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N4 Mechanotechnics Lecturer Guide

The N4 Mechanotechnics Lecturer Guide provides comprehensive guidance for teaching mechanotechnics, outlining general and specific aims, prerequisites, evaluation methods, and a detailed work schedule covering various modules. It emphasizes practical application of theoretical principles, continuous assessment, and the importance of workshop layout and equipment maintenance. The guide serves as a resource for educators to facilitate learning in mechanical engineering processes and practices.

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0% found this document useful (0 votes)

1K views102 pages

N4 Mechanotechnics Lecturer Guide

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tsibulamulanga

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MECHANOTECHNICS

N4 Mechanotechnics Lecturer Guide|Hands-On! i

N4
Mechanotechnics
Lecturer Guide
Fadzai Zhakata, Frederik H. Boltman,
Krizia Giammartini & Johan Els
© Future Managers 2020

All rights reserved. No part of this book may be reproduced in any form,
electronic, mechanical, photocopying, or otherwise, without prior permission
of the copyright owner.

ISBN 978-0-63910-958-9

First published 2020

To copy any part of this publication, you may contact DALRO for information
and copyright clearance.

Any unauthorised copying could lead to civil liability and/or criminal sanctions.

Telephone: 086 12 DALRO (from within South Africa); +27 (0)11 712-8000
Telefax: +27 (0)11 403-9094
Postal Address: P O Box 31627, Braamfontein, 2017, South Africa
www.dalro.co.za

Published by
Future Managers (Pty) Ltd
PO Box 13194, Mowbray, 7705
Tel (021) 462 3572
Fax (021) 462 3681
E-mail: info@futuremanagers.net
Website: www.futuremanagers.net
N4 Mechanotechnics Lecturer Guide|Hands-On! iii

Contents
Lecturer guidance................................................................................................................. v
1. General aims....................................................................................................................... v
2. Specific aims....................................................................................................................... v
3. Prerequisites....................................................................................................................... v
4. Duration.............................................................................................................................. v
5. Evaluation........................................................................................................................... v
6. Weighted value of modules............................................................................................... vi
7. Didactic guidelines............................................................................................................ vii
8. Work schedule.................................................................................................................... vii
9. Lesson plan template......................................................................................................... ix

Answers.................................................................................................................................... 1
Module 1: Workshop layout................................................................................................... 1
Module 2: Metal protection.................................................................................................... 11
Module 3: Lubrication............................................................................................................. 18
Module 4: Precision measuring of machine parts............................................................... 26
Module 5: Gear drives............................................................................................................. 37
Module 6: Belt drives.............................................................................................................. 49
Module 7: Hydraulic systems................................................................................................. 57
Module 8: Bearings.................................................................................................................. 70
Module 9: Metal cutting machines........................................................................................ 76

Glossary......................................................................................................... 81
Lecturer guidance

1. General aims
• To acquaint the student with workshop processes, procedures, practices and
calculations needed for the practical work situation.
• To help the student to gain an understanding of installation, maintenance and
application of equipment in mechanical engineering.

2. Specific aims
• To provide the prospective craftsman and mechanical supervisor with the required
theoretical knowledge.
• To equip the person specialising in the aspects prescribed by the syllabus with the
basic principles and theory with regard to mechanical engineering.

3. Prerequisites
A student must have passed at least the National Certificate Vocational, Engineering and
Related Design (ERD) Level 4 or the National Certificate N3 Engineering with a pass
in Mechanotechnology N3 and obtained a Senior Certificate (NSC) or equivalent with
a pass in Mathematics, Technical Mathematics, Physical Science and any mechanical
subjects.

4. Duration
Full-time: 7,5 hours per week for one trimester. This instructional offering may also be
offered part-time.

5. Evaluation
Evaluation is conducted continuously by means of class tests. An Internal Continuous
Assessment (ICASS) mark of at least 40% as well as a minimum examination mark of
40% is required to pass the instructional offering. The ICASS mark and the examination
mark will be calculated together in a ratio of 40:60 to derive the promotion mark.
vi Lecturer guidance

The examination in Mechanotechnics N4 (Engineering Studies – Report 191) will be

conducted as follows:
• ONE paper will be written.
• Paper 1: Modules 1 to 9 Marks: 100
• Duration: 3 hours
• Weighting: Recall, comprehension, application, analysis, synthesis and evaluation
of learning content are important aspects in determining a student’s knowledge and
understanding of the learning content of the instructional offering.

The following weights are consequently awarded to each category:

Knowledge and Application Analysis/synthesis

understanding and evaluation

30–45% 20–30% 15–25%

6. Weighted value of modules

The topic covered in N4 Mechanotechnics and their weighted values are:

Topic Weighted
value

Module 1: Workshop layout 5%

Module 2: Metal protection 5%

Module 3: Lubrication 5%

Module 4: Precision measuring of machine parts 15%

Module 5: Gear drives 15%

Module 6: Belt drives 5%

Module 7: Hydraulic systems 20%

Module 8: Bearings 15%

Module 9: Metal cutting machines 15%

TOTAL 100%
N4 Mechanotechnics Lecturer Guide|Hands-On! vii

7. Didactic guidelines
Theoretical principles should be applied to practical real-life situations.
Discussions and evaluations should be done on the basis of real practical workshop
situations.
Although the art of effective listening could be formally introduced and refined in oral
work, it should be practised continually and become part of the student’s way of life.
Excursions, videos and the internet could all contribute to an understanding and
evaluation of mechanotechnics.

8. Work schedule

Week Topic Content Hours

1 Module 1
Workshop layout 1.1 Introduction to workshop 5 hours
layout
1.2 Types of production
1.3 Factory layout
1.4 Graphic layout techniques
1.5 Considerations when placing
machines in a factory
Module 2
Metal protection 2.1 Introduction to corrosion and 5 hours
its prevention
2.2 Classification of corrosion
2.3 Different forms of corrosion
2.4 Corrosion tests
2.5 Metal protection process
2.6 Surface preparation for painting
2.7 Painting process
2 Module 3
Lubrication 3.1 Classification of lubricants 5 hours
3.2 Fluid film bearings
3.3 Selection of lubricants
3.4 Lubrication devices
3.5 Uses of lubricants
2–3 Module 4
Precision measuring of 4.1 Basic principles 15 hours
machine parts 4.2 Determining tapers using balls
4.3 Determining tapers of taper
plugs
4.4 Determining angles of
dovetails
4.5 Sine bars
viii Lecturer guidance

Week Topic Content Hours

4–5 Module 5
Gear drives 5.1 Introduction to gear drives 15 hours
5.2 Gear terminology
5.3 Simple and compound gear
trains
5.4 Epicyclic gear systems
5.5 Uses of epicyclic gears
5.6 Calculations of epicyclic gears
5 Module 6
Belt drives 6.1 Introduction to belt drives 5 hours
6.2 Belt drive
6–7 Module 7
Hydraulic systems 7.1 Basic principles of fluid 20 hours
statistics
7.2 Basic principles of fluid
dynamics
7.3 Energy stored in fluids
7.4 Bernoulli’s principle
7.5 Frictional losses in pipelines
7.6 Measurement of flow
7.7 Venturi meters
8–9 Module 8
Bearings 8.1 Load acting on shafts 15 hours
8.2 Bearing load distribution
8.3 Mean load
8.4 Equivalent load
9–10 Module 9
Metal cutting machines 9.1 Introduction to metal cutting 15 hours
machines
9.2 Calculations for cutting
machines
TOTAL 100 hours
9. Lesson plan template

Subject and level Campus

This page may be photocopied.

MODULE

1 Workshop layout
By the end of this module, students should be able to:
• list the advantages and disadvantages of a good workshop layout;
• list the factors that should be considered in the design of workshop layout;
• explain the differences between mass, individual and batch production;
• draw diagrams to illustrate the differences between the following layout processes:
– product
– fixed
– process;
• draw two-dimensional and three-dimensional models;
• explain how materials are handled in the workshop; and
• explain what is meant by each of the following requirements of process layout:
– economic placement of various sections
– highly skilled workers
– adaptability of inspection methods
– thorough planning of production.

Every factory starts out as a plan. Part of that plan is choosing the correct workshop
layout to carry out the plan. However, as the business grows and new equipment is
bought, it is usually placed wherever there is space, with no logical plan at all.

So, when planning a new or existing workshop, you should consider the following:
• The type of production needed
• The layout needed for the production type
• Which model to use, as different models are available to help plan the layout
• What to consider when placing new machines in the workshop.
2 Module 1 • Workshop layout

Exercise 1.1 SB page 5

1. Any five of the following:

• Predicting manufacturing and maintenance times will be more effective
because it is easy to determine how long it takes for materials to be
processed at different stations in the workshop.
•
Quality control will be improved because inspection can be done at
different levels of manufacturing.
•
The manufacturing of quality products will be increased by reducing the
material handling of products.
•
Manufacturing costs may be reduced by reducing the process inventory
and equipment requirements.
•
Available space can be used more effectively by strategically locating
equipment to perform multiple functions and developing up-to-date work
areas.
•
Employee idle time will be reduced because of a better flow of material and
fewer breakdowns.
•
Visibility will be improved.
•
Supervision will be improved due to better visibility of the entire workshop.
•
Communication between departments should improve.
•
Bottlenecks will be avoided because efficiency eliminates congestion.
•
Employee morale should improve because of better employee facilities and
better working conditions.
•
Unnecessary and costly changes can be prevented.
•
Safety conditions will be improved.

2. Any five of the following:

•
It may involve a large initial investment, as new or more machines may be
required.
•
More floor space may be needed for additional machines or workstations.
•
The chosen layout might not be flexible. Having a machine that can
perform a certain task places limits on the flexibility and variety of tasks
that an employee could perform.
•
One defective machine could stop the entire production process.
•
Small production volumes may result in higher manufacturing costs.
•
Strict supervision is needed at the start to ensure that layout procedures are
followed.
•
Multi-skilled labourers may be required to carry out different operations
that cost more. If the factory chooses not to hire new multi-skilled
labourers, they will have to train their current workforce. This will cost the
company more money, and during the training, production will slow down
or stop completely.
N4 Mechanotechnics Lecturer Guide|Hands-On! 3

•
The movement of materials may increase, which makes control and quality
checks more difficult.
•
Workers may not respond well to the processes they are used to being
changed.
•
By streamlining the workshop layout, fewer personnel may be needed. This
would increase the unemployment rate.

3. Any five of the following. One mark is awarded for the correct factor and one
mark is awarded for the correct explanation. If the wrong explanation was given,
no marks should be awarded:
• The goal of the organisation – The layout of the workshop must be
chosen based on the organisation’s or company’s goals, for example to be
the number one organisation in the country or to be a company where all
employees matter.
• Space requirements – Space is almost always a problem when designing a
workshop. Therefore, different manufacturing and maintenance processes
should be considered.
• Safety measures – Laws and regulations must be followed when setting up
a workshop.
• Country laws – Different countries have different standards for the
minimum space needed for a worker to operate a machine. Therefore, these
laws must be kept in mind when designing the workshop.
• Flow of materials – The layout should be designed so that the flow of
materials is not disturbed. The layout must enable an easy flow from
workstation to workstation, or from department to department. There
should be continuous flow with few congested areas.
• Material movement – The external movement of materials from the
raw materials warehouse or storage to the workshop, and to the finished
products section, should be smooth and efficient.
• O perator convenience – The manufacturing and maintenance must be
convenient for the operator/worker in the workshop. Ergonomic factors
should also be considered.
• Type of operations – As a manager, you must know the types of operations
that will be performed and the problems the operator may experience.
For example, some operations require high accuracy, such as watch
manufacturing, and those processes pose different problems than those in
a job shop or a foundry.
• Environmental conditions – The environmental conditions in which the
organisation will operate may have an unwanted effect on the products. For
example, in a watch factory, the entire workshop will be air-conditioned
and humidity will be carefully controlled to prevent water drops (called
condensation) from forming on the parts. In a foundry, however, there are
4 Module 1 • Workshop layout

furnaces that produce heat and air conditioning will not be able to reduce
such heat. The manager should remember this and provide enough space
for operators to move around without risking their health.
• Type of layout – The type of the layout followed by the company influences
the type of layout that will be designed. As a manager, you must consider
the type of layout followed by the company, seeing that each type of layout
requires a different design. Examples of types of layouts are product, fixed
and process layouts.
• Size of products – The size of the finished products must be considered
when planning the layout. The size of the products limits the number of
products that can be present in the workshop at any point in time. If the
size of the final product is too big to be moved by hand, the layout should
have enough space to allow cranes or forklifts to move around safely.
• Machinery – As a manager, you must gather all the necessary information
about the tools and machinery for inspection and processing. For example,
you must know about the type of electricity needed (single-phase/three-
phase), hydraulics, lubrication, and so on.
• W orkforce – The workforce is the most flexible element in a layout. As a
manager, you must look at the current skills level of the workers, the number
of people the setup needs, and the training the workforce will need.

Exercise 1.2 SB page 7

1. •
Mass production
•
Batch production
•
Individual production

2. Mass production – any four of the following:

• The products must flow from one operation point to the next in the
assembly line.
• One type of machine is required for each process and the operations must
be well defined.
• The tools, materials and methods used in the assembly line must be
standardised.
• The demand of the product must be constant and growing.
• The time for each operation for the standardisation and the flow of
operations must be measurable.
• Determining the quality of the products must be possible.

Batch production – any four of the following:

•
The machinery must specialise in producing a single product, but also be
flexible enough to produce different batches.
N4 Mechanotechnics Lecturer Guide|Hands-On! 5

•
There must be general-purpose machines in the process layout.
•
There should be repetitive production for stock and not always just for
orders.
•
Production schedules must be flexible and planned to reduce changeover
time.
•
Skilled labour must be employed in specific manufacturing processes, such
as CNC operation, milling, welding, drilling, etc.
•
Supervisors must have the required knowledge about the specific processes.
•
The production schedules must be flexible.

