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 T640(E)(M30)T
APRIL EXAMINATION

NATIONAL CERTIFICATE

FITTING AND MACHINING THEORY N2

(11022032)

30 March 2016 (X-Paper)

09:00–12:00

Calculators and drawing instruments may be used.

This question paper consists of 8 pages and 1 formula sheet.

Copyright reserved Please turn over

(11022032) -2- T640(E)(M30)T

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
NATIONAL CERTIFICATE
FITTING AND MACHINING THEORY N2
TIME: 3 HOURS
MARKS: 100

NOTE: If you answer more than the required number of questions, only the required
number of questions will be marked. All work you do not want to be marked
must be clearly crossed out.

INSTRUCTIONS AND INFORMATION

1. Answer ALL the questions in SECTION A.

2. Answer either QUESTION 1.1 or QUESTION 1.2 of Question 1.

3. Answer only TWO questions in SECTION B.

4. Read ALL the questions carefully.

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

6. Write neatly and legibly.

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(11022032) -3- T640(E)(M30)T

SECTION A

QUESTION 1: OCCUPATIONAL SAFETY

1.1 List FIVE factors to consider when constructing safety guards on machinery. [5]

OR

1.2 Describe what is meant by:

1.2.1 Illumination of machinery

1.2.2 Approved lamps in fiery mines and coal mines

1.2.3 Inspection and testing of boilers

1.2.4 Unprotected electrical cables

1.2.5 Lights to be carried

(5 x 1) [5]

QUESTION 2: COUPLINGS

State FIVE advantages of using short shafts joined by couplings instead of long shafts. [5]

QUESTION 3: LIMITS AND FITS

3.1 Explain the meaning of the following terms used in connection with limits and
fits:

3.1.1 Hole basis systems

3.1.2 Minimum allowance

3.1.3 Bilateral tolerance

3.1.4 Transition fit

(4 x 1) (4)

3.2 A shaft is to be fitted into a bush. The following sizes are given for the shaft
and the bush:
Shaft : 300,025
0,035 Bush : 300,025
0,015

3.2.1 Determine the minimum allowance of the fitted parts (3)

[7]

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(11022032) -4- T640(E)(M30)T

QUESTION 4: BEARINGS

4.1 List FOUR advantages of plain bearings. (4)

4.2 Name THREE tools that may be used to remove anti-friction bearing. (3)
[7]

QUESTION 5: LUBRICATION AND VALVES

5.1 Name TWO types of shut-off valves. (2)

5.2 Differentiate between a normally open and a normally closed valve. (2)

5.3 Name the FOUR different types of lubricators shown in FIGURE 1 below.
Write only the answer next to the question number (5.3.1–5.3.4). in the
ANSWER BOOK.

5.3.1 5.3.2 5.3.3 5.3.4

FIGURE 1 (4 x 1) (4)
[8]

QUESTION 6: PACKING, STUFFING BOXES AND JOINTS AND WATER-PIPE SYSTEMS

6.1 Name any FOUR types of sealing materials used in pipeline installations. (4)

6.2 State THREE reasons for the lagging (insulating) of steam-pipelines. (3)
[7]

QUESTION 7: PUMPS

7.1 Name the THREE categories into which pumps are classified. (3)

7.2 Briefly explain the operation of a centrifugal pump. (3)

[6]

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(11022032) -5- T640(E)(M30)T

QUESTION 8: COMPRESSORS

Name the FIVE compressor components labelled 8.1 – 8.5 in FIGURE 2 below. Write
only the name of the component next to the question number (8.1–8.5) in the
ANSWER BOOK.

8.5
8.2
8.1
8.3

8.4

FIGURE 2 [5]

QUESTION 9: V-BELT, CHAIN, GEAR DRIVES AND REDUCTION GEARBOXES

9.1 Explain the following terms relating to chain drives:

9.1.1 Chain pitch

9.1.2 Drive sprocket

(2 x 1) (2)

9.2 State TWO reasons for the use of a guard on chain drives. (2)

9.3 State THREE precautions to be taken when working on V-belt drives. (3)

9.4 List THREE advantages of gear drives over belt and chain drives. (3)
[10]

TOTAL SECTION A: 60

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(11022032) -6- T640(E)(M30)T

SECTION B

Answer only TWO of the questions in this section.

QUESTION 10: HYDRAULICS AND PNEUMATICS

10.1 Name the components (10.1.1–10.1.5) associated with the ISO symbols in
FIGURE 3 below. Write only the name of the component next to the question
number (10.1.1–10.1.5) in the ANSWER BOOK.

