x + y
N A = -26.666 + y
= - 26.666 r/min (3)
5.2 - x + y = 0 ................................(1)
- 4.5x + y = 120 ........................(2)
5.5x = -120
120
x=-
5.5
= -21.82
and y = +21.82
NE = y
= +21.82 r/min (3)
[14]
QUESTION 6
6.1 Vt = 2gh
= 2 ´ 9.81 ´ 34.5
= 26.0171 m/s (2)
p ´ D2
At =
4
p ´ 0.032
=
4
= 0.0007068 m 2 (2)

MECHANOTECHNICS N4
Q t = Vt ´ A t
= 26.0171 ´ 0.0007068 (2)
= 0.01839 m 3 / s
Qa
Cd =
Qt
0.0125
= (2)
0.01839
= 0.68
6.2 p ´ D2
Aa =
4
p ´ 0.0252
=
4
= 0.0004908 m 2
Aa
Cc =
At
0.0004908
=
0.0007068
= 0.695 (3)
6.3 Qa
Va =
Aa
0.0125
=
0.0004908
= 25.46
Va
CV =
Vt
25.46
=
26.02
= 0.978 (3)
[14]
TOTAL: 100

T1030(E)(N21)T
MECHANOTECHNICS N4
(8190194)
21 November 2014 (Y-Paper)

13:00–16:00

(8190194) -2- T1030(E)(N21)

MECHANOTECHNICS
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1030(E)(N21)
QUESTION 1
1.1 Name and describe FIVE ways in which ball and roller bearings can be
damaged. (10)
1.2 Computer-Aided design has replaced conventional drawings done by

draughtsman on the drawing board. Because of the tremendous advantages
of computers over the old, conventional design methods, it has revolutionised
layout design to a large extend.
Name SEVEN advantages and THREE disadvantages of using computers. (10)
1.3 Two main classes of corrosion can be distinguished, namely chemical and
electrochemical corrosion.
1.3.1 Briefly explain the process of electrochemical corrosion. (5)
1.3.2 Make a labelled drawing of the elements of electrochemical (5)

corrosion. [30]
QUESTION 2
The following information applies to a flat-belt drive:
Width of the belt = 300 mm

Thickness of the belt = 12 mm
Speed of the driving pulley = 450 r/min
Diameter of the driving pulley = 325 mm
Contact angle between belt and pulley = 1650
Coefficient of friction between belt and pulley = 0,35
Motor power = 30 kW
Efficiency of the drive = 85%
2.1 The output power at the driving pulley in kW. (2)
2.2 The ratio of the slack side of the driving belt to the tight side. (2)
2.3 The effective tension in the driving belt in kN (2)
2.4 The tensions at the tight and slack sides of the driving belt in kN (6)
2.5 The working stress in the material of the driving belt in MPa (2)
[14]

(8190194) -4- T1030(E)(N21)
QUESTION 3
FIGURE 1 shows the set-up of the cutting tool held in the tool holder of a shaping
machine.
The ram of the shaping machine has a mass of 100 kg and in operation with a cutting
stroke length of 250 mm. The total work done during one cutting stroke is equal to
3.1 The work done to overcome the friction between the ram and the slides. (3)
3.2 The cutting force exerted on the cutting tool. (3)
the clamping screw is 1 000 N. (8)
FIGURE 1 [14]

(8190194) -5- T1030(E)(N21)
QUESTION 4
FIGURE 2 shows a taper of 1-in-5 on the diameter that must be tested for correctness
by using 18 mm diameter rollers. The centre distance between the top and bottom
rollers is 55 mm. The taper is 80 mm long. The top diameter of the taper is 50 mm.
Calculate from a neat construction the distance across the top and bottom rollers.
FIGURE 2 [14]

(8190194) -6- T1030(E)(N21)
QUESTION 5
The following specifications apply to a simple gear train having a pinion A and a gear
wheel B:
Module = 10 mm
Pressure angle = 200
Gear ratio = 3:2
PCD of pinion = 160 mm
5.4 The pitch circle diameter of the gear wheel (1)
5.5 The total depth of tooth (1)

[14]

(8190194) -7- T1030(E)(N21)
QUESTION 6
6.1 A pipeline conveying water is equipped with a venturi meter with the following
specifications:
Diameter of the water pipes = 80 mm

Throat diameter of the venturi meter = 30 mm
Mecury reading in the manometer = 25 mm
Coefficient of delivery = 0,95 mm
Calculate the delivery of the pipe in litres per hour. (6)
6.2 A horizontal pipe line with a diameter of 90 mm conveys water at the rate of
20 ℓ/s with a pressure drop of 40 kPa for every 25 metres length of pipe.
Calculate the value of the coefficient of friction of (f) for the above-mentioned
6.3 Use Chezi's formula for the circumstances in QUESTION 6.2 and calculate
the values of:
6.3.1 The hydraulic mean depth 'm' (1)
6.3.2 The hydraulic gradient 'I' (1)
6.3.3 The Chezi coefficient 'C' (3)

[14]
TOTAL: 100

(8190194) -1-
-8- T1030(E)(N21)
MECHANOTECHNICS N4
FORMULAE
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
( D ± d )2
+ 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -2-
-9- T1030(E)(N21)
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -3-
-10- T1030(E)(N21)
a 62. T = 2p × N
60. T (acc drum) = I ´ a = mk 2 ´
R
61. P = T × T work done
64. Ke =
efficiency
1
63. Ke = I ´ w2
2 66. (I1 + I2)T3 = I1T1 + I2T2
65. P = Ke × operations/sec Tan q

68. h =
Tan ( q + f )
67. µ = Tan q
m ´ F ´ Re
70. T =
sin q
69. T = µ × F × Re × n 72. Fc = m × T 2 × g
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
MECHANOTECHNICS N4
21 NOVEMBER 2014

MECHANOTECHNICS N4
QUESTION 1
1.1 Damage to bearings

· Force applied to wrong ring during mounting
Care must be taken that the force required mounting that bearing is
exerted correctly. For example, the force should be applied to the inner
ring when the bearing is mounted on a shaft, but applied to the outer ring
when the bearing is mounted in housing.
· Damage by misalignment during mounting

When a bearing is mounted with hydraulic or any other equipment, it must
be ensured that the bearing is placed absolutely square and aligned before
it is press fitted onto a shaft or into housing. Misalignment during mounting
may cause damage to the races and rolling elements of the bearing
· Incorrect mounting of housing end cover