Individual production – any four of the following:

•
High-quality, unique or custom-made products require individual
production.
•
Highly skilled workers must be employed to ensure the required level of
quality and tolerances.
•
Plant flexibility is highly recommended.
•
Clear objectives and job specifications must be developed.
•
Good decision-making skills in a highly flexible plant must be a priority.

Exercise 1.3 SB page 11

1. & 2. •
Product layout: any type of product where raw material is used to produce
something through multiple manufacturing steps, such as transforming
iron ore into nuts and bolts.

•
Process layout: ovens in a bakery will be in one area, or any other relevant
example.

6 Module 1 • Workshop layout

•
Fixed layout: where ships, airplanes, boilers and turbines are manufactured.
Or any other relevant example of items that are just too big and heavy to be
moved from process to process.

3. •
Grouping
•
Flexibility
•
Production time
•
Products

Exercise 1.4 SB page 15

1. Any five of the following:

•
Size of the facility
•
Production requirements
•
Machines required to perform the work
•
Availability of trained personnel
•
Accessibility to electricity
•
Lighting arrangements

2. •
Install dust- and smoke-emitting machines in a separate area with good
ventilation, where the dust and smoke cannot damage other machines or
endanger people’s health.
•
Make sure that the design allows efficient workflow.
•
Separate the receiving area (raw materials) from the machining area. This
will keep the machine area organised.
•
Have a designated dispatch area for deliveries and pick-ups.
•
Leave space for new equipment to be installed without having to break
down the walls.
•
Include drainage in the design. Separate the drain systems, so there is one
system for washing floors and another system for disposing of unwanted
liquids.
•
Include walking space to be at least 500 mm and working space around
a machine at least 2 m.
N4 Mechanotechnics Lecturer Guide|Hands-On! 7

•
Include dedicated lighting for machines, natural lighting and lighting sources.
•
Make sure there is an adequate electricity supply and that it is convenient
for coupling the machines.
•
Explore the best way to provide enough ventilation for the total work area.

Exercise 1.5 SB page 19

1. •
Warehouse storage
•
Pipe and bar stock
•
Bagged material
•
Sheet metal
•
Chemical storage
•
Flammable goods storage

2. •
Economic placement of sections
•
Highly skilled workers
•
Adaptable inspection methods
•
Thorough production planning

Summative assessment SB page 21

1. 1.1 False. Ergonomics refers to the study of how equipment and furniture
can be arranged to make work more comfortable and more efficient, such
as not having a chair that is too low for a desk that causes neck pain, but
rather at the right height.
1.2 True
1.3 False. A product layout is used for large and heavy objects for easier
production.
1.4 False. A product layout is used for high volumes of standardised products.
1.5 True
1.6 False. The size of the facility is an important layout consideration.
1.7 False. A fixed layout is used for big and heavy products that can be
produced in small quantities.
1.8 False. In a process layout, machines that perform similar tasks are grouped
together.
1.9 True
1.10 False. The convenience of an operator is an important factor to consider
when a new factory layout is designed.
1.11 True (22)

2. There are three types of production types to choose from: mass, batch and
individual production. The question states that the customers are going to
order customised trucks, eliminating mass production. The question also states
8 Module 1 • Workshop layout

that some customers might order trucks in bulk, up to 10 trucks. So, a batch
production can be used. Ultimately, most of the truck orders will be different,
with only a few being the same. With this great number of customers and unique
products, the individual production method is recommended.
There are also three types of layout that can be selected. As mentioned, the trucks
require a high level of flexibility and therefore a product layout cannot be used.
Process and fixed layouts allow for flexibility. However, trucks are large products
and will be difficult to move from station to station. Therefore, a fixed layout is
recommended.(6)

Take note: If the student is able to provide a valid argument for using a different
production type and/or layout, marks can be awarded for each valid argument
supported by a fact about the production type and/or layout.

3. You must store chemicals in a place away from other chemical processes in a
properly ventilated room. Never store chemicals on the ground so they will not
be accidentally knocked over. There must be a first-aid kit and running water in
chemical storage in case chemicals spill on someone. There must also be a danger
sign on a tightly locked cabinet for all the very dangerous chemicals as well as the
names of the chemicals that must not come near them. Chemicals can cause skin
rashes, burns and even death if not treated and stored properly. Only authorised
workers with experience and who are wearing personal protective equipment
(PPE) must handle chemicals. (5)

4. Highly skilled workers are workers with knowledge and experience who know
how to do complicated tasks such as CNC programming. A process layout
environment needs highly skilled workers because it produces different types of
products that have different manufacturing needs. For example, Dave is a highly
skilled CNC operator. When the factory he works for produced the wheels of a
car, he programmed the five-axis machine. They then needed a bending machine
and a press to produce the doors. Instead of employing a new worker, the factory
used Dave again, because he could also operate a press and a bending machine
(relevant example). It is very important for a factory that uses a process layout
to employ highly skilled workers such as Dave. This prevents the factory from
constantly having to hire and fire employees as new jobs arise. Therefore, having
highly skilled workers saves time and money for the factory, because workers
such as Dave can do the job of five different people on their own. (4)
N4 Mechanotechnics Lecturer Guide|Hands-On! 9

5. Differences between product, process and fixed layouts are summarised in the
following table.

Product layout Fixed layout Process layout

Grouping According to Around the large or According to

the different heavy products machines that
manufacturing perform similar
steps tasks
Production Fast because of very Slow because Slower due to the
time few start-ups machines and number of start-
workers must be ups required for
moved instead of each operation
the product
Flexibility Little. Only allows High. Allows for More flexibility.
for one project type different products More than one type
with different of product can be
features to be produced
produced
Products Large volumes Low volumes of big Large volumes
of standardised or heavy products of products with
products similar features
(12)

6. Job shop (1)

7. There is no right or wrong answer for this question, as long as the student filled in
all the necessary information and motivated correctly. If the correct consideration
was given but the motivation is wrong, the student will not be awarded any
marks. Here is the suggested solution:

7.1 Sketch

10 Module 1 • Workshop layout

•
Grouping for each operation
•
Following the flow
•
All of the machines used
•
Routes clearly visible
•
All 30 workers used
•
Inflow and outflow indicated (9)

7.2 Considerations – any six of the following:

• The goal of the organisation
• Space requirements
• Safety measures
• Country laws
• Flow of materials
• Material movement
• Operator convenience
• Type of operations
• Environmental conditions
• Type of layout
• Size of products
• Machinery
• Workforce(6)
Total: 65
MODULE

2 Metal protection
By the end of this module, students should be able to:
• describe corrosion as the destruction of material as a result of chemical,
electrochemical or metallurgical reaction between the material and the
environment;
• explain the two main classes of corrosion;
• explain the following forms of corrosion:
– surface corrosion
– stress corrosion
– galvanic corrosion
– intercrystalline corrosion
– pitting corrosion;
• explain the most common types of corrosion tests;
• describe what each of the following metal protection processes involves:
– cathodic protection
– electroplating
– anodising
– phosphating;
• describe the following processes used to prepare steel for spray painting:
– sandblast cleaning
– descaling
– grease removal;
• explain the following painting processes:
– air spray painting
– airless spray painting
– electrostatic spray painting
– dip painting; and
• list the advantages and disadvantages of using each of the painting processes.

Metal is a solid material that is usually hard, shiny and a good conductor of heat and
electricity. Metals can be pressed or moulded into different shapes without breaking.
They are directly or indirectly used in most of the things that surround us. For example,
a cell phone has many different types of metals inside and outside of it, which are
needed to make it work. Unfortunately, metals’ major weakness is corrosion, which is
one of the main reasons why most metal-based structures fail.
12 Module 2 • Metal protection

In this section, you will learn more about the following:

• Corrosion and the different types of corrosion
• Causes of corrosion and how to test for corrosion
• How to protect metals against corrosion
• How to prepare a surface for the different types of painting.

Exercise 2.1 SB page 29

1. 1.1 G 1.2 D
1.3 E 1.4 A
1.5 F 1.6 H
1.7 C 1.8 I
1.9 B 1.10 J

2. 2.1 Pitting corrosion

2.2 Crystalline corrosion
2.3 Galvanic corrosion
2.4 Surface corrosion
2.5 Stress corrosion

3. 3.1 B 3.2 A
3.3 C 3.4 A
3.5 D

Exercise 2.2 SB page 34

1. •
Cathodic protection
•
Electroplating
•
Anodising
•
Phosphating

2. Cleaning, picking, rinsing, phosphating, rinsing, sealing, drying

3. Advantages (any one)

•
It is inexpensive.
•
No external electrical power is needed.
•
Anodes are easy to install.
•
Little maintenance is needed on the anodes.
•
Hull protection is always applied until the anode is completely used.

Disadvantages (any one)

• The anode current is uncontrollable.
• The fuel consumption increases.
N4 Mechanotechnics Lecturer Guide|Hands-On! 13

•
The anode must usually be replaced before the scheduled maintenance.
•
The water turbulence around the hull increases the noise level.

4. Galvanic protection and impressed current cathodic protection (ICCP)

Exercise 2.3 SB page 41

1. 1.1 False. Solvent cleaning

1.2 True
1.3 True
1.4 False. Airless spray painting
1.5 False. Hot alkaline detergent cleaning
1.6 False. Dip painting
1.7 False. Sandblasting
1.8 False. Electrostatic painting
1.9 False. Electrolytic cleaning
1.10 True

2. 2.1 •
Select sand that will not twist the metal and that is is reusable and
does not clog up the machine.
•
Take periodic breaks during the process to avoid overusing the
compressor.

3. 3.1 • Sandblasting
• Descaling
• Grease removal
3.2 Grease removal
3.3 The housing of a pump can become greasy if not cleaned properly and
paint will not stick to the surface.
3.4 • Solvent cleaning
• Hot alkaline detergent cleaning
• Electrolytic cleaning
• Acid etch cleaning

4. Any three of the following:

• Metal shot
• Sand
• Glass beads
• Soda

5. 5.1 C 5.2 D
5.3 A 5.4 B
5.5 E
14 Module 2 • Metal protection

Summative assessment SB page 44

1. 1.1 False. Metals and many other different materials. (2)

1.2 True (2)
1.3 False. Two metals (2)
1.4 True (2)
1.5 False. Cheap (2)
1.6 True (2)
1.7 True (2)
1.8 False. Chlorine and alcohol-based solvents (2)
1.9 False. Larger (2)
1.10 True (2)
1.11 True (2)
1.12 True (2)

2. 2.1 Advantages (any two)

Disadvantages:
• It is not very flexible.
• It requires a large amount of paint.
• It requires large and expensive machines.
• It is only suitable for items in large quantities to be cost-effective. (2)

3. 3.1 D
3.2 E
3.3 A
3.4 J
3.5 G
3.6 B
3.7 I
3.8 C
3.9 H
3.10 F (10)
16 Module 2 • Metal protection

4. 4.1 •
Chemical corrosion usually occurs at high temperatures or when
a metal reacts with water vapour.
•
Electrochemical corrosion occurs when a metal corrodes through
electrolysis.
•
Chemical corrosion occurs slower than electrochemical
corrosion.(4)

4.2 Both air spray and airless spray painting use spray guns to paint a large
area. The difference between the two methods is that an air spray gun
forms a vortex that draws the paint from a separate container into the
path of the air to paint a surface. In airless spray painting, spray guns
use high-pressure pumps to spray the paint directly onto the surface.
The high-pressure air breaks down the paint into smaller particles. (3)

4.3 A salt spray test is used to check the corrosion resistance of metal-based
materials and surface coatings.
The humidity test determines the corrosion rates in materials by exposing
the material samples to various environmental factors and corrosive
materials.
The sulphur dioxide test is used to test the resistance of materials against
an air pollution environment where acid rain is common. (6)

4.4 •
The three-stage process involves cleaning, rinsing and sealing.
• The five-stage process involves cleaning, rinsing, activated
rinsing, phosphating and sealing. (8)

4.5 There are two types of electrolytic cleaning: anodic and cathodic
cleaning. With anodic cleaning, the workpiece is the anode (positive
part). With cathodic cleaning, the workpiece is the cathode
(negative part). (4)

4.6 Galvanic corrosion occurs when two different metals are joined or
located together in a corrosive environment. The electrode potential
difference between the two different metals creates a chemical reaction
that corrodes the metal with the weaker corrosion potential. (7)

5. 5.1 5.1.1 • Clean the material.

• Identify the type of tools you need. (4)
5.1.2 Prepare the surrounding area to avoid unsafe conditions.
For example, place duct tape on the areas that will not be blasted
to protect delicate surfaces from damage. (2)
N4 Mechanotechnics Lecturer Guide|Hands-On! 17

5.2 5.2.1 Descaling (1)

5.2.2 A descaling agent or chemical removes the scale from the metal
surfaces that are in contact with hot water. (2)

6. 6.1 A
6.2 D
6.3 C
6.4 A
6.5 B
6.6 C
6.7 D (7)
Total: 90
MODULE

3 Lubrication
By the end of this module, students should be able to:
• list the different classes of lubricants and give examples of each;
• describe in detail hydrodynamic and hydrostatic lubrication;
• list factors that should be considered when selecting lubricants;
• draw and label different types of lubricating devices; and
• list different types of lubricants and their uses.

In a manufacturing environment, managers often tell the workers to ensure that their
machines are properly lubricated. But what exactly does the term ‘lubrication’ mean?
The primary purpose of a lubricant is to make moving parts more ‘slippery’ and reduce
friction. Friction is a force that stops two objects from moving when they touch each
other. The energy is usually converted into heat or sound. But too much heat causes
metal parts to melt or ‘jam’. For example, when you rub your hands together, they
will start to feel hot because of the heat developed by the frictional force between
your hands. Now imagine how hot it would get if you rubbed your hands together
3 600 times a minute. Your hands might start smoking and catch fire. But if you put
some moisturising cream on your hands, they will not get hot at all. This is what
lubricants do in machines. Lubricants also minimise corrosion on metal surfaces and
keep contaminants such as dust and metal shavings out of the machine.