FIGURE 3 (5)

10.2 Describe the main difference between a pneumatic system and a hydraulic
system. (2)

10.3 List the THREE ways by which directional control valves can be actuated. (3)

10.4 State the function of the following hydraulic components:

10.4.1 Hydraulic motor

10.4.2 Tank/Reservoir

10.4.3 Pressure-relief valve

(3 x 1) (3)

10.5 List TWO functions of valves in a hydraulic system. (2)

10.6 Name the components associated with the ISO symbols in FIGURE 4 below.
Write only the name of the component next to the question number (10.6.1–
10.6.5) in the ANSWER BOOK.

10.6.4

10.6.3

10.6.2

10.6.5
10.6.1

FIGURE 4 (5)
[20]
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(11022032) -7- T640(E)(M30)T

QUESTION 11: CENTRE LATHES

11.1 Briefly describe how the following lathe mandrels operate:

11.1.1 Sliding cone mandrel

11.1.2 Expanding mandrel

(2 x 2) (4)

11.2 The compound slide is used for taper turning on a centre lathe.

11.2.1 State TWO advantages of the use of the compound slide

11.2.2 State TWO disadvantages of the use of the compound slide

(2 x 2) (4)

11.3 State TWO methods of tailstock set-over, as applicable to taper-turning. (2)

11.4 Explain the main difference between the travelling steady and the fixed steady
used on centre lathes (2)

11.5 A taper of 1 in 40 has to be turned on a workpiece 280 mm long. Calculate

the amount of tailstock set-over required. (3)

11.6 A round shaft with an outside diameter of 45 mm must be provided with a two-
start thread with a 10 mm pitch. Calculate the helix angle of the thread (θ). (5)
[20]

QUESTION 12: MILLING MACHINES AND SURFACE GRINDERS

12.1 Identify the milling cutter types shown in FIGURE 5 below. Write the answers
next to the question number (12.1.1–12.1.3) in the ANSWER BOOK.

FIGURE 5 (3)

12.2 Name any FOUR components of a dividing head. (4)

12.3 State THREE possible factors which cause the burning of the workpiece when
surface grinding. (3)

Copyright reserved Please turn over

12.4 Calculate the cutting speed of the cutter, in metres per minute, when using a
cutter of 40 mm in diameter at a speed of 302 revolutions per minute. (3)

12.5 Climb milling is one of many milling processes.

12.5.1 Explain climb milling with the aid of a freehand drawing. (5)

12.5.2 State TWO advantages of climb milling. (2)

[20]

TOTAL SECTION B: 40
GRAND TOTAL: 100

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(11022032) T640(E)(M30)T

FITTING AND MACHINING THEORY N2

FORMULA SHEET

f = ft  T  N

πDN
S=
60

S=πDn

40
N

N
9

D-d length of workpiece

Set-over = 
2 length of taper

length of workpiece
Set-over =  Ratio
2

θ X
tan =
2 L

Leading angle = 90 - (Helix angle + clearance angle)

Following angle = 90 + (Helix angle - clearance angle)

Lead = No. of starts  pitch

Pitch
Mean diameter = OD -
2

Lead
tan θ =
Mean circumference

Copyright reserved
 MARKING GUIDELINE

NATIONAL CERTIFICATE

APRIL EXAMINATION

FITTING AND MACHINING THEORY N2

30 MARCH 2016

This marking guideline consists of 9 pages.

Copyright reserved Please turn over

MARKING GUIDELINE -2- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

SECTION A

QUESTION 1: OCCUPATIONAL SAFETY

1.1  Must be strong and long lasting

 Must not interfere with the operation of the machine
 Must be easy to repair
 Must be corrosion and fire resistant
 Must provide maximum protection
 Must not block access to other areas
 Must block access to danger zones during operation
 Must be free from hazards such as splinters and pinch points
 Should be a permanent part of the machine
 Effective operation of the machine should not be affected by the guard
(Any 5 x 1) [5]

OR

1.2 1.2.1 Area to be sufficiently illuminated so that moving parts can be

clearly seen.

1.2.2 No light or lamp is allowed inside a mine unless the director

general of mines approves it.

1.2.3 Safety valves must be tested regularly to ensure opening at

authorised gauge pressure.

1.2.4 No cables to be placed or suspended in an unprotected manner.

They must be laid in such a way that damage is avoided.

1.2.5 No person is allowed to work in and un-illuminated part of a mine

unless they carry a light.