If the housing end cover, which normally pushes against the outer ring, is
wrongly mounted, distortion of the bearing’s outer ring occurs. This leads
to failure of the bearing.
· Damage housing or shaft

Bearings should never be mounted on a damaged or worn shaft, or worn
housing since this may cause the inner or outer ring to start creeping, thus
reducing the effectiveness of the bearings. Movement or creep can also
damage the bearings seats.
· Bearing mounted the wrong way round

Some bearings, for instance single row angular contact bearings, can carry
loads in one direction only. If these bearings are mounted the wrong way
round, the bearing may be forced apart or the balls may be damaged,
leading to early bearing failure.
· Excessive lubrication
Too much grease forced between the rolling elements of bearings can
cause just as much damage as insufficient lubrication. Too much grease
results in rapid heating, which will be detrimental to effective working of the
bearing
(Any 5 x 2) (10)

MECHANOTECHNICS N4
1.2 Workshop layout

Advantages of using computers
· Ideas can be changed at will, within a few minutes.
· Even very complicated drawings can be done very quickly.
· Drawings can be done in any colour.
· Changes in the drawings are done very quickly.
· Two dimensional and three-dimensional drawings can be done on a
computer.
· The most complicated calculations are done quickly and accurately.
· It easy to store enormous amounts of information.
· Feasibility study can be readily done, various possible designs are fed into
the computer, which determines the most suitable design.
· Portable computers enable personnel to do calculations and make
changes or adjustments even in the workshop area. (Any 7 x 1) (7)
Disadvantage of using computers

· Computers and computer hardware are very expensive.
· Highly skilled draughtsmen with knowledge of computers are essential.
· Not all drawing or design offices are equipped with computers. (3)
1.3 1.3.1 Electrochemical corrosion
Three basic components are required for electrochemical

corrosion, namely an anode, a cathode and an electrolyte. Two
electrodes, the anode and the cathode, are placed in an
electrolyte. The electrodes may be two different metals, while the
electrolyte may be a liquid, such as water, which can be either acid
or alkaline. When the electrodes are joined by a conductor, current
in the form of electrons will flow through the conductor from the
positively charged electrode to the negative charged electrode.
When the electrodes are placed in an electrolyte and current flow

occurs, there is also an ion movement from anode to cathode. As
the electron and ion movement occurs from the anode to the
cathode, the anode will corrode. (5)

MECHANOTECHNICS N4
1.3.2
ELECTROCHEMICAL CORROSION (5)
6 Labels ½ each (3) Drawing (2) [30]
QUESTION 2
2.1 P0 = η ´ Pin
= 30 000 ´ 0.85
= 25.5 kW (2)
2.2 T1
= e uθ
T2
0.35´165
T1
=e 57.3
T2
T1 = 2.74T2 (2)
2.3 é P ù
ê T - T =
V úû
1 2
ë
π(D + t )N
V =
60
π (0,325 + 0,012) 450
=
60
= 7,94 m/s
[P = (T1 - T2 ) V ) (2)

MECHANOTECHNICS N4
2.4 2 5500
T1 - T2 =
7,94
T1 - T2 = 3211,59 N
2.74T2 - T2 = 3211,59
1.74T2 = 3211,59
3211,59
T2 =
1,74
= 1845,74 N
T1 = 2.74T2
T1 = 2.74 ´ 1845.74
= 5057,33 N
(6)
2.5 T1
δ=
t´w
5057,33
=
0.3 ´ 0.012
= 1,05 MPa (2)
[14]
QUESTION 3
3.1 Fμ
μ=
NR
Fμ = μ ´ N R
= 0,2 ´ 100 ´ 9,81
(2)
= 196,2 N
Wμ = 196,2 ´ 0,25
= 49,05 J (1)
3.2 WC = WT - Wm
= 125 - 49,05
= 75,958 J (2)

MECHANOTECHNICS N4
WC
F1 = (1)
S
75,95
=
0.25
= 303,8 N
3.3 F1 = 303.8 N 1000 N
50 40 40
A B
Taking moments about B
CWM = ACWM
A ´ 80 = (1 000 ´ 40) + (303,8 ´ 130 )
79 494
A=
80
= 993,674 N (4)
Taking moments about A
CWM = ACWM
1 000 ´ 40 = (B ´ 80 ) + (303,8 ´ 50 )
24 810
B=
80
= 310,125 N (4)
[14]

MECHANOTECHNICS N4
QUESTION 4
4.1 A
θ C
B 1
In ∆ABC
AC
tanθ =
BC
0,5
tanθ =
5
æ 0,5 ö
θ = tan -1 ç ÷
è 5 ø
θ = tan -1 (0,1)
= 5,7110
Included angle = 2 ´ 5,711

= 11,422 0
= 110 25 / (2)

MECHANOTECHNICS N4
50
B C
50-2BC
In ∆ABC
AB = 80
θ = 5,7110
BC
tanθ =
AB
BC = 80 ´ tan 5,711
BC = 8 mm
Small diameter = 50 - 2BC

= 50 - (2 ´ 8)
= 34 mm (3)

MECHANOTECHNICS N4
Bottom roller X
D
A θ
E
34 AE DE
[X = 34 + 2AE + 2DE]
DADE
1
φ = (90 - 5,711)
2
= 42.145 0
DE
tanφ =
AE
9
AE =
tan 42,145
= 9,944
X = 34 + 2 ´ 9,944 + 2 ´ 9
= 71,889 mm (4)
Top roller S
G H
D
θ
φ
E F

MECHANOTECHNICS N4
EF = AE = 9,944
HF = 80 - 55
= 25
GH
tanφ =
HF
GH = HFtanφ
= 25 tan 5,711
= 2,5 mm
Y = 50 - 2 GH + (2 ´ 9 ) + (2 ´ 9,944 )
= 50 - 2 ´ 2,5 + 18 + 19,988
= 82,988 mm (5)
[14]
QUESTION 5
5.1 PCD
T=
M
160
TA =
10
= 16 teeth
3
TB = ´ 16
2
= 24 teeth (4)
5.2 Addendum = 10 mm
Dedendum = 1,157 ´ 10
= 11,57 mm (2)
5.3 D A = m(TA + 2 )
= 10 ´ (16 + 2 )
= 180 mm
D B = m(TB + 2 )
= 10 ´ (24 + 2 )
= 260 mm (2)
5.4 PCD = mTB

= 10 ´ 24
= 240 mm (1)

