REPORT 191 PROGRAMMES SUBJECT SYLLABUS

REPORT 191 PROGRAMMES

SUBJECT SYLLABUS

MECHANOTECHNICS N4

SUBJECT CODE: 8190194

IMPLEMENTATION: JANUARY 2021

Syllabus: Mechanotechnics N4

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CONTENTS PAGE

1. General Aims 3

2. Specific Aims 3

3. Pre-requisite 3

4. Duration 3

5. Evaluation 3

6. Learning content 4

7. Mark Allocation 4

8. Module 1: Workshop layout 5

9. Module 2: Metal protection 5

10. Module 3: Lubrication 6

11. Module 4: Precision measuring of machine parts 6

12. Module 5: Gear drives 8

13. Module 6: Belt drives 8

14. Module 7: Hydraulic systems 9

15. Module 8: Bearings 10

16. Module 9: Metal cutting machines 11

17. Didactic guidelines 11


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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. Prerequisite

A student must have passed at least the National Certificate Vocational, Engineering

Related Design (ERD) Level 4 or National Certificate N3 Engineering with a pass in

Mechanotechnology N3. A student who has 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

5.1 Evaluation is conducted continuously by means of class test. 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.

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

conducted as follows:

5.2.1. ONE PAPER will be written.

5.2.2. PAPER 1: Modules 1 to 9 MARKS: 100


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5.2.3. DURATION: 3 HOURS

5.2.4 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 Understanding Applying Analysing / Synthesis and Evaluating

30 - 45 20 – 30 15 – 25

6. Learning content

THEORETICAL BACKGROUND

It is essential that this section should be illustrated and evaluated within the context of

practical workshop situation.

7. Mark allocation in the examination as an indication of the

weighting of the different modules

MODULES WEIGHTING

1. Workshop Layout 5

2. Metal Protection 5

3. Lubrication 5

4. Precision measuring of

machine parts

15

5. Gear drive 15

6. Belt drives 5

7. Hydraulic systems 20

8. Bearings 15

9. Metal cutting machines 15

TOTAL 100


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Module 1: Workshop Layout

General aim

1.1 Plan the layout of a workshop with due consideration of all the principles, advantages and disadvantages, factors, types of construct ion and various different types of processes.

LEARNING CONTENT LEARNING OUTCOMES

The student must be able to:

1. Introduction to workshop layout. List the advantages and disadvantages of good workshop layout

List the factors that should be considered in the design of workshop layout.

2. Types of production. Explain the differences between mass, individual and batch

production.

3. Factory Layout Draw diagrams to illustrate the differences between the

following processes of layouts - Product, Fixed and

Process

4. Graphic layout Techniques Draw two dimensional and three dimensional models

5. Considerations when placing

machines in a factory

Explain how materials are handled in the workshop.

Explain what is meant by each of the following

requirements of process layout:

a) Economic placing of various sections

b) Highly skilled workers

c) Adaptability of inspection methods

d) Thorough planning of production.

Module 2: Metal protection

Aim

2.1 Compare various types of corrosion, testing for corrosion and the relevant processes for

preserving metal.



1. Introduction to corrosion and its prevention.

2. Classification of corrosion.

3. Different forms of corrosion

Describe corrosion as the destruction of a material as a result of chemical, electrochemical or metallurgic interaction between the material and the environment.

Explain the two main classes of corrosion.

Explain the following forms of corrosion: Surface corrosion: a) Stress corrosion


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4. Corrosion tests

5. Metal protection process

6. Surface preparation for painting

7. Painting process

b) Galvanic corrosion c) Inter –crystalline corrosion d) Pitting corrosion.

Explain the most common types of corrosion tests

Describe what each of the following metal –protection involves: a) Cathodic protection b) Electroplating c) Anodising d) Phosphating.

Describe the following processes that we use to prepare steel for spray painting: Sandblast cleaning, Descaling and Grease removal

Explain the following painting processes: Air spray painting, Airless spray painting, Electrostatic spray painting and Dip painting.

List advantages and disadvantages of using each of the painting processes.

MODULE 3: Lubrication

AIMS

3.1 Identify types of lubricants, lubrication methods and explain uses of lubricants



1. Classification of lubricants

List the different classes of lubricants and give examples of each.

2. Fluid film bearings

Describe in detail hydrodynamic and hydrostatic lubrication.

3. Selection of lubricants

List factors that should be considered when selecting lubricants

4. Lubrication devices

Draw and label different types of lubricating devices.

5. Uses of lubricants

List different types of lubricants and their uses.


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MODULE 4: Precision measuring of machine parts

Aims

4.1 Apply precision measuring of machine parts and relevant calculations on machine parts

by means of precision measuring instruments



1. Basic Principles

2. Determining tapers using balls

3. Determining Tapers of taper

plugs

4. Determining angles of dovetails

5. Sine bars

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 a small ring gauge and internal tapers.

Analyse how to use 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

Calculate an inclined and included angles using sine bars.