Exercise 3.1 SB page 52

1. 1.1 F
1.2 D
1.3 A
1.4 H
1.5 B
1.6 I
1.7 G
1.8 C
1.9 E
1.10 J

2. Liquid, semi-solid and solid lubricants

N4 Mechanotechnics Lecturer Guide|Hands-On! 19

3. Any two:
• Animal and vegetable oils
• Mineral oils
• Blended oils

Exercise 3.2 SB page 55

1. 1.1 True
1.2 False. High speed, high load
1.3 False. Hydrodynamic bearings
1.4 False Hydrostatic bearings
1.5 False. Hydrostatic bearings
1.6 True
2. Hydrodynamic Hydrostatic

Forms a lubrication liquid wedge Forms a film layer between two metal
between two metal parts surfaces
Provides continuous lubrication Provides continuous lubrication
Relies on the high speeds of the journal to Has an external pump to provide the
create pressure to form the fluid wedge pressure needed to form the fluid layer
Operation Operation
• The journal moves at high speeds • Fluid or oil is pumped through a
and sucks the fluid onto the inner small hole and adjusts the pressure
surface of the bearing to form a fluid based on the rotation speed of the
wedge around or under the shaft. journal.
• When the load increases on the • The film layer keeps the two parts
journal, the pressure inside the fluid from ever touching.
wedge increases to form a pressure
wedge.
• The pressure wedge is capable of
pushing the journal back towards
the centre without the two parts ever
touching.
Loses efficiency during start-ups and No loss in efficiency
stops
In an environment with low speed and No need for an additional pump
frequent stops, an additional pump or
bearing can be installed
Not as versatile Can be used on more machine types

3. To reduce friction between two metal parts

20 Module 3 • Lubrication

Exercise 3.3 SB page 56

•
Cost of the lubricant: It is important to ensure that you buy the correct type and
quality of lubricants at the cheapest price. Poor-quality lubricants can shorten the
lifespan of the machines or lead to more frequent maintenance. New machines
and more maintenance also cost a lot of money.
•
Operating temperature and humidity: The lubricant must be able to protect the
machine against high operating temperatures as well as humidity in the air.
•
Clearance: The space between the two components must be taken into account.
Large spaces or gaps require thicker lubricants such as grease or solid lubricants,
while thinner gaps might only allow a liquid lubricant.
•
Operating speed: The faster the rotations of a bearing, the higher the
temperature of the bearing. At high speeds, you must use a lubricant with high
fluidity to ‘cool down’ the bearing.
•
Load: Higher loads will increase the pressure of the bearing. Higher pressure
requires thicker, heavy-duty lubricants to minimise damage to the bearing.

Exercise 3.4 SB page 63

1. 1.1 I
1.2 C
1.3 L
1.4 A
1.5 B
1.6 J
1.7 E
1.8 D
1.9 H
1.10 K
1.11 G
1.12 F

2. Device Name How it works

Stauffer cup Grease is filled into a

threaded seal that is
screwed down onto the
Grease bearing surface to be
lubricated.
N4 Mechanotechnics Lecturer Guide|Hands-On! 21

Device Name How it works

Scoop As the shaft rotates, a

lubricator small amount of oil is
scooped up where the oil
can travel through the
shaft and lubricate the
Mist part.

Scoop
Oil

Needle-feed The vibrations from

Oil lubricator the rotating shaft cause
the lubrication to flow
through the needle onto
the shaft.

Needle

Shaft

Nipple Grease gun The grease gun generates

pressure to force grease
into a grease nipple.

Oil gun

Exercise 3.5 SB page 65

•
Lubricants reduce wear and tear and surface deformation by avoiding direct
contact between the rubbing surfaces.
•
Lubricants reduce the loss of energy in the form of heat by acting as a coolant.
•
Lubricants increase the efficiency of the machine by reducing the waste of energy.
•
Lubricants reduce the expansion of metal through local frictional heat.
•
Lubricants reduce the maintenance as well as running cost of the machine to a
large extent.
•
Lubricants can also act as a seal in internal combustion engines.
•
Lubricants prevent the corrosion of metals.
•
Lubricants prevent dust and other particles from entering the machine and
causing damage.
22 Module 3 • Lubrication

Summative assessment SB page 67

1. 1.1 False. They are very good lubricants, they are just very expensive. (2)
1.2 True (2)
1.3 False. They are cheap, but have poor oiliness. (2)
1.4 True (2)
1.5 False. Graphite is the most commonly used. (2)
1.6 False. Graphite is non-flammable, making it ideal for high-temperature
environments. (2)
1.7 True (2)

2. 2.1 Hydrodynamic bearing

Load

Fluid wedge

Pressure wedge

Hydrostatic bearing
Load

Shaft

Bearing

Oil pump
From oil supply

Assessment guideline
• Both drawings are correct (2 marks)
• All the labels were correctly added (8 marks)
• Both drawings are neat (2 marks)
N4 Mechanotechnics Lecturer Guide|Hands-On! 23

2.2 Hydrodynamic Hydrostatic

Forms a lubrication liquid wedge Forms a film layer between two

between two metal parts (1) metal surfaces (1)
Provides continuous lubrication (1) Provides continuous lubrication (1)
Relies on the high speeds of the Has an external pump to provide
journal to create pressure to form the pressure needed to form the
the fluid wedge (1) fluid layer(1)
Operation Operation
• The journal moves at high Fluid or oil is pumped through
speeds and sucks the fluid onto a small hole and adjusts the
the inner surface of the bearing pressure based on the rotation
to form a fluid wedge around speed of the journal. (1)
or under the shaft. (1) The film layer keeps the two
• When the load increases on parts from ever touching. (1)
the journal, the pressure inside
the fluid wedge increases to
form a pressure wedge. (1)
• The pressure wedge is capable
of pushing the journal back
towards the centre without the
two parts ever touching. (1)
Loses efficiency during start-ups No loss in efficiency (1)
and stops(1)
In an environment with low No need for an additional pump (1)
speed and frequent stops, an
additional pump or bearing can
be installed(1)
Not as versatile (1) Can be used on more machine
types(1)

2.3 To reduce friction between two metal parts (1)

3. 3.1 A. Pipe mounted above

machine part

Adjuster

Lubrication drip
24 Module 3 • Lubrication

B.
Upside-down cup
Wick
Oil

C. Feed handle

Clear glass container

with lubricant

Sight glass

D.
Oil

Needle

Shaft

E.
Knob

Coil spring

Grease

Assessment guideline for each drawing:

• The drawing is correct (1 marks)
• The three components are correctly labelled (3 marks)
• The drawing is neat (1 marks)
N4 Mechanotechnics Lecturer Guide|Hands-On! 25

3.2 •
Cost of the lubricant
• Operating temperature and humidity
• Clearance
• Operating speed
• Load(6)

4. Any five:
• Lubricants reduce wear and tear and surface deformation by avoiding
direct contact between the rubbing surfaces.
• Lubricants reduce the loss of energy in the form of heat by acting as a
coolant.
• Lubricants increase the efficiency of the machine by reducing the waste of
energy.
• Lubricants reduce the expansion of metal through local frictional heat.
• Lubricants reduce the maintenance as well as running cost of the machine
to a large extent.
• Lubricants can also act as a seal in internal combustion engines.
• Lubricants prevent the corrosion of metals.
• Lubricants prevent dust and other particles from entering the machine
and causing damage. (5)
Total: 80
MODULE

4 Precision measuring of machine parts

By the end of this module, students should be able to:
• describe the concepts and terminology of precision measuring machines;
• explain how to measure tapers with balls, sine bars and rollers;
• explain how to use precision balls to determine the taper of a small ring gauge
and internal tapers;
• analyse how balls and slip gauges are used to determine the taper of a taper plug;
• explain how balls or rollers are used to determine angles of dovetails;
• draw and label a taper plug gauge with a sine bar; and
• calculate an inclined and included (taper) angles using sine bars.

The accurate measurement of machine parts that are round or form an arc, such as
tapers and dovetails, can be very difficult. Using a protractor and ruler to measure
these parts takes a lot of effort and most often produces inaccurate measurements. In
situations where a spec (specification) limit is very small, one degree outside of this limit
can cause parts to not fit or the subassembly to break soon after leaving the factory.

Exercise 4.1 SB page 71

1.  A
cos θ = __
C
 

  A  
∴ C = ____
cos θ
4
________
=   cos 36,87° 

= 5 mm
OR
B
sin θ = __
 C 

  B  
∴ C = ____
sin θ
3
_______
=   sin 36,87° 

= 5 mm
N4 Mechanotechnics Lecturer Guide|Hands-On! 27

Taper
angle

(One mark each for taper and taper angle)

3.
External
dovetail

Internal
dovetail

(One mark awarded for the correct sketch and one mark for the correct label for
each dovetail)

4. On drills, drill presses, milling machines, spindle, spindle noses (any two)

Exercise 4.2 SB page 76

1. Recommended auxiliary sketch for the question:

d1 = 11,2 mm
d2 = 114 mm

R
φ = 85,64 mm
R R

θ
–
2
r
r r
φ = 45,6 mm
28 Module 4 • Precision measuring of machine parts

Step 1:
Light grey line = R – r
85,64
R =  ____
2
 
= 42,82 mm
45,6
r = ____
  2 
= 22,8 mm
∴ Light grey line = 42,82 – 22,8
= 20,02 mm
Step 2:
Gap between two circles = d2 – d1 – R – R
= 114 – 11,2 – 42,82 – 42,82
= 17,16 mm
Step 3:
Dark grey line = gap between two circles + R + r
= 17,16 + 42,82 + 22,8
= 82,78 mm
Step 4:
light grey line
  θ2  = __________
tan __    
dark grey line
light grey line
 __θ2  = tan–1 __________
   
dark grey line
20,02
∴ θ = 2 × tan–1 ____
  82,78 
= 27,20°

2. Recommended auxiliary sketch for the question:

60 mm
B

φ = 20 mm A
θ = 60°
α
α
160 mm

C
80 mm

Step 1:
A = 160 – 80
= 80 mm
 A
tan 60° = __
B
 
N4 Mechanotechnics Lecturer Guide|Hands-On! 29

 tanA60° 
∴ B = _____
80
=  _____
tan 60°
 
= 46,188 mm

Step 2:
Opposite side = radius of the circle
 20
Radius of the circle = __ 2
 = 10 mm
∴ Opposite side = 10 mm
θ = 2 × α (corresponding angles of a triangle are equal)
 60°
∴ α = ___ 2
 
= 30°
opposite side
tan 30° = __________
  C
 
opposite side
∴ C = __________
  tan 30° 
10
=  _____
tan 30°
 
= 17,32 mm

Step 3:
x = 60 – B + C + r
= 60 – 46,188 + 17,32 + 10
= 41,132 mm

Exercise 4.3 SB page 82

1. Suggested auxillary sketch to solve this problem:

244,40 mm

α α
100 mm

φ = 10 mm

208,52 mm

Step 1:
2 × light grey line = 244,40 – 208,52
= 35,88
30 Module 4 • Precision measuring of machine parts

35,88
∴ Light grey line = ____
  2 
= 17,94 mm
Step 2:
Opposite side = light grey line + radius
10
=  __
2
 
= 5 mm
∴ Opposite side = 17,94 + 5
= 23,94 mm

Step 3:
Adjacent side = 100 – radius of bottom roller + radius of top roller
= 100 – 5 + 5
= 100 mm
Step 4:
θ=2×α
opposite side
tan α = __________
   
adjacent side
23,94
= ____
  100 
23,94
∴ α = tan–1(____
  100  )
= 13,463°
∴ θ = 2 × 13,463
= 26,926°

2. Auxilliary picture 1:

60°

θ A
θ

Step 1:
A = radius of the circle
20
=  __
2
 
= 10 mm
Step 2:
2 × θ = 60° (corresponding angles of a triangle are equal)
  60°
θ = ___ 2
 
= 30°
N4 Mechanotechnics Lecturer Guide|Hands-On! 31

Step 3:
 A
tan θ = __
B
 
  A  
∴ B = ____
tan θ
=   10  
____
tan θ
= 17,32 mm

Auxilliary picture 2:
D

60°

C
θ

Step 4:
θ + 60° + 90° = 180° (sum of the angles inside a triangle = 180°)
θ = 180° – 90° – 60°
= 30°

Step 5:
 D
tan θ = __
C
 
D = tan θ × C
= tan 30° × 60
= 51,96 mm

Step 6:
x = 200 – 17,32 – 17,32
= 165,36 mm

Step 7:
y = x + 17,32 + 17,32 + radius + radius
= 165,36 + 17,32 + 17,32 + 10 + 10
= 220 mm

Exercise 4.4 SB page 84

1. Place the taper on top of the sine bar and place slip gauges on one side of the sine
bar until just before the taper starts sliding off the sine bar. At this point, the angle
between the sine bar and the surface is the same as the taper angle of the taper.
Now, the taper angle of the taper can be calculated with trigonometry.
32 Module 4 • Precision measuring of machine parts

50
2. sin θ = ___
 250  
50
θ = sin–1(___
  250   )
= 11,54°

3. θ = angle between the sine bar and the horizontal surface

60
sin θ = ___
 200  
60
θ = sin–1(___
  200   )
= 17,46°

Summative assessment SB page 86

1. Step 1: Place the taper plug gauge on a flat surface and slide two precision
rollers next to the sides at the bottom of the taper plug gauge. Use a measuring
instrument, such as a micrometer or vernier, to measure the distance across
the rollers.(2)

(2 marks for sketch)

Step 2: Remove the precision rollers from the bottom of the taper plug gauge
and place them on top of a slip gauge on both sides of the taper plug gauge.
Gradually, keep increasing the height of the slip gauges until the rollers almost
touch the upper tips of the taper plug gauge. Use a measuring instrument, such
as a micrometer or vernier, to measure the distance across the rollers. also,
keep track of the total height of the stacked slip gauges. (2)

(2 marks for sketch)

N4 Mechanotechnics Lecturer Guide|Hands-On! 33

Step 3: You now know all the necessary measurements for the taper plug
gauge and its taper to do the calculations. (1)

2. This question must be answered with the aid of sketches.

2.1 0,5 0,5

5 5

αα

θ = included angle
=2×α
0,5
sin α = ___
  5 
0,5
α = sin–1(___
  5  )
= 5,74°
∴ θ = 2 × 5,74
= 11,48° (4)

2.2 (Suggested sketch)

0 mm
20

Assessment guidelines
• Sine bar (1 mark)
• Gauge blocks (1 mark)
• Taper gauge on online (1 mark)
• Two rollers (1 mark)
• Angle and length indication (1 mark)
34 Module 4 • Precision measuring of machine parts

2.3 (Suggested sketch)

m
0m
20

Difference in height = opposite side of the triangle

opposite side
sin θ = __________
  200 
Opposite side = 200 sin 11,48
= 39,81 mm
Difference in height = 39,81 mm (4)

3. (Suggested drawing)
y

100 mm

β β
1:5
160 mm

θ
110 mm

φ = 18 mm

Step 1: Calculate the angles θ and β.

