HARARE INSTITUTE OF TECHNOLOGY

SCHOOL OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF INDUSTRIAL AND MANUFACTURING ENGINEERING

B-TECH INDUSTRIAL AND MANUFACTURING ENGINEERING

B-TECH CHEMICAL AND PROCESS SYSTEMS ENGINEERING
B-TECH POLYMER TECHNOLOGY ENGINEERING
B-TECH FOOD PROCESSING TECHNOLOGY

EIM 118: WORKSHOP TECHNOLOGY I (Conventional/Parallel)

SEMESTER I EXAMINATION

Duration: 3 hours Date: November 2016

Instructions to Candidates:
1. Answer any Four questions from a total of Six
2. Each question carries 25 marks.
3. Where applicable, use large clearly labeled diagrams
4. Orderliness and smartness is a must.

Requirements:
1. Answer booklet
2. Graph paper
3. A non programmable calculator

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QUESTION 1

a) Differentiate between an Unsafe act and Unsafe condition citing examples. [4]
Unsafe acts violation of accepted norms or Performance of a task or other activity that is
conducted in a manner that may threaten the health and/or safety of workers. Examples are:
Operating equipment at unsafe speed, failure to warn, bypass or removal of safety devices
Un safe- condition is a condition in the work place that is likely to cause property damage
or injury. Examples are: Defective tools, equipment, or supplies
b) Explain why good housekeeping is important in the workshop. [5]

Good housekeeping involves every of industrial operations and should apply throughout
the entire premises, indoors and out. It is more than mere cleanliness.
A clean, well ordered, attractive work environment sets the tone for your establishment.

It encourages tidy work habits for your employees.

Reduces fatigue

Promotes good worker management relations.

Gives a lift to morale quality production and overall efficiency

c) Temperatures at which a material will burn fall into three categories. Describe these three
categories. [6]
FLASH POINT: The lowest temperature at which a flammable substance gives off vapours
and just flashes followed by extinguishment. It determines the conditions at which a
flammable substance becomes flammable.
FIRE POINT: Temperatures at which flame propagation is sustained after ignition. This
temperature characterises the ability of a substance to burn independently.
SPONTANEOUS IGNITION TEMPERATURE: Lowest temperature at which a substance
produces sufficient flammable vapour and heat to start combustion fire without the
application of external flame
d) Identify and explain the five classes of fire and in each case state the type of fire extinguisher
to be used to put out the fire. [10]

Page 2 of 9
[Total=25marks]

QUESTION 2

a) A typical flat file is shown in Fig Q2a below. Reproduce the file and label parts 1 to 5. [7]

Fig Q2a: Flat file

1. Point, 2. Face, 3. Heel, 4. Tang, 5. Length
b) With the aid of suitable diagrams, explain the following filing techniques:
i. Cross filing. [4]

ii. Draw filing. [4]

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 iii. Straight filing. [4]

c) Hammers are classified according to three principal factors. Identify and explain these three
factors. [6]
Shape of the head, weight and material from which the hammer is made from.

[Total=25marks]

QUESTION 3

a) Identify the five different types of chisels used in a mechanical workshop. [5]
Flat chisel, cross-cut chisel, half round chisel, diamond cut chisel, side chisel.
b) With the aid of neat diagrams:
i. Explain the purpose of a Set on a hacksaw blade. [4]

The purpose of a set is to enable the hacksaw blade to cut a gap which is wider than
the blade width to prevent jamming of the blade when cutting.
ii. Identify and explain the four types of Sets of teeth on a hacksaw blade. [9]

Alternate set (straight set) -where one tooth leans to the left and one to the right of the
length of the blade.

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 Double alternate set-With two teeth leaning to the right and two to the left of the
length of blade.
Raker set- Where single tooth alternate but every third tooth is straight.
Wavy set- Where short sections of teeth bend opposite each other.
c) An engineers square is a tool used for checking a workpiece for squareness as well as when
scribing lines which are 90 degree to the edge of a workpiece:
i. Explain how the size of an engineers square is measured. [2]
Stock and length of the blade

ii. Clearly draw and label all parts of an engineers square. [5]

[Total=25marks]
QUESTION 4
a) Briefly expound on the three important elements of a measurement. [6]
Measurand: It is the physical quantity or property like length, angle, diameter, thickness
etc to be measured.
Reference: It is a physical quantity or property to which quantitative comparisons are
made.
Comparator: It means of comparing measurand with some reference

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 b) Interchangeability is the principle normally employed for mass production. Outline the three
types of interchangeability using suitable examples. [9]
i. Full or universal interchangeability- means that any component will mate with any
other mating component without classifying manufactured components in subgroup
or without carrying out any minor alterations for mating purposes
ii. Selective assembly- the components produced by a machine are classified into several
groups according to size. This is done both for hole and shaft and then the
corresponding groups will match properly.
iii. Matched fit- the exact size of a finished part is accurately measured and then the
mating part is made to match with it.

c) With the aid of clearly labeled diagrams, describe the following types of fits;
i. Clearance fit. [3]
ii. Interference fit. [3]
iii. Transition fit. [3]

d) Explain the term Accuracy in reference to a measurement. [1]

The quality or state of being correct or precise or the degree to which the result of a
measurement, calculation, or specification conforms to the correct value or a standard
[Total=25marks]

Page 6 of 9
QUESTION 5

a Draw and label all parts of a twist drill. [10]

b Discuss the purpose of flutes on a twist drill. [4]

To aid head or cutting edge cooling
Dissipate heat
Allowing lubricant to access the drill tip
Remove Swarf
c Identify and explain application of two most common types of drill bit material. [4]
High speed steel (HSS) is a form of tool steel; HSS bits are hard, and much more resistant to
heat than high carbon steel. They can be used to drill metal, hardwood, and most other
materials at greater cutting speeds than carbon steel bits, and have largely replaced carbon
steels.
d Calculate time required for drilling a component as shown in FigQ5c. Assume the cutting
speed as 22m/min and feed as 0.02cm/rev. [7]

Fig Q5c: Drilled Component

Page 7 of 9
[Total=25marks]

QUESTION 6

a) Explain the functions and advantages of using coolant when drilling. [5]

i. Reduce friction and wear, thus improving tool life and the surface finish of the
workpiece.
ii. Cool the cutting zone, thus improving tool life and reducing the temperature and
thermal distortion of the workpiece.
iii. Reduce forces and energy consumption.
iv. Flush away the chips from the cutting zone, thus preventing the chips from interfering
with the cutting process, particularly in operations such as drilling and tapping.
v. Protect the machined surface from environmental corrosion

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b) Calculate the machining time for drilling 4 holes of diameter 16mm each on a flange
from the following data. Flange thickness=30mm; Cutting speed=22meters per minute,
and feed = 0.2mm/rev.
[7]
Solution
cutting speed x 1000
N= [1]
3.14 d
22 x 1000
=438 rpm [2]
3.14 x 16

L 30+(0.3 x 16) 34.8

For one hole T= = = min [2]
Nxf 438 x 0.2 87.6

4 x 34.8
Therefore for 4 holes; T = =1.47 min [2]
87.6

c) Discuss any three work holding devices that can be used to clamp work on a drilling
machine. [6]
Machine vice, clamps and V-Blocks
d) Using a neatly drawn and labeled diagram, show the construction of a bench fitters vice.
[8]

[Total=25marks]

END OF EXAMINATION

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