MECHANOTECHNICS N4
5.5 Total depth = adendum + dedendum

= 10 + 11,57
= 21,57 mm (1)
5.6 CP
Total thickness =
2
p ´ PCD
CP =
T
p ´ 160
=
16
= 31,415
31,45
Total thickness =
2
= 15,708 (4)
[14]
QUESTION 6
6.1 D2
A=π
4
0,08 2
=π
4
= 0,00503 m 2
D4
m2 =
d4
0,08 4
=
0,03 4
h = 12,6 h 1
= 12,6 ´ 0,025
= 0,315 m
2gh
Q = Cd ´ A ´
m2 -1
2 ´ 9,81 ´ 0,315
= 0,95 ´ 0,00503 ´
50,568 - 1
= 0,001687 m 3 / s (´ 60 ´ 60 ´ 1 000 )
= 6074,32 l/h (6)

MECHANOTECHNICS N4
6.2 é h F ´ 3,026 ´ d 5 ù
êF = ú
ë l ´ Q2 û
Pressure
hF =
r ´g
40 ´ 10 3
=
1000 ´ 9,81
= 4,077 m
4,077 ´ 3.026 ´ 0,095

F=
25 ´ 0,02 2
= 0,0072
(3)
6.3 6.3.1 d
m=
4
0,09
=
4
= 0,023 m (1)
6.3.2 hF
i=
l
4,077
=
25
= 0,163 (1)
6.3.3 0,02 ´ 4
V=
π ´ 0,09 2
= 3,144 m/s
3,144
C=
0.023 ´ 0,163
= 51,348
(3)
[14]
TOTAL: 100

T1020(E)(J31)T
AUGUST EXAMINATION
MECHANOTECHNICS N4
(8190194)
31 July 2014 (Y-Paper)

13:00–16:00
This question paper consists of 6 pages.

( 8190194 ) -2- T1020(E)(J31)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.
be regarded as rough work and will not be marked.

( 8190194 ) -3- T1020(E)(J31)T
QUESTION 1
related equipment in the different work areas, as well as arranging for storage
space or stores, staff facilities and administrative offices. The placing of the
machines on the floor of a workshop has to comply with six important
requirements.
Name and briefly discuss these FIVE requirements. (10)
1.2 State SIX advantages and FOUR disadvantages of airless spray painting. (10)
1.3 Lubrication devices are used to provide a regulated quantity of a lubricant to

machine parts.
1.3.1 Name FIVE general methods of lubrication. (5)
1.3.2 Make a labelled drawing of the sight-feed lubricator. (5)

[30]
QUESTION 2
Calculate the quantity of rock, in tonne per hour, which can be transported by a belt
conveyor having the following particulars.
2.1 Maximum tension in the belt = 35,5 kN (1)
2.2 Contact angle of the belt on the driving pulley = 185° (2)
2.3 Friction force = 2,5 kN (3)
2.4 Belt speed = 95 m/min (2)
2.5 Delivery height = 35 m (2)
2.6 Coefficient of friction = 0,3 (4)

[14]

( 8190194 ) -4- T1020(E)(J31)T
QUESTION 3
3.1 A grinding wheel with a diameter of 200 mm rotates at a speed of 2 500 r/min
exerting the tangential force of 60 N on a work piece. If the motor driving the
grinding wheel rotates at the speed of 1 500r/min with a machine efficiency of
85%, calculate the following:
3.1.1 The output power at the grinding wheel (3)
3.1.2 The input power of the motor (2)
3.1.3 The torque on the spindle of the motor (2)
3.2 A lathe is being driven by a motor providing a maximum output power of

3,5 kW at 1 750 r/min.
At the maximum power the machine efficiency is 80%
The maximum and the minimum revolutions of the lathe spindle are
3 500 r/min and 25 r/min respectively.
3.2.2 At the driving spindles of the lathe at maximum speed (3)
3.2.3 At the driving spindles of the lathe at minimum speed (2)

[14]

( 8190194 ) -5- T1020(E)(J31)T
QUESTION 4
A tapered gauge with a taper of 1 in 5 on the diameter, as shown in FIGURE 1 (below)

must be checked for accuracy by means of a 100 mm sine bar and a set of gauge
blocks.
FIGURE 1
4.1 Calculate the included angle of the plug gauge. (5)
4.2 Make a neat drawing of the set-up of the plug gauge, sine bar and gauge
blocks. (5)
4.3 Make use of the drawing and calculate the difference in height of the two
rollers of the sine bar. (4)
[14]

( 8190194 ) -6- T1020(E)(J31)T
QUESTION 5
FIGURE 2 (below) shows a motor attached to an epicyclic gearbox which consists of

an annulus (A) having 64 teeth, a sun gear (C) having 28 teeth, two planetary gears
(B) having 18 teeth each and an arm (D) driving two planetary gears.
FIGURE 2
5.1 If arm (D) rotates at 150 r/min, calculate the rotational speed of the sun gear
(C) when annulus (A) is fixed. (7)
5.2 Determine the speed of annulus (A) when the sun gear (C) is fixed and arm
(D) rotates at 150 r/min. (7)
[14]
QUESTION 6
A sharp-edge orifice 50 mm in diameter in the side of a large tank, is discharging water

under a constant pressure head of 3 m. The diameter of the vena contracta is 40 mm.
If the horizontal distance of the water jet is 2,5 m and the jet falls 550 mm vertically,
determine the following:
6.1 The theoretical area of the jet. (1)
6.2 The actual area of the jet. (1)
6.3 The theoretical flow velocity of the water. (1)
6.4 The actual flow velocity of the water. (1)
6.5 The theoretical delivery of the water. (2)
6.6 The actual delivery of the water. (2)
6.7 The coefficient of delivery (Cd). (2)
6.8 The coefficient of velocity (Cv). (2)
6.9 The coefficient of contraction (Cc). (2)

[14]
TOTAL: 100

MARKING GUIDELINE
AUGUST EXAMINATION
MECHANOTECHNICS N4
31 JULY 2014

MARKING GUIDELINE -2- T(E)(J31)T
MECHANOTECHNICS N4
QUESTION 1
1.1 Special requirements for placing of machines in the workshop

Space around and above each machine
Sufficient space around each machine is essential, so that the operator can
work unhindered. Provision must also be made for sufficient space above
each machine, allowing free movement of overhead hoisting
apparatus(cranes) to handle heavy work pieces.
Handling of workpiece
Mechanised hoisting of apparatus must be used to handle heavy workpieces
during machining.
Transport routes and aisles