0,5 0,5

5 5

αα
N4 Mechanotechnics Lecturer Guide|Hands-On! 35

θ=2×α
0,5
sin α = ___
  5 
0,5
α = sin–1(___
  5  )
= 5,74°
∴ θ = 2 × 5,74
= 11,48°
θ=2×β
11,48
β = ____
  2 
= 5,74°

Step 2: Set up the first equation.

y – x = 2 × light grey gap

Step 3: Calculate the size of the light grey gap.

Light grey gap = opposite side – radius
  18
Radius = __ 2
 
= 9 mm
opposite side
tan β = __________
   
adjacent side

Opposite side = adjacent side × tan β

= 110 × tan 5,74
= 11,06 mm
Light grey gap = 11,06 – 9
= 2,06 mm

Step 4: Calculate y.
y = 100 + radius + radius
= 100 + 18 + 18
= 136 mm

Step 5: Calculate x.
y – x = 2 × light grey gap
x = y – 2 × light grey gap
= 136 – (2 × 2,06)
= 136 – 4,12
= 131,88 mm (14)
36 Module 4 • Precision measuring of machine parts

4. Suggested sketch:
4.1

25,5 mm
α

140 mm
30°

60°

Assessment guidelines
• Original sketch with correct measurements (3 marks)
• Triangle (1 mark)
• 30° angle (1 mark)
• Isolating the line between the gap and the circle (1 mark)

4.2 Set up the first equation. The light grey line will be assigned the variable x.
x + a = 140 + 25,5 
= 165,5 
Set up the second equation:
0,5a
tan 30° = ______
 0,5a + x  
=  _1x  
  tan130°  
x = _____
= 1,73 mm 
Calculate the value of α.
x + a = 165,5
α = 165,5 – x
= 165,5 – 1,73 
= 163,77 mm (8)
Total: 50
MODULE

5 Gear drives
By the end of this module, students should be able to:
• list the advantages and disadvantages of gear drives when compared with V-belt
drives and chain drives;
• draw and label the following gear parts:
– involute
– module
– line of action and pressure angle
– pitch circle diameter
– circular pitch
– tooth thickness
– addendum and dedendum
– clearance
– whole depth
– working depth
– blank or outside diameter
– centre distance between gears on parallel shafts;
• explain the working principles of simple and compound gear trains;
• calculate the following on simple compound gear trains:
– module
– pitch circle diameter
– circular pitch
– tooth thickness
– addendum, dedendum
– clearance and whole depth
– working depth
– blank or outside diameter
– centre distance between shafts;
• explain the basic working principle of the epicyclic gear system;
• explain the following: speed increase with sun gear stationary, speed increase with
annulus stationary, speed reduction with sun gear stationary and speed increase
and direction reversal with planet stationary;
• list situations where epicyclic gears are used;
• list the advantages and disadvantages of epicyclic gear drives;
• explain the method of calculating epicyclic gear drives; and
38 Module 5 • Gear drives

• calculate the following epicyclic gears:

– the number of teeth or the revolutions per minute
– the number of teeth or the revolutions per minute of the input shaft,
intermediate shaft or output shaft.

This module covers gears in more detail, focusing on simple and compound gear trains
and epicyclic gear systems. Gears are wheels that have interlocking teeth. When one
wheel rotates, the other wheel rotates because of the locking action of the teeth. Gears
are used in most mechanical machines, such as CNC machines, pumps, generators, cars,
and so on. The car gearbox greatly regulates the car’s speed. To increase the speed of
the car, the car must be shifted to a smaller gear, such as shifting to the fifth gear on the
highway to travel faster.

Exercise 5.1 SB page 94

1. 1.1 B 1.6 C
1.2 B 1.7 B
1.3 C 1.8 A
1.4 A 1.9 C
1.5 C 1.10 A

2. Do not let the students just state the advantages and disadvantages. It is important
that they compare the three devices.
Possible answer:

V-belt drive Chain drive Gear drive

Used for high speed and Used for low speed and Used for high speed and
low torque high torque high torque
Working speed is Working speed is 10 m/s Working speed depends
between 12 and 40 m/s on the type of gear
– Positive drives with no Positive drives with no
slip or creep slip or creep
Low maintenance costs Low maintenance costs High maintenance costs
– Has a high velocity ratio Can achieve a velocity
of up to 8:1 ratio of up to 60:1 within
a small space
N4 Mechanotechnics Lecturer Guide|Hands-On! 39

V-belt drive Chain drive Gear drive

Does not require a – Motion can be

parallel shaft transmitted between two
non-parallel shafts
Shorter operation life Has a lower load capacity Longer service life than
compared to other power and service life than gear belt and chain drives
transmission devices drives
Velocity ratios are not Angular velocity remains Velocity ratio stays
constant due to belt slip constant, unlike in belt constant
drives
– Driving and driven –
shafts have to be parallel
and perfectly aligned to
function
Not noisy and little to no Noisy and causes Noise and vibration
vibration vibrations increase at high speed

Cheapest drive Installation costs are Expensive

higher than with belt
drives
Needs the most space of More compact and easier Compact and require less
the three to install than belt drives space

Most cost-effective power – Not suitable for

transmission device transferring motion over
when two shafts are far large distances
away from each other
– Can be used for both Cannot be used for
small and large centre shafts with large centre
distances distances
Power transmission is – Can be used for low,
limited to about 370 KW medium and high
because of heat build-up transmission.
Not ideal to use in high
velocities.
– Can have velocity Can transmit motion at
fluctuations when very low velocity, which
stretched the belt drives cannot do
– Lower load on shaft and Is mechanically strong,
bearings which allows for high
loads
Lower production costs Production costs are –
higher than a belt drive
40 Module 5 • Gear drives

Exercise 5.2 SB page 108

1. 1.1 Clearance
1.2 Centre distance
1.3 Involute
1.4 Circular pitch
1.5 Pitch circle diameter
1.6 Line of action
1.7 Pressure angle
1.8 Module
1.9 Addendum
1.10 Tooth thickness

2. PCD = m × T
= 2 × 50
= 150 mm

2.1 PCD = m × T
= 2 × 50
= 150 mm

2.2   PCD

P = (____ T )
  × π
400
= (___
  150  ) × π
= 2,667 × π
= 8,38 mm

2.3  P2 
Tooth thickness = __
  15
= __ 2
 
= 7,5 mm/tooth

2.4   PCD

m = ____ T
 
300
=  ___
150
 
∴ m = 2 mm/tooth
Addendum = m
∴ Addendum = 2 mm/tooth
Dedendum = 1,25 × m
= 1,25 × 2
= 2,25 mm/tooth
N4 Mechanotechnics Lecturer Guide|Hands-On! 41

2.5 Clearance = dedendum – addendum

= 6,4 – 3,2
= 3,2 mm/tooth

2.6 Working depth = addendum + addendum

= 3,2 + 3,2
= 6,4 mm/tooth

2.7 Whole depth = addendum + dedendum

= 3,2 + 6,4
= 9,8 mm/tooth

2.8 PCD = m × N
= 4 × 20
= 80 mm
Blank diameter = PCD + (2 × addendum)
= 80 + (2 × 4)
= 80 + 8
= 88 mm
T +T
2.9 C = m( ______
  A 2  B )

  20 +4 
= 2 × (______ 10
)
  30
= 2 × (__ 4)
 
= 2 × 7,5
= 15 mm

2.10 Involute
Line of action

Gear

Pressure
angle
Baseline

Assessment guidelines
• Two involutes between two circles (1 mark)
• Pressure angle between the base line and line of action (1 mark)
• Correct sketch of two meshing gears (1 mark)
42 Module 5 • Gear drives

Exercise 5.3 SB page 120

1. Various options are given as possible answers to the following questions. Choose
the answer and write only the letter (A–D) next to the question number (1.1–1.10).
1.1 B
1.2 C
1.3 D
1.4 A
1.5 B
1.6 D
1.7 C
1.8 B
1.9 D
1.10 A

2. 2.1

Driver gear Idler gear Driven gear

(INPUT) (OUTPUT)

Assessment guidelines
• Correct drawing (3 marks)
• Neat drawing (1 mark)
• Correctly identified components (3 marks)

2.2 Compound gear

Driven wheel

Driver

A B C

Assessment guidelines
• The drawing is correct (3 marks)
• The drawing is neat (1 mark)
• The components are correctly identified (3 marks)
N4 Mechanotechnics Lecturer Guide|Hands-On! 43

3. 3.1 Instruction Revolutions Revolutions Revolutions Revolutions

no. of carrier of annulus of planet of sun gear
gears
(NC) (NA) (NP) (NS)

1. 0 +1 +4 –2
2. y x+y 4x + y –2x + y
3. NC = ? 0 – 100

3.2 Ring gear, annulus, sun gear and carrier

3.3 Epicyclic gears are usually used when space and weight are an issue, but a
large amount of speed reduction and torque are needed.
OR
Any TWO of the following:
Manual transmission, robotic arms, turbine generators, in the back gear of
lathes, in hoists, pulley blocks, the armature of wind turbines, the back gauge
drive for press brakes, the axis drive for laser cutting machines, conveyor
systems.

Summative assessment SB page 124

1. 1.1 True
1.2 False
1.3 False
1.4 True
1.5 False
1.6 True
1.7 True
1.8 False
1.9 False
1.10 False (1 × 10) (10)

2. 2.1 A. Speed: decreases; rotation direction: same

B. Speed: increase; rotation direction: same
C. Speed: increase; rotation direction: same
D. Speed: increase; rotation direction: opposite (2 × 4) (8)
44 Module 5 • Gear drives

2.2 A. Involute.

Circle involute

Circle

B. Pitch circle diameter

PDM of driven gear

PDM of driver gear

C. Circular pitch
Circular pitch

D. Tooth thickness
Pitch
Tooth
thickness

Reference
line
N4 Mechanotechnics Lecturer Guide|Hands-On! 45

E. Addendum
Pitch
Tooth
thickness Tooth tip

Tooth depth
Addendum
Reference
line
Dedendum

Tooth root

F. Dedendum
Pitch
Tooth
thickness Tooth tip

Tooth depth
Addendum
Reference
line
Dedendum

Tooth root

G. Clearance

Addendum circle
Pitch circle
Dedendum circle

H. Working depth

Addendum circle
Pitch circle
Dedendum circle

I. Whole depth

Addendum circle
Pitch circle
Dedendum circle
46 Module 5 • Gear drives

J. Blank diameter

PCD

Blank
diameter

(3 × 10) (30)

2.3 There are three types of drive trains that Steve can use: belt drives,
chain drives and gear drives. Belt drives are not ideal for high speeds
and slip will occur. So, belt drives will not be recommended. Chain
drives and gear drives can handle high velocities and slip will not occur.
Chain drives are ideal for high speeds but not high loads.
Gear drives can achieve the highest velocity ratio of all the power
drives. Gear drives also have the highest service life of all the power
drives. The recommended power drive for Steve is a gear drive. Gear
drives will be able to handle the high load required by the fast car. Gear
drives have the best service life, so they would not have to be replaced
as often. There is no slip between gears. Gear drives allow for a high
velocity ratio so, in theory, gear drives would be able to deliver the highest
speed possible from al the gear drives. Gear drives meet all of Steve’s
requirements for a power drive when compared to chain drives and
belt drives.(9)

2.4 A. Seeing as gears D and E are on the same shaft, they will rotate at
the same speed. To calculate the speed at which they rotate, use
the gear ratio between F and E.
___ T N
 E
= ___
  E
N N  F F
__
    =   x  
20 ___
32 400

  20 ×32400
x = _______  

= 250 revs/min 
Therefore, gears D and E will rotate at a speed of 250 revs/min. (2)
N4 Mechanotechnics Lecturer Guide|Hands-On! 47

T N
B.  ___
C
= ___
  C
T N 
D D
TC ___
___
    =   750 
40 250

TC = _______   750250

× 40
 
= 120 teeth (2)

C. Addendum = m 
m = 1,5 mm (given)
∴ Addendum = 1,5 mm (2)

D. = m × 1,25
Dedendum
= 1,5 × 1,25 
= 1,875 mm (2)
T +T
E. C = m( ______
  F 2  E ) 

  32 +2 
= 1,5 (______
20
)
= 1,5 × 26

= 39 mm (3)

T +T
F. C = m( ______
  D 2  C ) 

  40 +2 
= 1,5( _______
120
)
= 1,5 × 80

= 120 mm (3)
T
2.5 A. ND = ___
  TA
D
120
___
=   
30 
= +4 (2)

B. Gear C will have the same velocity ratio as gear D. If the student
just answered +4, award two marks. If the calculation above is
repeated, award marks the same as the above. (2)
T T
C. NB = (+)  ___
A
T
× (–)  ___
C
T
D B
120 48
= ___
 
80
  × (–)  __ 
32 
= 1,5 × –1,5
= –2,25 (2)
(If the student got the sign wrong, only award one mark.)
48 Module 5 • Gear drives

D. Table of results:

No. A B C D E

1 +1 –2,25 +4 +4 0
2 x+y –2,25x + y 4x + y 4x + y y
3 ? 120 0

NB = 2,25x + y = 120 
NE = y = 0 
NA = x + y = ?
–2,25x + y = 120
y = 0
∴ –2,25x = 120 
x = –53,33 
∴ x + y = –53,33 + 0
∴ NA = 53,33 revs/min counterclockwise 
(Subtract one mark if the direction is wrong.) (4)

E. Table results:

No. A B C D E

1 +1 –2,25 +4 +4 0
2 x+y –2,25x + y 4x + y 4x + y y
3 0 120 ?

