POLITEKNIK UNGKU OMAR

DEPARTMENT OF MECHANICAL ENGINEERING

SESSION JUNE 2013
TEST 2
JJ104-WORKSHOP TECHNOLOGY 1
ANSWER ALL QUESTIONS
QUESTIONS 1(GRINDING MACHINE)
1. State FOUR (4) types of grinding wheels.[CLO3]
(4marks)
2. Name TWO (2) types of bonds and state the purpose of each type in the manufacturing
of grinding wheel.[CLO3]
(6marks)
3. State The definition component of grinding wheel below:[CLO3]
i.
Grade
ii.
structure
(4marks)
QUESTIONS 2 (OXY ACETYLENE WELDING)
1. Define:
i. Gas welding [CLO3]
ii. Low Pressure Gas Welding [CLO3]
iii. High Pressure Gas Welding [CLO3]
(6marks)
2. Sketch and label the oxy acetylene welding equipment. [CLO3]
(12marks)
3. State and sketch THREE (3) types of oxy-acetylene flame normally used in gas welding.
[CLO3]
(6marks)
QUESTIONS 3 (ARC WELDING)
1.

Explain TWO(2) methods to start an arc in arc welding process. [CLO3]

(4marks)

2. Describe the specifications of the arc welding electrodes below. [CLO3]

E 6013

(4marks)
3. Explain the factors below which affect the welding result. [CLO3]
i. Arc distance.
ii. Arc angle.
iii. Arc speed.
(6marks)

ANSWER AND SCHEME QUESTION 1

1. State FOUR (4) types of grinding wheels.
1) Straight
2) Cylindrical
3) Tapered

1) Diamond
2) Half side

( 1marks x4)

2. Name TWO (2) types of bonds and state the purpose of each type in the manufacture of
grinding wheel.
i. Vitrified

is used for rapid removal of metal and may be used in all types of grinding
operations

ii. Resinoid

- for cool cutting, snagging, rough grinding and remove stock rapidly

iii. Rubber bond- produce high finishes and for thin cutoff wheels due to its strength and
flexibility
iv, Shellac bond- is used for producing high finishes on parts such as cutlery and paper-mill rolls
v. Silicate

- is used when it is necessary to keep heat generation to a minimum

vi. Metal bonds- are used on diamond wheels and for electrolytic grinding operations where the
current must pass through the wheel
Minimum 2, type of bonds: 1 marks, purpose: 2 marks
(3marksx2)
3.State The definition component of grinding wheel below:
i.
ii.

Grade
structure

i.

ii.

Grade
- The degree of strength with which the bond holds the abrasive particles in the
bond setting
(2marks)
Structure
- Is the space relationship of the grain and bonding material to the avoid that
separate them.
(2marks)

ANSWER AND SCHEME QUESTION 2

1. Define:
i.

Gas welding
Metal joining process in which the ends of pieces to be joined are heated at their
interface by producing coalescence with one or more gas flames (such as oxygen
and acetylene), with or without the use of a filler metal.

ii.

Low Pressure Gas Welding

Low pressure gas welding received oxy acetylene supply with pressure less than
1.0 psi or 1.0 bar

iii.

High Pressure Gas Welding

High pressure gas welding received oxy acetylene supply with pressure in range
of 1-15 psi or 1 15 bar
(2 marks x3)

2.Sketch briefly and label oxy acetylene welding station system

(sketch; 4marks, label;1marks x 8)

3. State and sketch THREE (3) type of oxy-acetylene flame normally use in gas welding
i. Neutral flame

ii. Carburizing flame

iii. Oxidizing flame

(3x2
marks)
ANSWER AND SCHEME QUESTION 3
1.Explain TWO(2) methods to start an arc in arc welding process
i. Tapping Motion
The tapping-motion method is which the electrode is brought straight down on the plate and
instantly withdrawn a of 3-5 mm, this distance being equal to the core diameter of the
electrode.
ii. Scratching Method
The scratching method is which the electrode tilted at an angle and is then given a slight
circular movement similar to that of striking a match. As in the previous method the
electrode should keep a distance equal to its diameter, otherwise it will stick to the plate. If
the electrode does stick the holder should be given a sharp twist; failing this the electrode
should be released from holder, or the electric current should be switched off.
(2marksx2)

2.Describe the specifications of the arc welding electrodes below.

E 6013
Electrode specification for E6013
E

electrode for arc welding

60

tensile strength 60.000 psi.

positioning welding (all position)

types of electric current

(1marks x 4)

3.Explain the factors below which affect the welding result

i. Arc distance
-

Distance between workpiece surface and end of electrode

ii. Welding angle

-

Electrode inclination angle with workpiece surface

iii. Arc speed

-

Rate of the electrode movement during welding process.

(2 marks x 3)