Transport routes and aisles should not be used to store materials.
They should be kept open at all times for the safe transport of materials and
workpieces. Transport routes and passages must also be clearly marked and
be wide enough for the movement of handling and conveying equipment.
Storage facilities
Suitable storage facilities in the form of containers for workpieces, before and
after machining, must be placed at convenient places near the machine so
that the operator can reach them when placing workpieces into them or taking
them out. Sufficient space must be allowed around the storage containers for
the movement of handling and conveying equipment.
Supply of services
Supply services and service points for electricity, water, gas, steam and
compressed air must be within reach and should not obstruct the hoisting and
conveying of workpieces. Supply routes and service points should preferably
be housed in ducts in the floor or walls and should be protected by steel
covers.
Carrying capacity of the floor

Workshop floors have to be reinforced to safely carry the weight of extremely
heavy machinery. Floor areas where heavy cranes are used must be
sufficiently reinforced to carry the additional burden. (Any 5 × 2) (10)
1.2 Advantage of airless spray painting

· There is less overspray
· High pump delivery allows rapid working
· Air pockets in the paint supply are eliminated
· High spraying pressure allows thick paints to be used
· There are bigger savings in thinners
· Overhead spraying is easier (6)

MECHANOTECHNICS N4
Disadvantage of airless spray paintings

· This is an expensive method
· The spraying width is only party controllable
· The coat thickness of the paint is difficult to control
· There is possible overlapping of paint stroke when finishing paint is used (4)
1.3 1.3.1 · Gravity feed

· Grease lubrication
· Splash lubrication
· Forced lubrication
· Pressure-feed lubrication (5)
1.3.2
Label (6 ×½) (3)

Drawing (2)
[30]
QUESTION 2
2.1 v = 95 m/min
95
v=
60
= 1,583 m/s (1)
2.2 Pf = Ff ´ v
= 2 500 ´ 1,583
= 39 57,5 W (2)

MECHANOTECHNICS N4
2.3 T1
uθ
= e 57.3
T2
0,3 ´ 1850
= e 57,3
(1)
T1 = 2,634T2
T1
T2 =
2,634
35 500
=
2.634
= 13 477,6 N (2)
2.4 Pt = (T1 - T2 )V
= (35 500 - 13 477,6) ´ 1,583
= 34 861,459 W (2)
2.5 Pt = Pg + Pf
Pg = Pt - Pf
= 34 861,459 - 3 957,5
= 30 903,959 W
(2)
2.6 Pg = mgh
Pg
m=
gh
30 903,959
m=
9,81 ´ 35
= 90,007 kg/s
3 600
= 90,007 ´
1 000
= 324,025 t/h (4)
[14]

MECHANOTECHNICS N4
QUESTION 3
3.1 3.1.1 πDN

V=
60
π ´ 0,2 ´ 2 500
=
60
= 26,18 m/s
P0 = F ´ V
= 60 ´ 26,18
= 1 570,8 W (3)
3.1.2 PO
Pin =
η
1 570,8
=
0,85
= 1 848 W
= 1,848 kW (2)
3.1.3 T=
P ´ 60
2pN
1 848 ´ 60
=
2p ´ 1 500
= 11,7647 N.m (2)
3.2 3.2.1 P ´ 60
T=
2pN
3 500 ´ 60
=
2p ´ 1 750
= 19,1 N.m (2)
P0 = η ´ Pi
3.2.2 = 0,8 ´ 3 500
= 2 800 W (1)
2 800 ´ 60
T=
2pN
2 800 ´ 60
=
2p ´ 3 500
= 7,64 N.m (2)

MECHANOTECHNICS N4
3.2.3 P ´ 60
T=
2pN
2 800 ´ 60
=
2p ´ 25
= 1 069 ,52 N.m (2)
[14]
QUESTION 4
4.1 5
0.5
(1)
0.5
tanθ =
5
-1
θ = tan 0.1
= 5,710
Inclined angle = 2 ´ 5.71
(
= 11,42 0 110 25' ) (4)
4.2
0 mm
10 B
height h
A
C
11.42 0
(5)
MECHANOTECHNICS N4
4.3 In ∆ABC
h
sin11,42 =
100
h = 100 ´ sin11,42
= 19,8 mm (4)
[14]
QUESTION 5
NO. CONDITIONS A B C D
1 Fix arm D and
rotates; A + 1 rev +1 64 64 0
= 3,556 -
18 28
= - 2 286
2 Multiply by x and add X + y 3,556 + y -2,286 × +y y
y
3 NC = ? 0 NC = ? 150
NA = 0
N D = 150
4 NA = ? NA 0 150
(14 × ½) (7)
5.1 x+y=0
y = 150
x = -150
N C = -2,286x + y
= -2,286 ´ (- 150) + 150
= 342,9 + 150
= 492,9 r/min (4)
5.2 y = 150
- 2,286x + 150 = 0
- 2,286x = -150
x = 65.617
NA = x + y
= 62,617 + 150
= 215,617 (3)
[14]

MECHANOTECHNICS N4
QUESTION 6
6.1 πd 2t
At =
4
π ´ 0,05 2
=
4
= 0,002 m 2 (1)
6.2 πd a2
Aa =
4
π ´ 0,04 2
=
4
= 0,0013 m 2 (1)
6.3 Vt = 2gh
= 2 ´ 9,81 ´ 3
= 7,672 m/s (1)
6.4
gx 2
Va =
2y
9.81 ´ 2.5 2
=
2 ´ 0.55
= 7.4658 m/s (1)
6.5 Q t = Vt ´ A t
= 7,672 ´ 0,002
= 0,01534 m 3 /s (2)
6.6 Q a = Va ´ A a
= 7,4658 ´ 0,0013
= 0,009705 m 3 /s (2)
6.7 Qa
Cd =
Qt
0,009705
=
0,01534
= 0,6327 (2)

MECHANOTECHNICS N4
6.8 Va
Cv =
Vt
7,4658
=
7,672
= 0,973 (2)
6.9 Aa
Cc =
At
0,0013
=
0,002
= 0,65 (2)
[14]
TOTAL: 100

T1020(E)(A3)T
APRIL EXAMINATION
MECHANOTECHNICS N4
(8190194)
3 April 2014 (Y-Paper)

