UNIVERSITY OF SOUTH AFRICA

SCHOOL OF ENGINEERING
CONTINUOUS ASSESSMENT

ASSESSMENT 4: MINOR ASSESSMENT

Semester Course

MEMO MTC1501

MEMO MANUFACTURING TECHNOLOGY I

60 Marks

Duration: ------

Examiner: Mr I MABUDA

Moderator: Ms. LB MATHEBELA

Weight of Assessment: 5%

This paper consists of 3 pages including the cover page.

INSTRUCTIONS:

1. Answer all the questions.

2. Show all calculations.

3. In the event of uncertainties, state your assumptions clearly and carry on.

4. Please indicate the method of submission, platform for submission and honor pledge

5. Strictly submission on Moodle (Assessment 4) and no sending to the examiner’ email

6. Use SI units on your readings.

7. Start each question on a new page.

Question 1
1.1. List four highlighted parts of the bench drill machine and the function of each
part (8)

2 – Pillar - provides a solid support for the drill head and worktable.

3 – Worktable - provides a flat surface in correct alignment with the drill

spindle upon which the workpiece can be positioned.

5 – Handwheel - provides feed to the drill by means of a rack and

Pinion on the quill.

10 – Drill guard - provided to protect the operator from contact with the

revolving chuck and drill while still retaining visibility of the operation

1.2. At what spindle speed would a 15 mm diameter drill be run to drill a hole in a
mild steel workpiece at a cutting speed of 28 m/min? (4)
Given π = 3.14, and using equation: S = πdN/1000
S = 28 m/min
N =?
d =15 mm
N = [1000S]/πd = [1000 x 28]/[pi()x15]

= 594.480 rev/min
1.3. State three safety precautions to be observed when using cutting fluids. (3)
- Follow the instructions and training given by the employer.
- Open doors and windows where practicable, to improve natural ventilation.
- Wear adequate protective clothing.
- Take care not to contaminate the inside of your gloves with cutting fluid when putting
them on or taking then off.
- Only use disposable wipes or clean rags.
- Contaminated rags and tools should never be put into overall pockets.
- Avoid eating or drinking in areas where metalworking fluids are used.
- Do not use paraffin, petrol and similar solvents for skin cleaning purposes.
- Do not discard unwanted food, drink or other debris into the sump.
[15]

Question 2
Given a MAC AFRIC 2 m Lathe 560 X 2000 mm below
2.1. Mention the two capacities of lathe machine. (4)
• The second important capacity is the maximum length of workpiece which can be
held between the centers of the machine.

• The most important capacity is the largest diameter which can be rotated over the
bed of the machine, and this is known as the swing.
2.2. Discuss five basic operations of lathe machine. (5)
• Turning is the most basic lathe operation in which excess material from the given
workpiece is removed to reduce its diameter to the desired shape.
• Facing operations on the lathe are basically the removal or machining of the end or
face of the workpiece held in a chuck or on a faceplate. Facing is used to reduce the
length of the workpiece by machining the end face of the workpiece.
• Knurling operations are carried out on a lathe to produce a regularly patterned
rough surface on workpieces.
• Parting operations involve the cutting of a workpiece into two parts along the
longitudinal axis.
• Chamfering is the process of bevelling sharp ends of a workpiece to avoid any
injuries to the persons handling the finished product.
• Taper turning - During the taper turning on a workpiece, its diameter decreases
gradually until it becomes conical.
2.3. Label a) and b) for the MAC AFRIC below? (4)
a) Length workpiece = 2000 mm
b) Radius of workpiece = 280 mm
2.4. Name the four various ways in which a work part can be held in a lathe (4)
- Between centers,
- Chuck,
- Collet,
- Face plate.
2.5. Discuss four differences and improvements when using machines than
hand tools? (5)
- Higher productivity.
- Reduced scrap.
- Consistency in quality of the finished part.
- High machine utilization.
- High-quality products can be produced.
- The need for special tooling is almost eliminated.
- The cost per unit produced is less.
- The quality of the finished part is not dependent on the skill of the operator.
- It leads to reduced scrap.
- Reduced set-up time.
- Reduced in-process inventory
2.6. List four factors to consider when selecting the spindle speed of a
milling machine. (4)
• the diameter of the cutter
• the type of material being cut
• the material from which the cutting tool is made
• the availability of coolant

2.7. State the three characteristics used to identify the capacities of a

milling machine. (6)
- The capacity of these machines is identified by the size of the working surfaces of
the table,
- The length of travel of the longitudinal, transverse, and vertical movements,
- And the maximum distance from spindle to table surface on the horizontal model
or from spindle to column on the vertical model.
2.8. An engine lathe is used to turn a cylindrical work part 150 mm in diameter
by 500 mm long. Cutting speed = 2.50 m/s, feed = 0.30 mm/rev, and
depth of cut = 3.0 mm. Determine:
2.8.1. Cutting time (5)
 N = v/(πD)
fr = Nf
Tm = L/fr

N = v/(πD) = (2.50 m/s)/0.15 = 5.31 rev/s

fr = Nf = 6.757(.30) = 1.6 mm/s
Tm = L/fr = 500/1.6 = 313 s = 5.3 min

[37]
Question 3
3.1. Give the three main stages in problem solving (3)
Identifying the problem accurately and exploring possible ways of solving it
Trying out one or more possible solutions
Evaluating the results to check that the problem has been solved

3.2. Study the case study below and answer the questions that follows;
The Acme Warehouse Company received a consignment of 5m lengths of 50 mm
diameter stainless steel pipes. Acme had never handled pipe as part of their
warehousing operation. The forklift truck operator assigned to this job used the truck's
forks as a ram to load, handle, and unload the pipe. Inspection of the pipe by the
owners revealed that the forks were bending and damaging the pipe.

3.2.1. Suggest several alternative methods for eliminating the problem of pipe
damage. From a cost and ease in application standpoint, select one alternative
solution for adoption. (5)

Cut the pipes into smaller sizes upon arrival, to prevent them from
overlapping as the forklift has arms approximately 2 meters wide.

Put the pipes inside a container and use a forklift to carry the
container thereof, this will prevent pipes from overlapping on the
forklift and prevent pipes bending. etc

[8]
TOTAL MARK: 60 Marks

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