NB = 2,25x + y = 120 
NA = x + y = 0 
NE = y = ?
–2,25x + y = 120
x + y = 0
Subtract the second equation from the top equation:
–3,25x = 120 
x = –36,92
∴ NE = 36,92 revs/min counterclockwise 
(Subtract one mark if the direction is wrong.) (4)
Total: 85
MODULE

6 Belt drives
By the end of this module, students should be able to:
• explain concepts and terminology relating to belt drives;
• draw and explain belt drives – flat-, open-, crossed- and V-belt drives; and
• calculate the following on belt drives:
– effective diameter
– velocity ratio
– belt velocity
– belt length
– angle of contact
– tensions in the belt
– torque transmitted by the belt
– power transmitted by the belt
– force on bearings to all types of belt drives.

Belts have been used for more than 200 years to transmit power. The first belts
were flat belts running on flat pulleys and later, cotton or hemp rope was used with
V-grooved pulleys. In 1917, vulcanised rubber V-belts were developed, and around
1950, synchronous or toothed belts were developed. Later, fabric-reinforced elastomer
materials were developed, leading to the flat, v- and synchronous belting currently used
in power transmission.

Belt drives transmit motion and power by means of friction. They consist of two pulleys
with an endless belt wrapped around them, maintaining the required tension. Belt
drives are used on small- to long-distance power transmission and protect the system
against overload and vibration. Because the power is transmitted by the frictional force
between the pulley and the belt, the capacity of the belt drive is limited by frictional
characteristics, contact angle and initial tension.
50 Module 6 • Belt drives

Exercise 6.1 SB page 134

1. 1.1 F 1.2 E
1.3 D 1.4 B
1.5 A 1.6 B
1.7 E 1.8 C
1.9 C 1.10 E

2. 2.1 False 2.2 True

2.3 True 2.4 False
2.5 True

3. 3.1 Friction occurs between the belt and the pulley surface. Friction is used to
drive the machine elements.

3.2 Flat-belt drive V-belt drive

It has a rectangular cross section. It has a trapezoidal cross section. This

This means that the belt’s width is means that it looks like a triangle that
larger than its thickness. has its top sliced off parallel to the
bottom. The width of the larger side is
almost the same as its thickness.
It is jointed, causing vibration and It has no joints, making its operation
noise. smooth and quiet.
It has only one surface that remains It has two side surfaces that remain
in contact with the pulleys. in contact with the pulleys.
It has a problem with slippage, which It can transmit more power, as it
negatively affects the pulley speed. does not slip.
It is used to transmit power and It is mostly used to transmit power
motion over a long distance. and motion for a short to medium
distance.
It has an achievable speed reduction It has a speed reduction up to 1:7.
up to 1:4.
In a stepped pulley system, the belt The belt cannot be moved from
can be shifted from one diameter one pulley to another. Therefore, it
pulley to another without pausing cannot be used for stepped pulley
the rotation. systems.
Because of its simple construction, it Because of its complicated
is cheaper than a V-belt. construction, it is costlier.
It is made of reinforced synthetic It is made of rubber and other
materials. synthetic materials.
N4 Mechanotechnics Lecturer Guide|Hands-On! 51

4. 4.1
Sl
ac
ks
ide

Tig
ht
sid
e

Assessment guidelines
• Correct belt drive (1 mark)
• Correct direction of rotation for pulleys (2 marks)
• Correct label of slack and tight belt sides (2 marks)

4.2

Tight s
ide

Slack sid
e

Assessment guidelines
• Correct belt drive (1 mark)
• Correct direction of rotation for pulleys (2 marks)
• Correct label of slack and tight belt sides (2 marks)

5. 5.1 V-belt

Pulley

Assessment guidelines
• V-belt shape (1 mark)
• V-pulley (1 mark)
52 Module 6 • Belt drives

5.2 Flat belt

Cambered
pulley

Assessment guidelines
• Flat belt (1 mark)
• Cambered pulley (1 mark)

6.6.1 The V-belt drive has a higher driving torque than the flat-belt drive. The
V-belt has a larger contact surface area than the cambered pulley, which
creates a higher frictional force. A higher frictional force generates a higher
driving torque.
6.2 • Large pulley: 38°
• Small pulley: 32°

Exercise 6.2 SB page 156

1.   π × 60
V = ________D×N
 
π × 0,4 × 300
=  __________
60
 
= 6,283 m/s

π
θ = ___
  180 = π radians
μθ
e     = e    
__ 0,2 × π
___
sin β sin 20

= 6,278

T
σ = ___ 1
  area 
T1 = 7 × 106 × 300 × 10–6
= 2 100 N
T
 __
μθ
1
= e    
__

T
sin β
2

2 100
 ____
T2
= 6,278
T2 = 334,5 N
N4 Mechanotechnics Lecturer Guide|Hands-On! 53

P = (T1 – T2)v
= (2 100 – 334,5)6,283
= 11 093 W
P3 belts = 11 093 × 3 = 33,28 kW

T –T
2.  _____
μθ
1 c
= e    
__

T – T
sin β
2 c
= 2,2
2,2(560) – (725)
Tc = ____________
   
2,2 – 1
 = 422,5 N

Summative assessment SB page 159

1. 1.1 C (1)
1.2 E (1)
1.3 A (1)
1.4 B (1)
1.5 D (1)
1.6 The belt is used to connect pulleys. It transfers motion from one
piston to another, using frictional forces. (2)
D –d
2. 2.1 sin α = ______
  2C× C C 
0,355 – 0,2
=  ________  
2 × 0,5 
= 8,917° 

θ small pulley = 180 – 2α 

= 180 – 2 × 8,917 
π
= 162,1664 ×  ___
180 
 
= 2,83 radians 

  38
β = __ 2
  = 19° 
μθ
e     = e  
  
__ 0,2 × 2,83
____
sin β sin 19

= 5,689 

  π × 60
V = ________D×N
  
π × 0,2 × 1 420
= ___________
  60
  
= 14,87 m/s 
T
 __
1
T
= 5,689 
2

500 = 5,689 T2 

T2 = 87,89 N 
54 Module 6 • Belt drives

Pbelt = (T1 – T2)v 

= (500 – 87,89)14,87 
= 6 128 W 
power
No. of belts = _______
 powertotal
belt 

12
= ____
  6,128  
= 1,96 ≈ 2 belts (22)
  ¯ × v2 
2.2 TC = m 
= 0,6 × 14,872 
= 132,67 N 
T –T
 _____
1 c
T – T
= 5,689 
2 c
T – 132,67
 ________
1
T – 132,67
  = 5,689 
2

T1 – 132,67 = (T2 – 132,67) × 5,689 

500 – 132,67 = 5,689 T2 – 754,76 
500 – 132,67 + 754,76 = 5,689 T2 
T2 = 197,27 N 

Pbelt = (T1 – T2)v 

= (500 – 197,24)14,87 
= 4 502 W 
power
No. of belts = _______
 powertotal
belt 

12
= ____
  4,502  
= 2,6654 ≈ 3 belts (15)

3. 3.1 Output power at D:

power
η = _______
  powerout
in 

power
80 = _______ out
  20 × 100   

Powerout = 16 kW (3)

3.2 VA = VB 
π×D ×N π×D ×N
 _________
  
A
60
 A =  _________
  
B
60
 B 
0,2 × 700
NB = _______
  0,6  

= 233,33 rpm 
NB = NC = 233,33 rpm 
N4 Mechanotechnics Lecturer Guide|Hands-On! 55

VC = VD 
π×D ×N π×D ×N
 _________
  
C
60
 C =  _________
  
D
60
 D 
0,3 × 233,33
ND = _________
  0,8
  
= 87,5 rpm (9)

3.3   2 × π 60
P = __________×N×T
  
2 × π × 700 × T
20 000 = ____________
 
  
60
 A 

TA = 272,84 Nm 

  2 × π 60
P = __________×N×T
  
2 × π × 87,5 × T
20 000 = ____________
 
  
60
 D 

TD = 1 746,2 Nm (6)

4. 4.1 DE = 700 +12 = 712 mm 

dE = 300 +12 = 312 mm 
Vlarge = Vsmall 
π×D ×N π×d ×n
 ________
E
60
  = ________
  60E  
0,712 × N = 0,312 × 1 000 
N = 438,2 r/min (6)

4.2   π × 60
V = ________D×N
  
π × 0,712 × 438,2
= ____________
  
  60
  
= 16,34 m/s (3)
D –d
4.3 sin α = ______
  2E× C E 
0,712 – 0,312
=  __________
2×2
  
α = 5,739° (3)
π
4.4 θ = ___
  180  × 168,52 
= 2,94 radians 
T –T
 _____
μθ
1 c
= e     
__

T – T
sin β
2 c

= e 0,3 × 2,94 
= 2,416 (5)
56 Module 6 • Belt drives

4.5 P = (T1 – T2)v 

15 × 103 = (T1 – T2)16,34 
(T1 – T2) = 917,99 N 
T1 = 917,99 + T2 

  ¯ × v2 
TC = m 
= 0,75 × 16,342 
= 200,25 N 
T –T
 _____
μθ
1 c
= e     
__

T – T
sin β
2 c
T1 – 200,25
 ________
T2 – 200,25
  = 2,416 

T1 – 200,25 = (T2 – 200,25) × 2,416 

917,99 – 200,25 = 2,416 T2 – T2 + 483,8 
T2 = 848,55 N 

T1 = 917,99 + T2 
= 917,99 + 848,55 
= 1 766,54 (15)

4.6 T1 = Tmax × w 
1 766,54
=  ______
20
  
= 88,327 mm (3)

[D + d ]2
4.7   π2  [DC + dC] + ________
L = __   4C × CC + 2 × C 
[0,712 – 0,312]2
  π2  [0,712 + 0,312] +  ___________
= __   
4×2
 + 2 × 2 
= 5,6285 m (3)
Total: 100
MODULE

7 Hydraulic systems
By the end of this module, students should be able to:
• explain the following concepts and terms:
– properties of water
– density
– relative density
– fluid pressure on a surface
– pressure intensity
– pressure head
– atmospheric pressure;
• explain the following: flow rate, mass flow and continuity of flow;
• explain the following concepts: potential energy, kinetic energy and pressure energy;
• describe Bernoulli’s theorem;
• calculate potential, kinetic and pressure energy;
• list the three variations of Bernoulli’s theorem;
• describe frictional losses in pipelines;
• apply Darcy’s formula to calculate the flow of fluids in pipes;
• apply Chezy’s formula to calculate the flow of fluids in an open channel;
• explain and calculate following processes:
– nozzles and orifices
– theoretical velocity
– theoretical area
– theoretical quantity
– actual velocity
– actual area
– actual quantity
– coefficient of velocity
– coefficient of contraction
– coefficient of discharge
– general formula
– distance travelled by a waterjet
– energy loss at orifice;
• explain how a venturi meter is used to measure the flow rate of fluids through
pipelines;
• calculate energy loss on a venturi meter; and
• draw and label a venturi meter.
58 Module 7 • Hydraulic systems

A hydraulic system is a power transmission system that uses fluid to transfer power.
Hydraulic systems can perform major functions with very small input energy required.

Exercise 7.1 SB page 172

1. 1.1 D
1.2 F
1.3 B
1.4 A
1.5 C
1.6 G
1.7 E

2. 2.1 F
2.2 D
2.3 A
2.4 E
2.5 C
2.6 B

3. 3.1 Pressure
3.2 Density
3.3 Pressure head
3.4 Fluid pressure or pressure
3.5 Viscosity
3.6 Specific volume
3.7 Pressure intensity

Exercise 7.2 SB page 174

1. 1.1 Fluid dynamics is used to explain fluids in motion and the flow of fluids
through pipe systems.

1.2 •
Fluid statics is used to explain fluids at rest (zero velocity) and the
effect of force.
•
Fluid dynamics is used to explain fluids in motion and the flow of
fluids through pipe systems.

1.3 1.3.1 It measures the speed of water flowing past a certain point in a system.
1.3.2 It is a measure of the mass of a fluid passing a point in the system per
unit time.
N4 Mechanotechnics Lecturer Guide|Hands-On! 59

1.3.3 It states that the mass flow rate into a system is equal to the mass
flow rate out of the system for steady-state flow.
1.3.4 The properties of fluid do not change over time.

2.
2.1 Q = A × V
2.2 m˙  = ρAV
2.3 m˙  =ρQ
2.4 m˙ in = m
˙ out
(ρAV)in = ( ρAV)out

Exercise 7.3 SB page 176

1. 1.1 A = pressure energy

B = potential energy
C = kinetic energy
1.2 A = pressure: Energy stored in fluid from the force or weight transferred
onto a surface
B = potential: Energy stored from a change in elevation of a body moving
from one point to another point
C = kinetic: Energy possessed by an object in the form of movement
F
1.3 A = pressure energy P = __
 A 
B = potential energy PE = mgh
C = kinetic energy KE = _ 12  mV2

2. True

Exercise 7.4 SB page 180

1. 1.1 An increase in the speed of a fluid occurs at the same time as the decrease
in pressure

1.2 Constant kinetic energy (v1 = v2)

P1 + ρgh1 = P2 + ρgh2
Constant potential energy (h1 = h2)
P1 + _  12  ρV12 = P2 + _  12  ρV22
Constant pressure energy (P1 = P2)
  12  ρV12 + ρgh1 = _  12  ρV22 + ρgh2
_

2. 2.1 P1 + _  12  ρV12 + ρgh1 = P2 + _  12  ρV22 + ρgh2

Choose point 2 as the reference height (or you can choose point 1):
h2 = 0
60 Module 7 • Hydraulic systems

The inlet and outlet pressures are at atmospheric pressure: P1 = P2 = Patm

The density of water is constant in the pipeline: ρ = constant
Patm + _  12  ρV12 + ρgh1 = Patm + _  12  ρV22 + ρg(0)
 _12  V12 + gh1 = _  12  V22

2.2  _12  V12 + gh1 = _  12  V22

Rearrange the equation above to solve for V2 .
_________
V2 = √
V12 + 2gh1
Substitute the values into the equation.
________________________
V2 = √
(5
   m/s)2 + 2(9,8 m/s2)(60 m) 
= 34,7 m/s
The velocity is V2 ≈ 35 m/s.