13:00–16:00

(8190194) -2- T1020(E)(A3)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1020(E)(A3)T
QUESTION 1
1.1 The layout of a workshop depends on the type of product manufactured or the
type of assembly done in the workshop. Usually either product - or process
layouts occurs. A combination of these two layouts is often used to
manufacture the final product.
1.1.1 Name FIVE requirements for product layout. (5)
1.1.2 Name FIVE requirements for process layout. (5)
1.2 A journal or plain bearing consists of a shaft rotating in a hole made in a

machine part. The part of the shaft which is supported is called a journal,
while the part supporting the journal is known as the bearing.
1.2.1 State FIVE advantages of journal bearings. (5)
1.2.2 State FIVE disadvantages of journal bearings. (5)
1.3 Answer the following questions on corrosion.
1.3.1 Explain the dip painting method. (5)
1.3.2 Make a labelled drawing of the dip painting method. (5)

[30]
QUESTION 2
The following applies to a flat-belt drive:

· The width is 250 mm.
· The thickness is 6 mm.
· The tension in the tight side of the belt is two and half times more than that in
the slack side.
· The safe working stress is 350 kPa.
· The centre distance between two shafts carrying pulleys with diameters of
1 500 mm and 500 mm respectively, is 2 m.
· The larger pulley rotates at 150 r/min.
2.1 The power transmitted (10)
2.2 The length of the open belt drive (2)
2.3 The length of the belt if the drive is changed to crossed-belt drive (2)
[14]

(8190194) -4- T1020(E)(A3)T
QUESTION 3
3.1 Calculate the following:
3.1.1 The power consumed by a lathe operation if:

· the cutting force applied to the cutting tool is 1 000 N
· the rotational speed of the work piece is 350 r/min
· the diameter of the work piece is 350 mm (3)
3.1.2 The power consumed by a shaper operation if:
· the cutting force is 750 N
· the stroke length is 120 mm
· it takes 8 s to complete (4)
3.2 FIGURE 1 below shows the set-up of a square cutting tool which is held in a
lathe tool post.
3.2.1 The minimum force which the clamping screw F must exert on the
cutting tool to hold it in position if a downward force of 350 N is
acting on the tip of the tool (4)
3.2.2 The maximum horizontal cutting force which may be applied to the
cutting tool, assuming a coefficient of friction 0,25 between the
clamping screw tip and the tool (3)
[14]
FIGURE 1
(8190194) -5- T1020(E)(A3)T
QUESTION 4
4.1 Answer the following questions on a gear-tooth vernier.
4.1.1 Explain step by step how to use the gear-tooth vernier. (4)
4.1.2 Calculate the constant-chord width and height of a gear having a

module of 8 mm and a pressure angle of 20°. (5)
4.2 An ISO screw thread of 3.5 mm pitch has an effective diameter of 30 mm. The
size method is used for the test wires.
Calculate the micrometre reading over the three wires. (5)

[14]

(8190194) -6- T1020(E)(A3)T
QUESTION 5
A compound gearing system is shown in FIGURE 2 below. It consists of:

· an input gear (A) with 60 teeth rotating at 750 r/min
· an intermediate shaft on which two gears, (B) and (C), with 36 and 84 teeth
respectively are mounted
· an output gear (D) rotating at 3 500 r/min.
Calculate the following if this gearing system has a module of 2,5 mm:
5.1 The rotating speed of gears (B) and (C) (2)
5.2 The number of teeth on the output gear (D) (2)
5.3 The addendum of the gear teeth (2)
5.4 The dedendum of the gear teeth (2)
5.5 The centre distance ‘X’ (3)
5.6 The centre distance ‘Y’ (3)
[14]
FIGURE 2
(8190194) -7- T1020(E)(A3)T
QUESTION 6
A sharp edged orifice in the side of the tank discharges water under a constant
pressure head of 3 m. The diameter of the orifice in the side of the tank is 50 mm while
the vena contracta has a diameter of 40 mm. The horizontal distance of the jet is 2,5 m
and the jet falls 550 mm vertically.
6.1 The theoretical area of the jet (1)
6.2 The actual area of the jet (1)
6.3 The theoretical velocity of the water (1)
6.4 The actual velocity of the water (1)
6.5 The theoretical delivery of the water through the orifice (2)
6.6 The actual delivery of the water through the orifice (2)
6.7 The coefficient of delivery Cd (2)
6.8 The coefficient of velocity Cv (2)
6.9 The coefficient of contraction Cc (2)

[14]
TOTAL: 100

(8190194) 1
-8- T1020(E)(A3)T
MECHANOTECHNICS N4
FORMULAE
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) 2
-9- T1020(E)(A3)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
f ´ l ´ O2
4 ´ f ´ l ´ v2 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) 3
-10- T1020(E)(A3)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R
61. P = T × T 62. T = 2p × N
1 work done
63. Ke = I ´ w2 64. Ke =
2 efficiency
Tan q
67. µ = Tan q 68. h =
Tan ( q + f )
m ´ F ´ Re
70. T =
69. T = µ × F × Re × n sin q
72. Fc = m × T 2 × g
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
APRIL EXAMINATION
MECHANOTECHNICS N4
3 APRIL 2014

MECHANOTECHNICS N4
QUESTION 1
1.1 Workshop layout
1.1.1 Requirements for product layout
 Large enough volume has to be manufactured.

 Changes in design of product must be minimised.
 There must be a sufficient supply of raw materials to prevent
interruption.
 There must be sufficient spares for maintenance of machines.
 Strict inspection requirements are set.
 Careful production planning is required.
(Any 5 x 1) (5)
1.1.2 Requirements for process layout
 The various sections must be placed economically.

 The shortest possible transport routes between sections must
be used.
 Highly skilled workers are required.
 Strict control over workers must be maintained.
 Adaptable inspection methods must be used.
 Production must be thoroughly planned.
(Any 5 x 1) (5)
1.2 Journal or plain bearing
1.2.1 Advantages of a journal bearings
 They can be repaired when wear occurs.

 The cost of repair or replacement is relatively low.
 The length of a journal bearing is unlimited, providing rigidity.
 They are quiet in operation, even at high speeds.
 Their life is not limited by fatigue. (5)
1.2.2 Disadvantages of journal bearings
 They are very dependent on sufficient lubrication.