(5 x 1) [5]

QUESTION 2: COUPLINGS

 Easier to handle short shafts than long shafts

 Easier to transport short shafts than long shafts
 Maintenance is easier on short shafts than on long shafts
 Cheaper to manufacture short shafts than long shafts
 Manpower is reduced during maintenance
 Shorts shafts do not bend as much as long shafts
(Any 5 x 1) [5]

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MARKING GUIDELINE -3- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

QUESTION 3: LIMITS AND FITS

3.1 3.1.1 The hole basis system is used when a shaft is machined within
limits to fit a standard existing hole.

3.1.2  Minimum allowance is the smallest distance between the

smallest hole size and the largest shaft size.
 Minimum allowance is the smallest allowable distance between
two mating components. (Any 1 x 1)

3.1.3 Bilateral tolerance is when the tolerance range is allowed on both

sides of the basic size.

3.1.4 Transition fit is a fit in which the shaft may be slightly larger or
smaller in diameter than the hole and still remain within limits.
(4 x 1) (4)

3.2 Minimum allowance = smallest hole size – largest shaft size 

= (30 - 0,015) – (30 - 0,025) 
= 0,01 mm  (3)
[7]

QUESTION 4: BEARINGS

4.1  The operation is quiet

 Low cost
 Great rigidity
 Can be replaced when worn
 Life is not limited by fatigue
 Easy to manufacture
(Any 4 x 1) (4)

4.2  Screw puller

 Hydraulic puller
 Puller plates
 Impact puller
 Hydraulic press
 Bearing induction heater
 Heated oil bath
 Heating lamps
 Wheel puller (Any 3 x 1) (3)
[7]

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MARKING GUIDELINE -4- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

QUESTION 5: LUBRICATION AND VALVES

5.1  Ball valve

 Gate valve
 Globe valve
 Diaphragm valve
(Any 2 x 1) (2)

5.2 Normally open valves are designed to be opened when in use  whereas a
normally closed valve is closed during normal use  (2)

5.3 5.3.1 Stauffer grease lubricator

5.3.2 Wick-feed lubricator
5.3.3 Hand-operated grease pump
5.3.4 Grease gun
(4 x 1) (4)
[8]

QUESTION 6: PACKING, STUFFING BOXES AND JOINTS AND WATER-PIPE SYSTEMS

6.1  Asbestos
 Cotton
 Nylon
 Rubber
 Neoprene
 Teflon
 Graphite
 Aluminium
 Babbit or white metal
 Cork
(Any 4 x 1) (4)

6.2  Prevent heat loss as the pipeline carries steam or hot water from one place
to another.
 To prevent condensation or water forming in a steam pipeline
 To prevent water hammer in steam pipelines
 For more accurate gauge readings
 To prevent water entering the machine
(Any 3 x 1) (3)
[7]

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MARKING GUIDELINE -5- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

QUESTION 7: PUMPS

7.1  Centrifugal pump

 Reciprocating pump
 Rotary pump (3 x 1) (3)

7.2 As water circulates inside the casing a vortex is created at the centre, which
causes a vacuum.  This vacuum allows more water to be drawn into the
casing.  A centrifugal force causes the water at the outside circumference
of the casing to be forced through the delivery outlet.  (3)
[6]

QUESTION 8: COMPRESSORS

8.1 Lubricator
8.2 Sheave
8.3 Piston
8.4 Connecting rod
8.5 Cotter [5]

QUESTION 9: V-BELT, CHAIN, GEAR DRIVES AND REDUCTION GEARBOXES

9.1 9.1.1 Chain pitch is the distance from the centre of one pin to the centre
of the next pin.

9.1.2 The drive sprocket is the sprocket that is attached to the motor
from which the driving motion is performed.
(2 x 1) (2)

9.2  Protect persons working in close proximity to a chain drive, in case of

chain breakage.
 Protect machinery, in case of chain breakage.
 Houses the lubrication system. (Any 2 x 1) (2)

9.3  Always make sure that the V-belt drive has a guard around it
 Make sure that the machine is switched off when replacing V-belts
 Never adjust the slack of a V-belt while the machine is in motion
 Use tensioning pulleys to adjust the slack of the belt
 Use the correct size V-belt for the pulley and type of drive
 Keep dirt and oil off the drive to prevent slip
 Make sure that the pulleys are tightly fitted onto the shafts
 Ensure that the pulleys are in line with each other
 Always keep spare V-belts so that broken ones can be replaced
immediately. (Any 3 x 1) (3)

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MARKING GUIDELINE -6- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

9.4  Unlike V-belt and chain drives, gear drives are positive drive, that is, no
slip is possible 
 Gear drives can be used in confined spaces whereas V-belt and chain
drives are used over longer distances 
 Gear drives can deal with higher torque than V-belt and chain drives 
 Gear drives are more durable than V-belt and chain drives (Any 3 x 1) (3)
[10]

TOTAL SECTION A: 60

Copyright reserved
MARKING GUIDELINE -7- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

SECTION B

Candidates must answer only TWO questions in this section.