Exercise 7.5 SB page 185

1. Convert the diameter to metres.

d = 20 cm × 10–2 = 0,2 m
Use the Darcy-Weisbach equation.
2
L __
hf = f  ___   V  
D 2g
h

Rearrange the equation to find f.

D 2g
f = hf  ___
h __
   
L 2
V
(0,2 m) 2(9,8 m/s2)
= (127 m)  ______
(460 m)
  ________
  2

(5,6 m/s)
= 0,0345

2. The area of the square is:

A = base × half the height
= 0,4 m × 0,2 m
= 0,08 m2
The wetted perimeter is:
Pw = base + 2(half the height)
= 0,4 m + 2(0,2 m)
= 0,8 m
Solve for the hydraulic diameter.
  4A
Dh = ___ P w
4(0,08 m2)
= ________
  (0,8 m) 
= 0,4 m
N4 Mechanotechnics Lecturer Guide|Hands-On! 61

3. The Chezy coefficient is:

√
8g
C = __
    
f
________

√
=  
8(9,8 m/s2
_______
(0,029)
  

= 51,99 ≅ 52 m    12/s 1

_
2

The hydraulic radius is:

D 0,7 m
Rh = ___
  2h  = ____
  2 = 0,35 m
Substitute Chezy’s coefficient and hydraulic radius into the mean flow velocity
equation.
____
V = C√ RhS 
____________
= (52 m    12/s)√ (0,35
  
1
_
2 m)(0,02) 
= 4,35 m/s

4. The hydraulic radius is:

D
Rh = ___   1 2m = 0,5 m
  2h  = ___
The area of a circle is:
A = πRh2
= π(0,5 m)2 = 0,785 m2
The flow rate
____is:
Q = AC √ RhS  _________
= (0,785 m2)(77 m    12/s)√ (0,5 m)(2) 
1
_
2

= 60,4 m3/s

5. Determine the slope value.

  ∆z
S = __ L
10 m
  =  _____
200 m
  = 0,05
Use the ____
mean flow velocity equation.
V = C √ RhS 
Rearrange to solve for Chezy’s coefficient.
V
C = _____
  ____  
√ RhS 
(5 m/s)
=  ____________
____________  
  
√ (0,25
   m)(0,05) 
= 44,72 m    12/s 1
_
2
62 Module 7 • Hydraulic systems

Exercise 7.6 SB page 194

1.   π4  d 2 = __
A = __   π4  (0,04 m)2 = 0,00126 m2

2.   π4  d 2 = __
A = __   π4  (0,035 m)2 = 0,00096 m2

3. Use Bernoulli’s equation.

P1 + _  12  ρV12 + ρgh1 = P2 + _  21  ρV22 + ρgh2
Given: ∆h = 7m
Also, the water is in a large tank, therefore, assume that ρ = constant, V1 = 0 and
P1 = P2 = Patm. The equation simplifies to:
g∆h = _  12  V22
Solve for V2 . _______________
_____
2∆gh  = √
V2 = √ × 9,8 m/s2 × 7 m = 11,71 m/s
2  

4. Use the kinematic equations y = _  12  gt 2 and x = Vt to solve for the velocity, V.
Use the y-equation to solve for time, t.
__ _______
√ √
2y 2(0,65 m)
t = __
  g   = _______
  2 = 0,364 s
9,8 m/s
Substitute time, t, into the x-equation and solve for the velocity, V.
V = _  xt  = _____ 4m
  0,364 s
 = 10,99 m/s

5. Q = VA = (11,71 m/s)(0,00126 m2) = 0,015 m3/s

6. Q = VA = (10,99 m/s)(0,00096 m2) = 0,011 m3/s

A 0,00096 m2
7. Cc = _______
  A actual = ________
 
2 = 0,76
theoretical 0,00126 m
V 10,99 m/s
8. Cv = _______
  V actual = _______
  11,71 m/s  = 0,94
theoretical

9. Cd = Cv x Cc = 0,94 × 0,76 = 0,71

OR
Q 0,011 m3/s
Cd = _______
  Q actual = ________
  3   = 0,73
theoretical 0,015 m /s

Exercise 7.7 SB page 197

1. The length of the pipe is shaped in such a way to reduce the inside diameter or
converging pipe, which causes an increase in velocity and a similar pressure drop.
In the converging cone section, the cross-sectional area decreases, which causes
the flow velocity to increase and the pressure to decrease. The throat section,
the cross-sectional area and flow velocity are constant, and the pressure can
N4 Mechanotechnics Lecturer Guide|Hands-On! 63

be measured. Pressure measurements are taken at the inlet and throat, and the
difference between these two points can be calculated. The cross-sectional area
increases in the diverging section, causing a decrease in velocity and an increase
in pressure.

2. Cylindrical Converging Diverging Cylindrical

inlet cone cone outlet
Throat
A1 A2
V1 V2
P1 P2
D1 D2

Pressure
h differential

Assessment guidelines
• The drawing is correct (1 mark)
• All labels have been included (15 marks)
• The drawing is neat (1 mark)

3. Use Bernoulli’s equation.

P1 + _  21  ρV12 + ρgh1 = P2 + _  12  ρV22 + ρgh2
The Venturi meter lies horizontal, therefore, h1 = h2.
P1 – P2 = _  12  ρV22 – _  21  ρV12
The pressure difference is ∆P = P1 – P2 = ρgh.
ρgh = _  12  ρV22 – _  12  ρV12
The density is constant.
gh = _  21  ρV22 – _  12  ρV12
Find V2 using the flow continuity equation.
A1V1 = A2V2
A V1
V2 = ____
  A1
2

Substitute the equation for V2 into the Bernoulli equation.

A V1
gh = _  21  ( ____
  A1 )2 – _  12  V12
2
64 Module 7 • Hydraulic systems

Solve for V1 .
A
2gh = V12[( __
  A1 )2 – 1]
2
_________

√
2gh
V1 = _________
  A 2
[( __
  1 )
A2
– 1]

Substitute values into the equation.

_______________

√
2
2(9,8 m/s )(0,675 m)
V1 = _______________
     0,15 m2 2
   = 2,29 m/s
[( __
 
0,08 m2
) – 1]

Summative assessment SB page 199

1. 1.1 G
1.2 C
1.3 J
1.4 A
1.5 H
1.6 B
1.7 D
1.8 I
1.9 F
1.10 E (10)

2. 2.1 Measures the speed of water flowing past a certain point in a system
2.2 The properties of fluid do not change over time
2.3 Energy stored from a change in elevation of a body moving from one point
to another point
2.4 The sum of the kinetic energy, potential energy and pressure energy of the
fluid flowing in the system
2.5 It describes the flow velocity and flow rate of water flowing in an open channel
2.6 The ratio of the actual discharge of flow to the theoretical discharge of an
orifice or a nozzle
2.7 A device that restricts flow or controls flow in a piping system
2.8 Used to calculate frictional losses in pipelines
2.9 The ratio between the density of an object and a reference substance
2.10 The ratio of the area at the vena contracta to the area of the
orifice (10 × 1) (10)

3. 3.1 Convert litres to cubic metres.

5 500 ℓ × 0,001 = 5,5 m3
Find the mass of water.
m = ρ × V
= 998 kg/m3 × 5,5 m3 = 5 489 kg
N4 Mechanotechnics Lecturer Guide|Hands-On! 65

Determine the potential energy.

PE = mgh = (5 489 kg)(9,8 m/s2)(5 m) 
= 268 961 J ≅ 269 kJ (3)

3.2 Rearrange the equation to solve for V.

KE = _  12  mV2
_____
√ 2(KE)
V = _____
  m   
________

√
2(15 000 J)
(a) V = ________
     = 245 m/s 
(5 kg)
________

√________   = 122 m/s 

2(15 000 J)
________
(b) V =  
(20 kg)

√
2(15 000 J)
________
(c) V =      = 55 m/s 
(100 kg)

Conclusion: As the mass increases, the velocity decreases. (5)

3.3 Calculate the weight of the water in the tank.

W = mg = (4 300 kg)(9,8 m/s2) = 42 140 N
Determine the area of the base of the tank.
  π4  d 2 = __
A = __   π4  (1,5 m)2 = 1,767 m2
Solve for the pressure energy.
F
P = __
  A   

  42 140 N2 = 23 848,3 Pa 

= _______
1,767 m
P ≅ 23,8 kPa (3)

3.4 3.4.1 Increases

3.4.2 Decreases
3.4.3 Remains constant
3.4.4 Increases (4 × 1) (4)

4. 4.1 Variation 1: Constant kinetic energy (v1 = v2)

P1 + ρgh1 = P2 + ρgh2 
Variation 2: Constant potential energy (h1 = h2)
P1 + _  12  ρV12 = P2 + _  12  ρV22 
Variation 3: Constant pressure energy (P1 = P2)
  12  ρV12 + ρgh1 = _  12  ρV22 + ρgh2 
_ (3)

4.2 •
Steady-flow velocity (the velocity must not change) – a laminar flow
• Incompressible density – it cannot change with pressure
• Frictionless fluid – there is no friction from viscous forces (6)
66 Module 7 • Hydraulic systems

4.3 V2Δt = S2

P2 V2

V1Δt = S1
A2
h2
P1 V1
A1 h1

Assessment guidelines
• The sketch is correct (1 mark)
• All the variables are given (10 × _  12  = 5 marks)
• The sketch is neat (1 mark)

4.4 4.4.1 Bernoulli’s equation:

P1 + _  12  ρV12 + ρgh1 = P2 + _  12  ρV22 + ρgh2
The water flows horizontally through the Venturi meter,
therefore, h1 = h2.
P1 – P2 = _  12  ρV22 – _  12  ρV12 
Find V1 using the flow continuity equation.
A1V1 = A2V2
A V2
V1 = ____
  A2 
1

Substitute V1 into the Bernoulli equation.

AV
P1 – P2 = _  12  ρV22 – _  12  ρ(____
  A2 2 )2 
1

Simplify the equation to solve for V2.

2
__ 2 __2 2 A
ρ  (P1 – P2) = V2 – V2 (  A )
2
 
1
A
= V22 [1 – __( )]
  A2 2
1
__________

√
2(P1 – P2)
V2 =  __________
A 2  ρ [1 – (____
  2 ) ]
A1

Determine the inlet area.

  π4  (0,12 m)2 = 0,011 m2 
A1 = __
The throat area is:
  π4  (0,06 m)2 = 0,003 m2 
A2 = __
N4 Mechanotechnics Lecturer Guide|Hands-On! 67

Substitute values into the equation.

__________

√
2(10 500 Pa – 5 000 Pa)
V2 = __________
   
   0,003 m2 2
3 (998 kg/m ) [1 – (____
  2 ) ]
0,011 m

= 3,45 m/s (8)

4.4.2 Q2 = A2V2 = (0,003 m2)(3,45 m/s) = 0,01 m3/s (2)

4.4.3 A1V1 = Q2
Q (0,01 m3/s)
V1 = ___
  A2 = ________
  2  = 0,91 m/s (2)
1 (0,011 m )

4.4.4 The velocity increases with a decrease in area and a decrease in

pressure. (2)

5. 5.1 Flange
Orifice plate

Flow

ΔP

Assessment guidelines
• The sketch is correct (1 mark)
• All the variables are given (4 ×  _12 = 2 marks)
• The sketch is neat (1 mark)

5.2
Fluid velocity:
____
V=√ 2gh  
_______________
=√ 2(9,8
   m/s2)(1,5 m)  
= 5,42 m/s 
Volume flow rate:
Q = AVx Cd 
= (0,009 m2)(5,42 m/s)x(0,65) 
= 0,032 m3/s (6)
68 Module 7 • Hydraulic systems

6. 6.1 Find the Chezy coefficient.

√
8g
C = __
    
f
________
___

√  
=
8(9,8 m/s2)
________
(0,064)
   = 35 √ m /s 

Rearrange the mean velocity equation to solve for the slope.

____
V = C √ RhS 
( )   V 2
__
  RC
S = _____ 
h
(6 m/s) 2
[ ______
___   ]
35√ m /s
________
=   0,1 = 0,29 (3)
2
6.2 L __
hf = f  ___   V  
D 2g
h
(20 m) (7 m/s)2
= (0,002) ______
(0,1 m)
  ________
  2   
2(9,8 m/s )
= 1 m (2)

6.3
The hydraulic radius is:
A = πRh2 ________
__
A
√ (0,519 m2)
__   = ________
Rh =   
π   √
π   = 0,41 m 
(a)
The flow rate for a slope of 0,5 is:
____
√ RhS 
Q = AC
___________
__
= (0,519 m )(48 m /s)√ (0,41 m)(0,5)  
2 √
= 11,28 m3/s 

(b)
The flow rate for a slope of 2 is:
____
Q = AC√ RhS  __________
__
= (0,519 m2)(48 √ m /s)√ (0,41 m)(2)  
= 22,56 m3/s (5)

7. 7.1 m = ρV
= (998 kg/m3)(40 m3) = 39 920 kg (1)

7.2 W = mg
= (39 920 kg)(9,8 m/s2) = 391 216 N (1)

7.3 Calculate the area.

  π4  (1 m)2 = 0,785 m2
A = __
N4 Mechanotechnics Lecturer Guide|Hands-On! 69

Determine the pressure (point 2).