 There are strict requirements as to the quality and quantity of
the lubricant.
 Foreign elements or dirt in the lubricant may easily cause
damage.
 Due to more friction the starting torque is also bigger.
 The power consumption is increased due to the bigger friction. (5)

MECHANOTECHNICS N4
1.3 Corrosion
1.3.1 Dip painting
This method is used for mass production. It is suitable when all

surfaces must be painted, including places that are difficult to reach
by hand. A conveyor system transports the parts. Work pieces are
cleaned and degreased and dipped in the paint dip by the conveyor
system. They then move over an overflow pan before going to the
baking oven for the bind finish. (5)
1.3.2  
 



THE DIP PAINTING METHOD
Any 6 labels ½ each = 3

Drawing relevance = 2 (5)
[30]

MECHANOTECHNICS N4
QUESTION 2
2.1 V  πD  t N
 π1.5  0.006  2.5
 11.828 m/s (2)
A  tw
 0.006  0.25
 0.0015 m 2 (2)
T1  δ  A
 350  10 3  0.0015
 525 N (2)
T1
T2 
2.5
525

2.5
 210 N (2)
P  T1  T2   V
 525  210  11.828
 3725.82 W (2)
1.5  0.5  1.5  0.5  2  2

2
2.2 π
L
2 42
 3.142  0.125  4
 7.267 m (2)
2.3 π
L  1.5  0.5 
1.5  0.5  2  2
2
2 42
 3.142  0.5  4
 7.642 m (2)
[14]

MECHANOTECHNICS N4
QUESTION 3
3.1 3.1.1 DN

V
60
  0.35  350

60
 6.41408 m/s
P  FV
 1000  6.41408
 6414.08 W (3)
3.1.2 s
V
t
0.12

8
 0.015 m/s (2)
P  FV
 750  0.015
 11.25 W
(2)
3.2 3.2.1 F
350
75
45
30 65
45 65
CWM  ACWM
F  65  350  45
350  45
F 
65
F  242,3 N (4)
3.2.2 F = μ × FR
= 0.25 × 24 2,3
= 60.58N (3)
[14]

MECHANOTECHNICS N4
QUESTION 4
4.1.1 Calculate the chordal width and chordal height of the tooth by using the
following formulae:
πm
w= ( ) cos2Ɵ and
2
 
h  m1   sin   cos  
 4
 Adjust the vertical scale (for chordal height) for reading as calculated
above.
 Adjust the horizontal scale and measure the thickness of the tooth (chordal
width).
 Now compare the measured width of the tooth with the calculated value of
the chordal if the readings of values correspond, then the tooth will be
correct. (4)
4.1.2  π 
h  m [1 -  sinθ  cosθ  ]
 4 
 π 
 81  sin20 0 cos20 0  
 4 
 81 0.2524
 5.9809 mm (3)
πm
w=( )cos 2 θ
2
8π
= cos 2 20 0
2
= 11.096 mm
(2)
4.2 d  0.577 p
 0.577  3.5
 2.019 mm (2)
w = D + 3d 1.516p
= 30 + ( 3 × 2.019) - (1.516 × 3.5)
= 30.754 mm (3)
[14]

MECHANOTECHNICS N4
QUESTION 5
5.1 TA  N A  TB  N B
TA  N A
NB 
TB
60  750

36
 1250 r/min
NB  NC (2)
5.2 TA × N A × TC
TD =
TB × N D
60 ×750 × 84
=
36 × 3500
= 30 teeth (2)
5.3 Addendum  module

 2.5 mm (2)
5.4 Dedendum = 1.157 × module

= 1.157 × 2.5
= 2.8925 (2)
5.5 m
X TA  TB 
2
2.5
 60  36
2
 120 mm (3)
5.6 m
Y TC  TD 
2
2.5
 84  30
2
 142.5 mm (3)
[14]

MECHANOTECHNICS N4
QUESTION 6
6.1 D2
At  π
4
0.05 2
π
4
 0.002 m 2 (1)
6.2 D2
Aa = π
4
0.04 2
=π
4
= 0.0013 m 2 (1)
6.3 Vt  2gh
 2gh
= 7.2672
× 9m/s
,81 × 3 (1)
= 7.672m/s
6.4 gx 2
Va =
2y
9.81 × 2.5 2
=
2 × 0.55
= 7.466 m/s (1)
6.5 Q t  Vt  A t
 7.672  0.002
 0.01534 (2)
6.6 Q a  Va  A a
 7.466  0.0013
 0.00971 (2)
6.7 Qa
Cd =
Qt
0.00971
=
0.01534
= 0.633 (2)

MECHANOTECHNICS N4
6.8 Va
CV =
Vt
7.466
=
7.672
= 0.973 (2)
6.9 Aa
Cc =
At
0,0013
=
0,002
= 0,65 (2)
[14]
TOTAL: 100

T1120(E)(N19)T
MECHANOTECHNICS N4
(8190194)

09:00–12:00

(8190194) -2- T1120(E)(N19)T

MECHANOTECHNICS N4
TIME: 3 HOURS
MARKS: 100
paper.

(8190194) -3- T1120(E)(N19)T
QUESTION 1
particular layout would differ from one layout to another.
Name TEN important factors to be considered in the design of the layout of a

workshop layout. (10)
1.2 Name and explain FIVE faults which can occur with ball and roller bearings.
(5 × 2) (10)
1.3 Electroplating is a process by which a metal is electrolytically deposited onto

another metal.
1.3.1 Explain the process of electroplating.
1.3.2 Make a labelled drawing of electroplating.

(2 × 5) (10)
[30]
QUESTION 2
The following information applies to an incline conveyor belt:
Angle of inclination of the conveyor = 17 °

Inclined length of the belt = 100 m
Speed of the belt = 1,8 m/s
Belt conveys = 400 t of rock per hour
Contact angle of the driving pulley = 240 °
Force required to overcome belt friction = 4 000 N
Coefficient of friction between belt and pulley = 0,2
Efficiency of the drive = 90%
2.1 Power required from the driving motor. (7)
2.2 The tight and the slack side-belt tensions. (7)

[14]

(8190194) -4- T1120(E)(N19)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.
3.2 The belt drive from the electric motor transmits an effective driving force of
800 N to the 250 mm diameter-driving pulley on a milling machine. The
torque to overcome friction on the driving parts of the machine can be
assumed as 8 N.m.
3.2.1 Torque transmitted to the machine pulley.
3.2.2 Torque that is available at the milling cutter.
diameter milling cutter.
(3 × 2) (6)
[14]

(8190194) -5- T1120(E)(N19)T
QUESTION 4
4.1 An external dovetail is machined to an angle of 45° as shown in FIGURE 1.

