POLITEKNIK UNGKU OMAR

DEPARTMENT OF MECHANICAL ENGINEERING

SESSION JUN 2013
TEST 1 JJ104 WORKSYOP TECHNOLOGY 1
NAME : ......................................................................................................................................
REGISTRATION NUMBER : .................................................................................................
ANSWER ALL QUESTION
1. State FIVE(5) safety precautions while in workshop.

(5 marks)

2.List down FOUR (4) system how the drill sizes are determine

(4 marks)

3. State the THREE (3) functions flute of twist drill.

(3 marks)

4.Sketch and label FIVE (5) parts of a twist drill bit.

(7 marks)

5.Sketch and explain the functions of drill bit below:i.

ii.
iii.

Countersink
Counterbores
Center drill

(9 marks)

6.Calculate the RPM for the drilling a 20 mm thickness of a brass. The cutting speed for brass
is given as 50 m/mm.

(3 marks)

7.State the purpose of universal milling machine parts below:i.

ii.

Column
Spindle
(4 Marks)

8. Explain briefly about the direct indexing head.

(3 marks)

9. Sketch and explain the used of the milling cutter below:

i.
ii.
iii.

End Mills
Plain milling cutter
Face miling cutter

SKEMA JAWAPAN

(12 marks)

ANSWER 1
1. Always wear SAFETY GLASSES in the shop.
2. Do not set up or operate any machinery unless an instructor is in the shop.
3. Do not operate any machine unless authorized to do so by an instructor or under an
instructor's supervision.
4. Use the proper tool for the job. Many cuts in the shop occur because a wrench slips
and a hand hits a sharp cutting tool.
5. Check tools before use to assure they are safe to use.
6. Do not leave tools or work on the table of a machine even if the machine is not
running. Tools or work may fall off and cause a toe or foot injury.
7. Put tools away when not in use.
8. Place all scrap pieces in the correct containers.
9. Never handle chips with your hands or fingers. Chips are extremely sharp and can
easily cause cuts.
10. Use a brush to remove chips -- not hands, fingers, or rags.

ANSWER 2
i.
ii.
iii.
iv.

Metrik system-0.4mm dia. to 50mm dia

Fractional-1/64 to 3 1/4 dia. in 1/64 steps
Number-#1 = 0.228 dia. to #80 = 0.0135 dia.
Letter-A = 0.234 dia. to Z = 0.413 dia.
( 1 marks x 4 )

ANSWER 3
1). They allow chip to escape
2). They admit cutting fluid
3). They form cutting edge
( 1 marks x 3 )

ANSWER 4

ANSWER 5

i.

( 2 marks )
Countersink
are special angled cutters used to countersink holes for flathead screws
so they are flush with the surface when mounted.
( 1 marks )

( 2 marks )
ii.

Counterbores
are special cutters that use a pilot to guide the cutting action to enlarge
a portion of a hole. Common uses are for enlarging a hole to make a
bolt head fit flush with the surface.
( 1 marks )

( 2 marks )
iii.

Center drill

is used to start holes accurately. These tools are mainly used to

center drill and countersink the end of round stock in a lathe
machine.
( 1 marks )

ANSWER 6
RPM

Cutting Speed(CS)
xD

x 1000............................... ( marks )

50 x 1000 ...............................( marks )

x 20

50000 .........................................( 1 marks )

62.84

795

...........................................( 1 marks )

ANSWER 7
i. Column
The column houses the spindle, the bearings, the gear box, the clutches, the shafts, the
pumps, and the shifting mechanisms for transmitting power from the electric motor
to the spindle at a selected speed.
( 2 marks )
ii. Saddle
The saddle consists of two slide ways, one on the top and one at the bottom located
at 90 to each other, for providing motions in the X or Y axes by means of lead
screws andAllows translation of the worktable.
( 2 marks)

ANSWER 8

Whittleis the process ofremoving or even metal or material fromthe work piece to create a
feed to the rotary milling cutter.
workcan be donein themillingmachineiswhittleflat,angularface, drill, bore, cuta helical
groove,andspecialwork
ANSWER 9
1. End Mills
( 2 marks )
-The face and sides at the bottom end of this tool are used for
plunge cutting (two flutes) and side and end cuts (four flute).
( 2 marks )
2. Plain milling cutter

( 2 marks )
- These mills are used to cut with the sides only. They are
generally mounted on an
( 2 marks )
3. Face milling cutter

( 2 marks )
- Used as combination cutter for roughing and finishing cut in
one pass
( 2 marks )