F
P = __
  A  

  391 216 N

= ________ 2
 

0,785 m
= 498 365 Pa (2)

7.4 P1 + _  12  ρV12 + ρgh1 = P2 + _  12  ρV22 + ρgh2

Assume the velocity at point 1 is 0, because the area at point 1 is
much larger than at point 2 (V1 = 0). The pressure at points 1 and 2 is
atmospheric (P1 = P2 = Patm).
Patm + ρgh1 = Patm + _  12  ρV22 + ρgh2 

Rearrange to solve for the velocity at point 2.

ρg(h1 – h2) = _  12  ρV22 
_________
V2 = √
2g(h1 – h2)  
______________
√ 2(9,8
=    m/s2)(5 m)  
= 9,899 m/s ≈ 10 m/s (5)
___
7.5 √
  2h
x = V __ g  
________

√
2(3 m)
= (10 m/s) _______
  2     (9,8 m/s )
= 7,82 m (2)

7.6 Inlet area:

Ain = __   π4  d in2 = __
  π4  (0,05 m)2 = 0,0020 m2 
Outlet area:
  π4  dout2 = __
Aout = __   π4  (0,02 m)2 = 0,0003 m2 
Outlet velocity using flow continuity:
AinVin = AoutVout
A V (0,0020 m2)(10 m/s)
Vout = _____
  Ain in  = _____________
   
   2   
out (0,0003 m )
= 66,7 m/s (4)
Total: 100
MODULE

8 Bearings
By the end of this module, students should be able to:
• explain different types of loads that act on a shaft, including dead load of the
rotator, load produced when the machine performs work and load produced by
transmission of dynamic force;
• calculate loads acting on parallel-shaft gears and cross-shaft gears;
• calculate applied bearing loads;
• explain the concept of mean load;
• draw graphs to depict fluctuating stepped load, continuously fluctuating load,
linear fluctuating load and sinusoidal fluctuating load;
• discuss the following types of equivalent loads:
– dynamic equivalent radial load
– dynamic equivalent axial load
– static equivalent axial load;
• compare the following types of static equivalent axial loads:
– static equivalent axial load
– static equivalent radial load;
• calculate the load for angular contact ball bearings and tapered ball bearings; and
• calculate bearing rating life and load.

Bearings are devices that are used to support shafts. They keep the shaft stable and
allow it to rotate without friction. Motion is limited by bearings, which only allows for
linear and rotational motion about the axis. The shaft can rotate or shift axially in the
bearing. Bearings are made to take pure radial loads (rotation only), pure axial loads or
a combination of both.

Exercise 8.1 SB page 214

1. 1.1 B
1.2 C
1.3 E
1.4 A
1.5 D
N4 Mechanotechnics Lecturer Guide|Hands-On! 71

2. 2.1 •
Dead load of a rotator
• Load produced when the machine performs work
• Load produced by the transmission of dynamic force

2.2 •
Tangential
• Axial
• Radial

2.3 •
The direction of the helix angle
• The direction of rotation
• Whether the gear is the driving side or the driven side

3. 3.1 False
3.2 True
3.3 True
3.4 False
19,1 × 106 · H
4. 4.1 Kt = __________
  D · n 
p
19,1 × 106 · (2,5 kW)
=  __________________
  
   
(50 mm) · (1 450 rev/min)
= 658,62 N
cos δ
4.2 Ks = Kt [tan α  ____ + tan β sin δ]
cos β
cos (45°)
= (450 N)[tan [14,5°]  _______
cos (15°)
 + tan (15°) sin (45°)]
= 492 N

Exercise 8.2 SB page 219

1. 1.1 C 1.2 E
1.3 D 1.4 B
1.5 A

2. Radial load on bearing A:

  0 +360
FrA = _________360 mm
mm
  240
   120 mm
  (0 kN) + ______________
mm + 120 mm
  (10 kN)
= 3,3 kN
Radial load on bearing B:
0 mm 240 mm
FrB = –  ___________  + ______________
  240
   mm + 120 mm
  (10 kN)
360 mm (0 kN)
= 6,6 kN
If the radial loads on bearings A and B are added together, it should equal the
radial shaft load.
72 Module 8 • Bearings

3. Break F1 into horizontal and vertical components.

Horizontal component:
F1, h = F1 cos θ
= (7 kN) sin 30° = 6,06 kN
Vertical component:
F1, h = F1 sin θ
= (7 kN) sin 30° = 3,50 kN
Radial loads on bearing A
There are three radial loads, therefore the equation must sum three values.
(90 + 800 + 250)
FA = _______________
    (3,5) + _______
   
(90 + 800 + 250) – 90
  800250
+ 250
  (800
   50
  (20) + _______________
+ 250 + 50) – 50
  (3)
= 3,8 + 4,76 + 0,14 = 8,7 kN
Loads on bearing B
Radial loads:
There are three radial loads, therefore the equation must sum three values.
90 (800 + 250 + 50)
FB = _______________
  (90
   + 800 + 250) – 90
  800800
  (3,5) + _______ + 250
  (20) + _______________
  
  (800
   + 250 + 50) – 50
  (3)
= 0,3 + 15,24 + 1,05 = 16,59 kN
Axial
There is only one axial load.
FB = 6,06 kN
Bearing B stops the shaft (at the step) from moving along the axis, therefore the
shaft applies an axial load to it. Bearing A does not stop the shaft from moving
axially because there is no step in the shaft.
l
4. 4.1 R1 = ____
  2
l1 – l2
l
R2 = ____
  1   P
l1 – l2
4.2 Yes

Exercise 8.3 SB page 225

1. 1.1 True
1.2 False
1.3 False

2. 2.1 C
2.2 D
2.3 B
2.4 A
N4 Mechanotechnics Lecturer Guide|Hands-On! 73

3. •
F-axis label
• nt-axis label
• Bar graphs
• Correct curve

860 N

750 N

630 N
590 N

nt
54 × 10° 72 × 10° 68 × 10° 66 × 10°

4. Use the formula for a linear fluctuating load.

F + 2F
Fm = _________
min
    3
max
 

Rearrange the equation to solve for Fmax .

3F – F
Fmax = ________
  m 2 
min

Substitute the values.

3(1 975 N) – (640 N)
Fmax = _______________
    2
 
= 2 642,5 N

5. Fm = 0,75 Fmax
= 0,75 (550 N)
= 412,5 N

Exercise 8.4 SB page 234

1. 1.1 Equivalent load is the relationship between axial and radial forces on a
bearing and how it affects the distribution of loads on the different rolling
elements.
1.2 Dynamic equivalent load is when both dynamic radial and dynamic axial
loads act on a bearing at the same time, which gives the same service life as
if the bearing had only a radial load or only an axial load acting on it.
1.3 It is a load that occurs when both static radial and static axial loads
are applied simultaneously to the bearing, which causes the same total
permanent deformation at the most heavily stressed contact point between
the rolling elements and the raceway as under actual load conditions.
74 Module 8 • Bearings

1.4 The bearing life is a measure of the total number of revolutions (or hours
at constant speed) of an operating bearing until the failure criterion is
developed/measured of how long you can expect the bearing to last under
standard operating conditions.

2. Static equivalent radial loads are used purely in radial bearings, while static
equivalent axial loads are used in thrust bearings.

3. Using the dynamic equivalent radial load:

Pr = Fr = 3,2 kN
The basic dynamic load rating Cr for bearing 6 208 given on page B-12 is 29,1 kN,
ball bearing speed factor fn relative to rotational speed n = 650 min–1 from the
table above is fn = 0,37. Therefore, the life factor fh is.
C 29,1
fh = fn  __
r
P  
= 0,37 × ____
 3,2  = 3,36
r

Therefore, with fh = 3,36 from the table above, the rated life L1 0 h is approximately
19 000 hours.

Summative assessment SB page 238

1. 1.1 • Inner ring – houses the shaft

• Outer ring – supports or houses the inner ring and rolling element
• Rolling elements (between the two rings) – allow the inner ring
to rotate(6)
________
1.2 Kr = √
Kt2 + Ks2
________________
√ (120
=    N)2 + (36 N)2  
= 125,3 N (2)
19,1 × 106 · H 19,1 × 106 · 65
2. 2.1 2.1.1 Kt = __________
  D · n  = __________
  250 · 650 = 11,64 N
p

2.1.2 Ks = Kt · tan α = 11 640 · tan 5 = 1,02 kN

  tan α = 1 018 · _____

2.1.3 Ks = Kt · ____ tan 5
 cos 3,5
 = 89,3 N
cos β
2.1.4 Ka = Kt · tan β = 11 640 · tan 3,5 = 711,9 kN (2 × 4) (8)

2.2   a + b FI + ____

FrA = ____   d   FII 
b c+d
FrB = –  __a  FI + ____
  d   FII 
b c+d
N4 Mechanotechnics Lecturer Guide|Hands-On! 75

0,16 + 0,25 0,15

From 1: 25 = ________
  0,25  FI + ________
  0,10 + 0,15  FII 
0,16 0,10
From 2: 45 = ____
 0,25  FI + ________
  0,10 + 0,15  FII 
25 = 1,64FI + 0,6FII 
45 = 1,64FI + 0,4FII 

∴ FI = –62,5 N 
FII = 212,5 N (10)
to
2.3 Fm = ( __ ) 
1  ∫ F(t)p dt    
1
_
p
to 0
1   ∫ 60(t 3 – 2t2 – t + 3)  dt    
= ( __

60 0
)  3
_
10
3
_
10

= 101,32 kN (3)
F + 2F
2.4 Fm = _________
min
    3
max
  
3 000 + 2 × 18 000
=  _____________
   3
  
= 13 kN (3)

2.5 Case A
Fm = 0,75Fmax 
= 0,75 × 300 
= 225 N 
Case B
Fm = 0,65Fmax 
= 0,65 × 300 
= 195 N (6)

2.6 Using the dynamic equivalent radial load:

Pr = Fr = 250 kg × 9,8 m/s2 = 2 450 N 
The basic dynamic load rating Cr for bearing 6 308 on SKF catalogue
is 42 300. 
p = 3 for ball bearings 
10 __r p 6 C
L10 = ___
  60n  (   P   ) 
r
6
  60 ×102 800  _____
= ________   42
( 300 3
 
9 800  )
= 30 634 hours (7)
Total: 45
MODULE

9 Metal cutting machines

By the end of this module, students should be able to:
• list the different types of cutting machines and identify their uses; and
• calculate power, moment of force, circumferential speed and torque, efficiency,
coefficient of friction, cutting pressure and cutting area.

In this module students will learn about five types of cutting machines used to remove
material from a workpiece. It will be helpful for them to look at the video links provided
where they will be able to see how the different machines work. In the second part of
the module they will learn to do many different types of machine calculations. It is
important that they understand the principles of these calculations, as they may be
required to do calculations not specifically outlined here.

Exercise 9.1 SB page 251

1. Shaping machines, drilling machines, milling machines, surface grinding

machines and lathes

2. • They require less physical effort to drill into hard materials.

• The workpiece can be clamped to the drill’s table.
• The drilling angle is fixed and the drill is stable for more accurate holes.
• Drill presses have powerful motors and larger drill bits can be used.

3. • The drill can easily be taken to where the item is.

• It is easier to drill at different angles.

4. A milling machine removes material from a workpiece using a rotary cutter,

also referred to as a tool or a bit. The primary cutting action is perpendicular to
the rotation direction of its cutter. This means that the cutting is mostly done
by the sides of the tool. To do its work, the workpiece is clamped to the bed of
the machine, which can move sideways and forwards and backwards, while the
cutting head is moved vertically to cut the right depth.
N4 Mechanotechnics Lecturer Guide|Hands-On! 77

5. • End milling
• Slab milling
• Boring
• Saw cutting
• Drilling and reaming

Exercise 9.2 SB page 273

1. 1.1 Cutting distance:

Ac = w × sc
A 1,0
∴ sc = __
  wc  = ____
  0,02 = 50 m
With a cutting speed of 0,35 m/s:
s 50
∴ t = __
  vcc  = ____
  0,35 = 142,86 s
1.2 Cutting force:
Fc = P × w × d = 1 600 × 20 × 0,02 = 640 N
1.3 Work done and power used for cutting:
W = Fc × sc = 640 × 50 = 32 000 J
P = Fc × vc = 640 × 0,35 = 224 W

2. Force diagram:
FC FA

25 mm 50 mm

∑Fcwr = ∑Fccwr (around B)

FA × rA = Fc × rc
∴ FA × 50 = 650 × 25
∴ FA = 325 N
∑Fup = ∑Fdown
∴ FB = FA + Fc = 650 + 325 = 975 N

3. 3.1 Force diagram:

A FC

400 mm 100 mm
B
78 Module 9 • Metal cutting machines

∑Fcw r = ∑Fccw r (around B)

Fc × rc = FA × rA
∴ 4 000 × 100 = FA × 400
  4 000400
∴ FA = _________ × 100
 = 1 000 N
∑Fup = ∑Fdown
∴ FB = FA + Fc = 1 000 + 4 000 = 5 000 N

3.2 Friction power loss:

Ff A = μFA = 0,02 × 1 000 = 20 N
Ff B = μFB = 0,02 × 5 000 = 100 N
1 200 × π × 0,04
  Nπd
v = ____ 60
  = ____________
   60
 = 2,51 m/s
P = Fv = (20 + 100) × 2,51 = 301,2 W

4. Ignore friction force and normal force, as they do not perform any
useful work.
Pc = Fc × v = 800 × 0,6 = 480 W
P
η = ___  480
  Pout  × 100 = ___
750
  = 64%
in

5. 5.1 Total cutting distance and time:

2
Number of teeth: n = ____
  0,08 = 250 teeth
Cut length = length per cut × number of cuts per tooth × number of teeth
s = l × c × n = 0,06 × 20 × 250 = 30 m
t = _  vs   = ___ 30
  0,1 = 300 seconds

5.2 Friction power losses:

Fn = mg = 40 × 9,81 = 392,4 N
Ff = μs × Fn + μw × Fn = 0,1 × 392,4 + 0,5 × 392,4 = 235,44 N (2)
Pf = Ff × v = 235,44 × 0,1 = 23,54 W

5.3 Cutting force, work done and power:

Fc = PA = 2 900 × 1,5 = 4 350 N
Wc = Fc × s = 4 350 × 30 = 130 500 Nm
Pc = Fc × v = 4 350 × 0,1 = 435 W

5.4 Machine efficiency:

P
η = _______   500435
  P ×out100  = _______ × 100
  = 87%
in
N4 Mechanotechnics Lecturer Guide|Hands-On! 79

Summative assessment SB page 276

1. 1.1 G
1.2 C
1.3 F
1.4 J
1.5 H
1.6 B
1.7 E
1.8 I
1.9 A
1.10 D (10)

2. 2.1 Work done:

Fn = mg = 70 × 9,81 = 686,7 N 
Ff = μFn = 0,1 × 686,7 = 68,67 N 
W = Ff × s = 68,67 × 0,22 = 151,1 J (6)

2.2 Cutting force:

Wt = Wf + Wc
∴ Wc = Wt – Wf = 380 – 151,1 = 228,9 J 
W 228,9
Fc = ___
  s c = ____
  0,22 = 1 040,6 N (4)

2.3 Clamping force on A and B:

Force diagram: 
1 040 N 2 200 N

FC Fs

60 mm 35 mm 35 mm
FA FB

Take moments around A.