The angles are tested for correctness by means of two precision rollers of
15 mm diameters each.
4.1.2 Use the given dimensions and calculate distance 'X'. (5)
FIGURE 1
0B
4.2 An ISO screw thread of 4 mm pitch has an effective diameter of 35 mm. The
size is used for the test wires.
Calculate the micrometre reading over the three wires. (7)

[14]

(8190194) -6- T1120(E)(N19)T
QUESTION 5
5.1 FIGURE 2 shows a simple epicyclic gear comprising a gear wheel 'B' having
60 teeth and a pinion 'A' having 20 teeth.
Determine the speed and direction of rotation of pinion 'A' if gear wheel 'B' is
fixed. The two gears are mounted on arm 'C' rotating clockwise at 100 r/min.
FIGURE 2
1B (10)
5.2 Two shafts are to be connected by spur gears having a module of 8 mm. The
centre distance between the shafts is approximately 639 mm. Assuming the
gear wheels to have a velocity ratio of 3 : 1.
Calculate the number of teeth on each gear. (4)

[14]

(8190194) -7- T1120(E)(N19)T
QUESTION 6
The following particulars apply to an orifice provided in the side of a tank:
Diameter of the orifice = 30 mm

Delivery of water = 0,75 m3/min
Diameter of vena contracta = 25 mm
Pressure head = 34,5 m
6.1 The coefficient to discharge (Cd) (8)
6.2 The coefficient of contracta (Cc) (3)
6.3 The coefficient of velocity (Cv) (3)

[14]
TOTAL: 100

(8190194) -8--1- T1120(E)(N19)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
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 =
PCD
14. Ta = TA + +
13. T" = Ie × "A ( NA ) h1 ( NA ) h1h 2
NB wB aB IA
NA wA aA IB
p ´ PCD
17. P = 18. Ti + To + Th = 0
n
19. TA = TS + 2TP 20. =
21. v = p × (d + t) × N 22. P = Te × v
T1
23. = e mq 24. T1 = * × A
T2
T 1 - TC
25. Tc = m × v2 26. = e mqcosec a
T 2 - TC
27. L =
p
´ (D + d ) +
(D ± d )2 + 2C
2 4Ć
28. Tg = m × g × sin f 29. v = T × r

(8190194) -9-
-2- T1120(E)(N19)T
g ´b´r
30. v = m ´ g ´ r 31. v =
2´h
32. v = gr ê ú 33. v = gr ê
ë1 - mTan q û ú
n
34. =ê 35. Cos =
ú 2 C
T 2 ë1 - mTan q û
f R+r
36. Cos = 37. m = w × t × L × D
2 C
38. T1 = w × n × ft 39. P = Pg + Pµ
I ´w 2´p ´ N ´T
40. t = 41. P =
T 60
42. T = F × r 43. w = do + 3d - 1,5155P
p ´m
44. do = de + 0,65P 45. w = (cos 2 q )
2
é p ù
ë 4 û
p1 ( v1 )2 p 2 ( v 2 )2
47. + + gh1 = + + gh 2
Rho 2 Rho 2
gx 2
48. Vw ( Va ) = 49. v = C mi
2y
2 f ´ l ´ O2
4 ´ f ´ l ´v 51. hf =
50. hf = 3,026 ´ d 5
2´ g ´d
Cd ´ A ´ a ´ ( 2 gh )
52. Q = ( 2 gh )
2 2 53. Q = Cd ´ A ´
(A -a )
( m2 - 1 )
m´s
r´v
56. L = 2C + pD m1 ´ g ´ S 2
57. Self-weight =
8´ h
m2 ´ g ´ S
58. One load =
4´h 59. T (acc load) = (T1 - T2)R

(8190194) -10- -3- T1120(E)(N19)T
a
60. T (acc drum) = I ´ a = mk 2 ´
R
61. P = T × T 62. T = 2p × N
1 work done
63. Ke = I ´ w2 64. Ke =
2 efficiency
Tan q
67. µ = Tan q 68. h =
Tan ( q + f )
m ´ F ´ Re
70. T =
69. T = µ × F × Re × n sin q
72. Fc = m × T 2 × g
71. T = µ × n × (Fc - S)R
mv 2
73. Fc =
g
FcCosq - mgSinq
76. m =
mgCosq + FcSinq
77. Pl = CmgL + mgh

MARKING GUIDELINE
MECHANOTECHNICS N4
19 NOVEMBER 2013

MECHANOTECHNICS N4
QUESTION 1
1.1 · Type of production required, e.g. mass production, batch production or

individual production
· Inspection requirements to be met
· The type of equipment needed, and the quantity thereof
· The quantity of material required
· Sequence in which production is to take place
· Volume of the final product to be manufactured
workers
· Regulation of the local authority (10 × 1) (10)
1.2 Rust or corrosion

This fault can be caused by using the wrong lubricant, or by water or moisture
entering the bearing.
Cage failure
The cage which spaces the rollers or balls is placed under light strain during
the operation of the bearing. Because they are very sensitive to poor
lubrication, the places where they touch the rolling elements will begin to
show wear and will later even give and break.
Indentation of the element

When lubrication is ineffective or the bearing is not protected against the entry
of impurities or dust, the small particles will damage the raceway as well as
the balls and rollers by being pressed between the rolling elements and the
raceway.
Flaking
If the bearing is used incorrectly, small fatigue cracks may appear on the
rolling elements and raceways. These cracks cause very small fragments to
break off and flake. Although the flaking fragments are very small, continuous
use of the bearing causes the flaking to spread over the entire loaded zone,
with the result that the bearing eventually becomes completely useless.
Abnormal noise
Abnormal noise can be caused by wear or damage to the bearings and rolling
elements, dust or dirt entering the rolling elements, or poor or insufficient
lubrication.
Cracks and fractures

Cracks and fractures may be the results of incorrect mounting, where the
inner race is fitted to the shaft or the outer race fits too tight in the sleeve.
Cracks and fractures can also be caused by loads on the bearing which are
too heavy or the use of the wrong type of bearing for a specific application.
(Any 5 × 2) (10)

MECHANOTECHNICS N4
1.3 1.3.1 Electroplating
The metal to be plated called the cathode, is connected to the

negative pole of a low voltage direct current source while a plating
metal, the anode, is connected to the positive pole of the direct
current source.
When the two electrodes are placed in the electrolyte, electron and
ion movement occurs in the electrolyte, from the anode to the
cathode.
As this electron and ion movement takes place the anode starts
corroding and a metal deposit forms on the cathode.
When two copper wires are connected to the negative and positive
poles of a low voltage direct current source and placed in a diluted
solution of copper sulphate, a plating process will start. The anode
gradually gets thinner, while the cathode gradually gets thicker.
The loss in mass of the anode will be exactly equal to the gain in
mass of the cathode. The copper sulphate solution in the plating
bath undergoes no change. (5)
1.3.2 Electroplating
1 Per label (4)