QUESTION 10: HYDRAULICS AND PNEUMATICS

10.1 10.1.1 Air dryer

10.1.2 Filter with manual drain
10.1.3 Filter with automatic drain
10.1.4 Filter or regulator
10.1.5 Single-acting cylinder with spring return
(5 x 1) (5)

10.2  In hydraulic systems, oil is the working medium  whereas in pneumatics

systems, air is the working medium. 

 In hydraulic systems, the excess oil is returned to the reservoir 

whereas in pneumatic systems, the excess air is exhausted to the
atmosphere.  (Any 1 x 2) (2)

10.3  Manually
 Electrically
 By fluid pressure (pilot pressure) (3 x 1) (3)

10.4 10.4.1 Hydraulic motor is a hydraulic source of rotary power, which drives
components

10.4.2 Tank/Reservoir is a storage container for hydraulic oil which is to

be used in the system and acts as return station.

10.4.3 Pressure-relief valve regulates the system pressure, keeping it at a

fixed pressure for end use.
(3 x 1) (3)

10.5  Controls energy flow

 Opens or closes the path of flow
 Directs the flow
 Regulates the flow (Any 2 x 1) (2)

10.6 10.6.1 Pump

10.6.2 Single-acting cylinder
10.6.3 Check valve
10.6.4 4/3 way directional control valve
10.6.5 Tank/Reservoir
(5 x 1) (5)
[20]

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MARKING GUIDELINE -8- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

QUESTION 11: CENTRE LATHES

11.1 11.1.1 The fixed cone holds the work in position  while the sliding cone
can be tightened onto the workpiece by means of a fastening nut
on the back end. 

11.1.2 A split tapered bush fits over a tapered shaft.  By driving the shaft
into the bush, the bush opens up to accommodate workpieces of
various hole sizes. 
(2 x 2) (4)

11.2 11.2.1  Time saving

 Concentricity is guaranteed
 Simplicity of operation and calculations
 Internal and external tapers can be turned
 Short tapers can be turned to any angle (Any 2 x 1) (2)

11.2.2  The length of the taper is limited to the length of the travel of the
compound slide.
 No automatic feed, only by hand
 Not very accurate angle (set by eye judgement) (Any 2 x 1) (2)

11.3  The dial test indicator method

 The graduated sleeve method (2)

11.4 The travelling steady is fitted to the carriage of the lathe and travels along with
the tool  whereas the fixed steady is clamped on the slideway of the lathe
and does not move with the tool.  (2)

11.5 Lengthof workpiece

Tailstock set - over = × Ratio 
2
280 1
= ×
2 40 
= 3,5 mm  (3)

11.6 Lead=No. of starts × Pitch = 2 × 10 = 20 mm 

Pitch 10
Mean diameter = OD - = 45 - = 40 mm 
2 2

Lead 20
tan θ = = = 0,159 
Mean Circumference π × 40


θ = tan-1 0,159 = 9,043° 

(5)
[20]

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MARKING GUIDELINE -9- T640(E)(M30)T
FITTING AND MACHINING THEORY N2

QUESTION 12: MILLING MACHINES AND SURFACE GRINDERS

12.1 12.1.1 Ball-nose cutter

12.1.2 T-slot cutter
12.1.3 Dove-tail cutter
(3 x 1) (3)

12.2  Rapid index plate

 Index plate for simple indexing
 Angular head with degrees on
 Spindle
 Crank handle
 Single-start worm
 Worm wheel
 Sector arms (Any 4 x 1) (4)

12.3  Too slow a speed

 Metal clogging the space between abrasive particles/wheel clogged
 Wrong wheel/wheel too hard
 Insufficient coolant/disruption in coolant supply
(Any 3 x 1) (3)

12.4 S= DN 
=   0,04  302 
= 37,95 m/min  (3)

12.5 12.5.1

 (for drawing)

The teeth cuts from top to bottom.  The direction of cutter and (5)
feed  is in the same. 

12.5.2  Deeper cuts can be taken

 A finer finish is obtained (2)

[20]

TOTAL SECTION B: 40
GRAND TOTAL: 100

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