∑Fcw × r = ∑Fccw × r 
∴ Fs × 35 = FB × 70 + Fc × 60 
(2 200 × 35 – 1 040,6 × 60)
∴ FB = ___________________
    70
 = 208,1 N 
∑Fup = ∑Fdown 
FA + FB = Fc + Fs 
∴ FA = 2 200 + 1 040,6 – 208,1 = 3 032,5 N (10)

3. 3.1 Cutting force:

Fc = P × w × d = 3 100 × 7,5 × 0,06 = 1 395 N (2)
80 Module 9 • Metal cutting machines

3.2 Time to complete job:

Total number of passes = number of grooves × depth of groove
÷ depth per pass 
  80,06
N = _____ × 12
 = 1 600 passes 
Total cut length: Lc = 1 600 × 0,212 = 339,2 m 
L 339,2
t = __
  vc  = ____
  0,35 = 969,1 sec (16 min 9 sec) (5)

3.3 Work done for cutting:

W = Fc × Lc = 1 395 × 339,2 = 473 184 J (2)

3.4 Cutting power requirement:

Pc = Fc × v = 1 395 × 0,35 = 488,3 W (2)

3.5 Friction:
Fn = mg = 75 × 9,81 = 735,75 N 
Ff = (Fn × μ)slide + (Fn × μ)workpiece
= 735,75 × 0,05 + 735,75 × 0,4
= 331,1 N 
Wf = Ff × Lc = 331,1 × 339,2 = 112 305 J 
Pf = Ff × v = 112 305 × 0,35 = 115,9 W (9)

3.6 Clamping:
Fc = μFf 
F
∴ Ff = __   10,6
  μc  = ____ 395
 = 2 325 N 
As each of the jaws of the vice clamps with the same force, the clamp
force is:
  2 325
Fv = ____ 2
 = 1 162,5 N (4)

3.7 Efficiency:
P 488,3
η = _______
  P ×out100  = _______
  750 × 100  = 65% (2)
in

4. 4.1 For aluminium, 1 m/s is recommended. 

  60v  = _______
N = ___   π 60 ×1
× 0,095
 = 201 rpm 
πd
Select 200 rpm. (4)

4.2 Cut depth is:

F = wdKc 
500
  KFw  = _______
∴ d = ___   (800 × 6)
 = 0,10 mm (3)
c

4.3 Power usage is:

P = Fv = 500 × 1 = 500 W (2)
Total: 65
Glossary

A Cathodic protection – a method used to protect

Acid bath – a suitable container that holds up to a metal structure under water from corrosion by
several litres of concentrated acid making it the cathode in an electrochemical cell
Acid etch cleaning – applying an acid to a metal to Ceramics – materials made from clay that is
prepare it for the next process hardened by heat, e.g. plates, glasses and mugs
Acidic – having the properties of an acid Concentric – when two objects (usually circular)
share the same axis or centre
Aggregate – a term used for any particulate or
granular material used on the surface of a grinding Corrosion – the slow destruction of a material
wheel (usually a metal) by a chemical, electrochemical or
metallurgical reaction between the material and
Altitude – the height of the ground above sea level the environment
Anode – the positively charged electrode that Creep – deform over time
attracts anions (negative ions) during electrolysis
Crossed-drive pulleys – the two pulleys rotate
Anodic cleaning – a pre-treatment process used to in opposite directions and the angle of contact is
remove corrosion products from a metal surface by the same on both pulleys (even if one is smaller
electrolysis, with the metal being the anode than the other), but bigger than on an open-belt
Atmospheric pressure – the pressure applied on drive pulley
the surface of the earth by the weight of the gas
particles of the atmosphere D
Axial load – acting parallel to the axis of rotation Dead load – also known as a constant or static
Axially – around its own axis load; is the load of a structure that stays relatively
constant over time; it is permanent
B Direct current (DC) – a current that only flows in
Belt tracking – the ability to maintain control of one direction
the desired path of a flat belt once it is aligned Dispersant – a liquid or gas used to remove small
and installed particles in a medium
Bending moment – the reaction (it bends) caused Dovetail – a joint that is formed by one or more
in a structural element when an external force is tapered projections on one piece that interlock
applied to it with corresponding notches or recesses in another
Dynamic force – the amount of acceleration or
C velocity needed to move an object
Cambered – curving upward from the leading edge
and downward again to the trailing edge E
Cathode – the negatively charged electrode Electrolysis – the process by which an electric
to which cations (positive ions) are attracted current flowing through a liquid containing ions
during electrolysis causes the liquid to undergo a chemical change
Cathodic cleaning – a procedure used to remove Electrolytic cleaning – a method used to remove
the build-up or corrosion formations from a metal scale or corrosion products from a metal surface
surface by wiring it as an electrode to an electric by subjecting the metal as an electrode to an
current in an electrolytic cell electric current in an electrolytic bath
82 Glossary

Electrons – negatively charged particles rotating Mean velocity – the average velocity of the belt
around an atom, which act as the primary carriers (pulleys of different sizes and rotational speeds
of electricity have different belt velocities; therefore, the average
Ergonomics – the study of how equipment and must be taken to do calculations)
furniture can be arranged to make work more Metal fatigue – weakness of a metal due to various
comfortable and more efficient, such as ensuring types of stress
that a chair is not too low for a desk to prevent
neck pain μm – a micrometre is one millionth of a metre;
1 μm = 1 × 10–6 m
F
Fluidity – the ability of a liquid to flow easily
O
One bar – 100 000 Pa
G Open channel flow – fluid flow over a free surface
Galvanic protection – a method where the more that is open to the atmosphere
electrochemically reactive metal is attached to the Open flat-belt drive pulleys – pulleys that rotate
vulnerable metal surface where it is exposed to in the same direction and where the angle of
an electrolyte contact is smaller on the smaller pulley than the
Gauge pressure – measures the difference larger pulley
between the measured pressure in a fluid and the
Orifice – small exact hole to control pressures
atmospheric pressure
and flows
Gear train – a system of gears that transmits
motion from one shaft to another Oxidation reaction – a chemical reaction involving
the loss or moving of electrons
I
Impressed current cathodic protection
P
(ICCP) – a method that consists of anodes that Pitch circle – an imaginary circle that, by pure
are connected to a power source that provides rolling action, will give the same motion as the
a continuous source of electrical flow actual gear
Incompressible – cannot be compressed Pitch circle diameter (PCD) – the diameter of an
Induction motors – can produce high torque and imaginary circle drawn through the centre of the
can reverse direction by switching pulley’s bolt holes
Insoluble – cannot dissolve in a solvent Planing – a manufacturing process to flatten and
Involute – a particular type of curve that is smooth a surface
dependent on another shape or curve Polymers – large molecules made up of many
smaller molecules of the same kind; plastic is the
J most common example of a polymer
Job shop – small manufacturing factories or Precision roller – a solid cylindrical rod of
workshops that handle small to medium-sized different diameters and lengths
customer orders or batch jobs
Pressure angle – the angle between the pressure
L line and the common tangent to the pitch circles
Line of action – the path through which one gear Primer – also called an undercoat; a preparatory
acts upon another coating put on materials before painting
Process inventory – includes receiving, temporary
M storage, labelling and storage, withdrawal, issuing,
Mean load – also known as the average; the sum of and movement of the item through the work-in-
all the values divided by the number of values process routine
N4 Mechanotechnics Lecturer Guide|Hands-On! 83

R T
Radial load – acting at right angles to the shaft (the Tangential load – acting on the side of a body to
bearing’s axis of rotation) either rotate the body or stop the rotation
Reaming – the process of enlarging the size of a Taper – reduce in thickness towards one end; a
previously formed hole by a small amount but with conical-shaped system in machine tools used to
a high degree of accuracy to leave smooth sides secure the tool holder or the tool
Reciprocating – ongoing backwards and forwards Taper plug – a solid that fits in a tapered hole with
movement a face that has the same taper angle as the hole
Redox reaction – chemical reaction where Taper plug gauge – an internal gauge in the shape
electrons are transferred between two substances, of a cone used to measure internal tapers
e.g. from iron to a drop of water Tapping – the process of cutting a thread inside a
Reference diameter – the diameter of the standard hole so that a cap screw or bolt can be threaded
pitch circle into the hole
Reservoir – container to hold or store fluids Tool holder shank – a short steel bar having a
Reynold number – an important quantity that shank (long narrow part) at one end by which it is
is used to determine whether the fluid flow clamped to a machine and a clamp at the other end
is laminar (constant) or turbulent (moving to hold small interchangeable cutting bits
unsteadily or violently) Torque – a twisting or turning force that tends to
Rotator – a rotating part of a mechanical device cause rotation around an axis
Transverse position – a position perpendicular to
S the direction of working
Scale – the forming of a type of flaky rust on the Tungsten carbide – a material with many
surface of metal applications and characterised by its high strength,
Separating force – acting on the gears in a radial toughness and hardness
direction
Shear force – the effect of two forces close to each V
other but in opposite directions on a body, or a V-belt – a V-shaped belt in a V-shaped groove in a
single force on a rigid body close to its surface pulley for wedging and better traction
Sine bar – a device used to accurately measure Vena contracta – the point in the flow stream
angles or to position workpieces prior to grinding where the diameter is the least and the velocity is
and other machining procedures at maximum
Slip gauge – a very precisely manufactured steel Vice – used to secure or clamp an object to allow
block used for measuring fine tolerance limits, work to be performed on it
setting up of sizes and calibrating precision Volumetric – the measurement of volume (m3)
measuring instruments or inspection gauges Vortex – a circular motion that forms a vacuum
Spalling – a process of metallic surface failure in that is able to draw another fluid or component
which the metal is broken down into small flakes into the vortex
(spalls) from a larger solid body
Spindle – the rotating axis of a machine W
Sprocket gear – a toothed wheel whose teeth Whale blubber – a thick layer of fat directly
engage the links of a chain underneath the whale’s skin
Steady-state flow – the properties of fluid do not Wick – a strip of porous material up which liquid
change over time fuel is drawn
0001MG

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N4 Mechanotechnics Lecturer Guide

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N4 Mechanotechnics Lecturer Guide

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MECHANOTECHNICS

N4 Mechanotechnics Lecturer Guide|Hands-On! i

First published 2020

The examination in Mechanotechnics N4 (Engineering Studies – Report 191) will be

The following weights are consequently awarded to each category:

Knowledge and Application Analysis/synthesis

30–45% 20–30% 15–25%

6. Weighted value of modules

Module 1: Workshop layout 5%

Module 2: Metal protection 5%

Module 4: Precision measuring of machine parts 15%

Module 5: Gear drives 15%

Module 6: Belt drives 5%

Module 7: Hydraulic systems 20%

Module 8: Bearings 15%

Module 9: Metal cutting machines 15%

Week Topic Content Hours

Week Topic Content Hours

Subject and level Campus

Lecture White board/OHP

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Lecture White board/OHP

Group work Models

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Lecture White board/OHP

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Lecture White board/OHP

Group work Models

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Lecture White board/OHP

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Lecture White board/OHP

Group work Models

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Lecture White board/OHP

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Lecture White board/OHP

Group work Models

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Lecture White board/OHP

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Lecture White board/OHP

Group work Models

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Exercise 1.1 SB page 5

1. Any five of the following:

2. Any five of the following:

Exercise 1.2 SB page 7

2. Mass production – any four of the following:

Batch production – any four of the following:

Individual production – any four of the following:

Exercise 1.3 SB page 11

Exercise 1.4 SB page 15

1. Any five of the following:

Exercise 1.5 SB page 19

Summative assessment SB page 21

Product layout Fixed layout Process layout

Grouping According to Around the large or According to

6. Job shop (1)

7.2 Considerations – any six of the following:

In this section, you will learn more about the following:

Exercise 2.1 SB page 29

2. 2.1 Pitting corrosion

Exercise 2.2 SB page 34

2. Cleaning, picking, rinsing, phosphating, rinsing, sealing, drying

3. Advantages (any one)

Disadvantages (any one)

4. Galvanic protection and impressed current cathodic protection (ICCP)

Exercise 2.3 SB page 41

1. 1.1 False. Solvent cleaning

4. Any three of the following:

Summative assessment SB page 44

1. 1.1 False. Metals and many other different materials. (2)

2. 2.1 Advantages (any two)

Disadvantages (any two)

2.2 Advantages (any two)

6. Job shop (1)

1. 1.1 False. Metals and many other different materials. (2)

5. 5.1 5.1.1 • Clean the material.

5.2 5.2.1 Descaling (1)

2.3 To reduce friction between two metal parts (1)

(2 marks for sketch)

(2 marks for sketch)

Opposite side = adjacent side × tan β

2.2   PCD

2.4   PCD

2.5 Clearance = dedendum – addendum

2.6 Working depth = addendum + addendum

2.7 Whole depth = addendum + dedendum

TC = _______   750250