Drawing (1) (5)
[30]

MECHANOTECHNICS N4
QUESTION 2
h = 100sin17 0
= 29.227 m
Pg = mgh
= 111.1 ´ 9.81 ´ 29.237
= 31 868.33 W
Pf = F ´ V
= 4 000 ´ 1.8
= 72 00 W
Pt = Pg + Pf
= 31 868.33 + 7 200
= 39 068.33 W
Pt
Pi =
h
39 068.33
Pi =
0.9
= 43 409 W (7)
2.2 P = (T1 - T2 )
39 068.33 = (T1 - T2 ) ´ 1.8
39 068.33
T1 - T2 =
1.8
= 21 704.63 N
4θ
T1 57.3
=e
T2
4θ
57.3
T1 = T2 e
0.2´240
57.3
= T2 e
= 2.31T2

MECHANOTECHNICS N4
T1 - T2 = 21704.63
2.31T2 - T2 = 21 704.63
1.31T2 = 21 704.63
21 704.63
T2 =
1.31
= 16 568.42N
T1 = 2.31T2
= 2.31 ´ 16 568.4
= 38 273.05 N (7)
[14]
QUESTION 3
3.1 3.1.1 Pi
T=
2 πN motor
2.5 ´ 103 ´ 60
=
2π ´ 1 500
= 15.915 N.m (2)
3.1.2 Pu = η ´ Pi
= 0.85 ´ 2 500
= 2 125 W
Pu ´ 60
T=
2π ´ 3 500
2 125 ´ 60
=
2π ´ 3 500
= 5.798 N.m (4)
3.1.3 Pu ´ 60
T=
2π ´ 30
2 125 ´ 60
=
2π ´ 30
= 676.409 N.m (2)

MECHANOTECHNICS N4
3.2 3.2.1 T = F´ r
= 800 ´ 0.125
= 100 N.m
3.2.2 T = TPulley - TFriction
= 100 - 8
= 92 N.m
3.2.3 T
F=
r
92
=
0.0575
= 1 600 N
(3 × 2) (6)
[14]
QUESTION 4
4.1
f 15
450
C
A
B
125
ΔABC
7.5
tan22.50 =
AB
7.5
AB =
tan22.50
= 18.106 mm
X = 125 - 2AB - 2r
= 125 - 36.213 - 15
= 73.786 (7)

MECHANOTECHNICS N4
4.2 d = 0.577 ´ 4
= 2.308 mm
d 0 = d e + 0.65P
= 35 + 0.65 ´ 4
= 37.6 mm
w = d0 + 3d - 1.516P
= 37.6 + 3 ´ 2.308 - 1.516 ´ 4
= 38.46 mm (7)
[14]
QUESTION 5
5.1 NO. Conditions A B C

1 Fix arm C 60 1 0
= -3
and rotates; - 20
B = 1 rev
2 Multiply by x 3x+y x+y y
and add y
3 NA = ? NA = ? 0 100
NB = 0
N C = 100
y = 100
x+y=0
x = -y
x = -100
- 3x + y = N A
N A = -3 ´ (- 100 ) + 100
= 400 r/min (10)

MECHANOTECHNICS N4
5.2 VR = 3 : 1
TA = 3T B
m
C= (TA +T B )
2
8
639 = (3T B +T B )
2
4T B = 159.75
TB = 39.938
= 40
TA = 4 ´ 40
(4)
= 120
[14]
QUESTION 6
6.1 Vt = 2gh
= 2 ´ 9.81 ´ 34.5
= 26.0171 m/s
D2
At = π
4
0.032
=π
4
= 0.0007068 m 2
Qt = Vt ´ At
= 26.0171 ´ 0.0007068
= 0.01839
Q
Cd = a
Qt
0.0125
=
0.0184
= 0.68 (8)
6.2 Aa
CC =
At
0.025 2
Aa = π ´
4
= 0.0004908 m 2
0.0004908
CC =
0.0007068
= 0.695 (3)
MECHANOTECHNICS N4
6.3 Qa
Va =
Aa
0.0125
=
0.0004908
= 25.49 m/s
V
CV = a
Vt
25.46
=
0.978 (3)
[14]
TOTAL: 100

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T1100(E)(A1)T

1 April 2019 (X-Paper)

This question paper consists of 5 pages and a formula sheet of 3 pages.

Copyright reserved Please turn over

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions.

2. Read ALL the questions carefully.

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

5. Write neatly and legibly.

Copyright reserved Please turn over

1.1 What is meant by individual production? (3)

1.3 Name FIVE characteristics of individual production. (5)

1.6 Make a labelled drawing of the dip-painting method. (5)

1.7 State FIVE disadvantages of the dip-painting method. (5)

Copyright reserved Please turn over

Calculate the following:

3.2 The cutting force exerted on the cutting tool (3)

4.2 Use FIGURE 2 to calculate the distance 'h'. (6)

Copyright reserved Please turn over

An epicyclic gear train is shown in FIGURE 3 below. Gear wheel D rotates at

5.1 Determine the speed of gear wheel A if arm E is stationery. (10)

5.2 Determine the speed of arm E if gear wheel A is fixed. (4)

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

28. Tg = m × g × sin  29. v = T × r

Copyright reserved Please turn over

Copyright reserved Please turn over

71. T = µ × n × (Fc - S)R

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

75. Side thrust = FcCos   mg Sin

77. Pl  CmgL  mgh

26 July 2018 (X-Paper)

This question paper consists of 5 pages and a formula sheet of 3 pages.

Copyright reserved Please turn over

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions.

2. Read ALL the questions carefully.

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

5. Write neatly and legibly.

Copyright reserved Please turn over

1.3 Ball and roller bearings sometimes overheat during use.

Give FIVE reasons for this occurrence. (5)

1.4 1.4.1 Make a labelled drawing of electrostatic spray painting. (6)

1.4.2 State TWO advantages of electrostatic spray painting. (2)

1.4.3 State TWO disadvantages of electrostatic spray painting. (2)

The following applies to a flat-belt drive:

The width is 250 mm

Calculate the following:

2.1 The power transmitted (10)

2.2 The length of the open belt drive (2)

Copyright reserved Please turn over

3.1 A workpiece with a diameter of 250 mm is machined in a lathe at a spindle

Calculate the following:

3.1.1 The cutting pressure on the tool (N/mm2) (3)

3.1.2 The power required to machine the workpiece (kW) (3)

Determine the following:

3.2.1 Torque transmitted to the machine pulley

3.2.2 Torque that is available at the milling cutter