2010 MET PAST PAPER QUESTION SOLUTIONS

QUESTION 1: Design Question

 Students will attempt answering it based on class discussions

QUESTION 2: Centre Lathe Machine Question

(a) (i) Steps of procedure to produce component

N.B. Operating from the right side of the component
- Face
- Parallel turn to diameter 20 mm and length 63 mm.
- Parallel turn to diameter 16 mm and length 33 mm.
- Cut the 3 mm gap.
- Parallel turn to diameter 12 mm and length 20 mm.
- Chamfer end to be threaded.
- Commence the threading with the required die on the machine to ensure it is
square (the threading will be done by hand. Remove die.
- Turn work piece
- Face
- Set compound slide for taper turning
- Cut taper
- Part-off.
- Secure work piece in a vice with soft jaws.
- Resume threading the work piece with die in wrench.
- Polish Work piece.

(ii) Procedure for Threading Squarely

- Square the end of the work piece and chamfer it using a file, grinding
machine or centre lathe for easy start.
- Grip the die, held in the stock, firmly and squarely on the work piece.
- Turn clockwise, about a quarter turn and ease back to remove chipping.
- Apply a good supply of oil (lubricant).
- Make adjustments of the screws after a full cut until depth required is
achieved.

See link for more information: https://technologystudent.com/equip_flsh/exthread1.html

(b) Cutting Tool Geometry
Rake angle displays the inclination of rake surface of the cutting tool from reference plane. Since
rake surface is the chip flowing surface, so rake angle also indicates chip flow direction. On the
other hand, clearance angle displays the inclination of flank surface of the cutting tool from
cutting velocity vector. This angle has no direct influence on chip flow. However, both the angle
can be measured on different planes (directions) to get clear ides about inclination of
corresponding surfaces.

(c) Calculation of Spindle Speed / RPM

Formula: RPM = CS x 320 = 30 x 320 / 20 = 480
D
(d) Chucks and Faceplate. See https://www.slideshare.net/garfieldTulloch/work-holding-
on-lathe-machine

(e) Do not make adjustments while the machine is operating.

Do not place hands on work turning in the lathe.
QUESTION 3
(a) (i) Marking-out Procedure

 Coat material with layout die or chalk

 Mark all Horizontal lines
 Scribe all vertical lines
 Locate all centre points
 Scribe all arcs and circles
 Mark all angular lines
 Outline template
(ii) Marking out tools

 Scriber
 Steel rule
 Try square
 Odd leg caliper
 Protractor
 Divider
 Centre Punch
 Hammer
(b) (i) Cutting out Slot A

 Centre Punch
 Chain drill
 Chisel/ hacksaw
 File

(ii) Tools to be used to cut out slot

 Centre punch
 Drill File
 Chisel
 File

(c) Two Precautions for Accurate cutting Out of Slot

 Follow the correct procedure

 Use the right technique
 Ensure that the template is firmly secured
 Ensure tools are in good working condition.

(d) Safety Precautions for using Layout tools

 Hold/ use tools properly

 Ensure tools are not defective
QUESTION #6
(a) What is joining?
 Joining is one of the manufacturing processes that is used to assemble two or more solid
components or structures together. It can be employed to permanently or temporarily
join any type of engineering materials such as metals, ceramics, plastics and composites.
 Read more: http://www.differencebox.com/engineering/difference-between-joining-
and-welding/
b. - Used on joints that need to be relatively strong.
- Used on joints that need to withstand a reasonable amount of heat.
c. General Sheet Metal Work: Composition 60% Tin, 40% Lead, which melts at 188 °C (370
°F).
Soldering Electrical Component: Composition 63% Tin [Sn] / 37% Lead [Pb].
d. Fluxes are used generally to help molten metal flow and to shield its surface against the
atmosphere to help prevent the formation of Oxides.
Fluxes may be Passive, whereby their role is mainly protective, or Active in that they
also, to a greater or less extent, clean the metal surface - usually by means of a corrosive
acid. For this reason, acid fluxes tend not to be used when soldering electrical or
electronic connections although some are mildly active above a certain temperature but
form a useful insulating coating when cooled.
e. Active: Bakers Fluid Flux/ Bakers Solderine Paste Flux
Passive: Borax
f. Double-strap butt joint:
https://www.youtube.com/watch?v=BzcU3hB-ZjI&ab_channel=ITILIFEGYAN
Double riveted lap joint:
https://www.youtube.com/watch?v=YQoegtLFL5A&ab_channel=KTUWeb
QUESTION #9
(a)

MACHINE SHOP MAINTENANCE SCHEDULE

Machines Daily Weekly Monthly Annually
Drill Press - Clean after Organize clamps Wax machine Change pulley
used and work area. table. belts if needed
Lathe Machine - Cleaning chips -Check auto -Lubricate the -Replace gear
from carriage, drain on filter way covers box oil
cross slide, regulator
compound rest -Remove pump -Check and
and bed. -Clean out small from coolant replace drive
chip catch pan in tank and clean it belt
- Check the head coolant tank
stock oil level -Check the gear
through box oil level, top
inspection up if necessary
glass.
(b) 1. Reduces the chances of complete machine breakdown.
2. Saves money on electricity
3. Reduces the chances of emergency repairs calls.

(c) Preventive maintenance (or preventative maintenance) is maintenance that is regularly

performed on a piece of equipment to lessen the likelihood of it failing. It is performed
while the equipment is still working so that it does not break down unexpectedly.
Corrective maintenance is a maintenance task performed to identify, isolate, and rectify
a fault so that the failed equipment, machine, or system can be restored to an
operational condition within the tolerances or limits established for in-service
operations.

(d) Oil, Grease, Penetrating lubricants and Dry Lubricants.

(e) Classification of Lubrication Methods: 1. Conventional and Automated.

Conventional
1. Manual greasing using a grease gun.
2. Using a brush to apply oil.
3. Oil Bath
4. Drip Oil Feed
5. Splash Oil Feed
(f) Drip oil feed Lubrication:
Systems operating on low speed, low load & low to moderate speed have bearings where
small quantity of oil at regular intervals is expected. Drip oil feed systems consists of a
loosely covered manifold of oil placed above the bearing that meters out oil at regular
intervals. The supply is controlled by needle valve and can be adjusted as per
requirement.

A drip feed reservoir connected to one bearing is called as single point system and when
connected to several bearings is referred as multiple point systems. A drip oil feed system
can also be pressurized to supply oil to bearing system under pressure. The reservoir is
partially or completely transparent and can be refilled by hand.
For more Info visit: https://www.mosil.com/blog/lubrication-methods-used-in-
industries/