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Module 5: Gear drives

Aim

5.1 Apply elementary calculations in respect of spur gear systems, as well as epicyclic

gear systems.



1. Introduction to gear drives

2. Gear terminology

3. Simple and compound gear

trains.

4. Epicyclic gear systems

5. Uses of epicyclic gears

List advantages and disadvantages of gear drives when

compared with v –belt drives and chain drives.

Draw and label the following gear parts:

a) Involute,

b) Module,

c) Line of action and pressure angle,

d) Pitch circle diameter,

e) Circular pitch,

f) Tooth thickness,

g) Addendum,

h) Dedendum,

i) Clearance,

j) Whole depth,

k) Working depth,

l) Blank or outside diameter,

m) 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:

a) Module,

b) Pitch circle diameter,

c) Circular pitch,

d) Tooth thickness,

e) Addendum, Dedendum,

f) Clearance, Whole depth,

g) Working depth,

h) Blank or outside diameter,

i) Centre distance between shafts.

Explain basic working principle of epicyclic gear

system.

Explain the following: Speed increase with sun gear

stationary, Speed increase with annulus stationary,

Speed reduction with sun gear stationary, Speed

increase and direction reversal with planet stationary.

List situations where epicyclic gears are used.


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6. Calculations of epicyclic gears

List advantages and disadvantages of epicyclic

Explain the method of calculating epicyclic gear drives.

Calculate the following epicyclic gears:

a) The number of teeth or the revolutions per minute,

b) The number of teeth or the revolution per minute of

the minute of input shaft,

c) Intermediate shaft or output shaft, PCD

Module 6: Belt drives

Aim

6.1 Apply calculations of a flat, vee and conveyor belt drives



1. Introduction to belt drives

2. Belt drive

Explain concepts and terminology.

Draw and explain belt drives – flat, open, crossed and

vee belt drives.

Calculate the following on belt drives:

a) Effective diameter,

b) Velocity ratio,

c) Belt velocity,

d) Belt length,

e) Angle of contact,

f) Tensions in the belt,

g) Torque transmitted by the belt,

h) Power transmitted by the belt

i) Force on bearings to all types of belt drives.

Module 7: Hydraulic systems

Aim

7.1 Apply elementary calculations on hydraulic systems, specifically of flow of water

through pipes and Venturi meters.



1. Basic principles of fluid statistics.

Explain the following concepts and terms:

a) Properties of water, b) Density, c) Relative density, d) Fluid pressure on a surface,


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2. Basic principles of fluid dynamics

3. Energy stored in fluids

4. Bernoulli’s principle

5. Frictional losses in pipelines

Darcy’s equation for frictional losses

Chezy’s equation for frictional losses

6. Measurement of flow

7. Venturi meters

e) Pressure intensity, f) Pressure head, g) Atmospheric pressure.

Explain the following: Flow rate (Q), Mass flow, Continuity of flow.

Explain the following concepts: Potential energy, Kinetic energy, Pressure energy.

Describe Bernoulli’s Theorem

Calculate the 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: a) Nozzles and orifices, b) Theoretical velocity, c) Theoretical area, d) Theoretical quantity, e) Actual velocity, f) Actual area, g) Actual quantity, h) Coefficient of velocity, i) Coefficient of contraction, j) Coefficient of discharge, k) General formula, l) Distance travelled by a waterjet, m) Energy loss at orifice.

Explain how a venturi meter is used to measure the flowrate of fluids through pipelines.

Calculate energy loss on venturi meter.

Draw and label a venturi meter.

Module 8: Bearings

Aim 8.1 To compute bearing loads on the forces which act on the shaft being supported by the

bearing.




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1. Load acting on shafts

2. Bearing load distribution

3. Mean load

4. Equivalent load

Explain different types of loads which 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 a 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, Sinusoidal fluctuating load.

Discuss the following types of equivalent load: a) Dynamic equivalent radial load, b) Dynamic equivalent axial load, c) Static equivalent axial load.

Compare the following types of static equivalent axial load:

a) Static equivalent axial load, b) Static equivalent radial load.

Calculate the load for angular contact ball bearing and tapered ball bearings.

Calculate bearing rating life and load

MODULE 9: Metal cutting machines

General aims

9.1 Do calculations regarding forces acting on machine cutting tools.

9.2 Calculate power, speed, torque, forces and efficiency of cutting machines.



1. Introduction to metal cutting

machines

2. Calculations for cutting

machines.

List the different types of cutting machines and identify their uses.

Calculate power, moment of force, circumferential speed, and torque, and efficiency, coefficiency of friction, cutting pressure and cutting area.


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Didactic guidelines

1. Theoretical principles should be applied to practical real-life situations.

2. Discussion and evaluations should be done on the basis of real practical workshop

situations.

3. 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.

4. Excursions, videos and internet could all contribute to an understanding and evaluation

of the Mechanotechnics.

Documents

REPORT 191 PROGRAMMES SUBJECT SYLLABUS