govt.tool room & training centre semester: … term courses/diploma in... · 4 tdm404...

Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DTDM COURSE Page No: 1

GOVT.TOOL ROOM & TRAINING CENTRE

SEMESTER: FOURTH

Course: DIPLOMA IN TOOL & DIE MAKING

Syllabus -Theory and practical Subjects

SL. NO

CODE SUBJECTS Contact

Hours/Week Contact Hours/Semester

1 TDM401 Production Technology – IV (Grinding)

3 60

2 TDM402 Press Tool Theory-II 3 60

3 TDM403 Mould Theory-I 3 60

4 TDM404 Mechatronics 2 40

5 TDM405 Jigs & Fixtures Design 4 80

Practical

6 TDM406 Work Shop – IV 26.5 530

7 TDM407 CAD Lab - II 3 60

8 TDM408 Material Testing Lab 3 60

Scheme of Examination

Course: DIPLOMA IN TOOL & DIE MAKING

SI. No

Sub. Code

Subjects

Contact Hours

per Week

Exam Scheme of Examination

Total Marks

Min marks

for passin

g

Duration Exam

Internal Assessment

Theory Max Min Max Min

Marks Marks Marks Marks

1 TDM401 Production Technology – IV (Grinding)

3 3 100 50 20 10 120 60

2 TDM402 Press Tool Theory-II 3 3 100 50 20 10 120 60

3 TDM403 Mould Theory-I 3 3 100 50 20 10 120 60

4 TDM404 Mechatronics 2 3 100 50 20 10 120 60

5 TDM405 Jigs & Fixtures Design 4 4 100 50 20 10 120 60

Practical

6 TDM406 Work Shop – IV 26.5 10 900 540 100 60 1000 600

7 TDM407 CAD Lab – II 3 3 100 50 20 10 120 60

8 TDM408 Material Testing Lab 3 3 100 50 20 10 120 60

Total 47.5

1600 890 240 130 1840 1020


PRODUCTION TECHNOLOGY-IV (GRINDING)

SUBJECT CODE: TDM 401

Learning goals for Production Technology-IV

On completion of this subject, the trainees will be able to:

Explain the operations on various types of grinding machines, Tool and Cutter

Grinder and non-conventional machines like Electric discharge machines, Jig

grinding machines etc.

Explain safety precautions to be followed on the above machines

Calculate the various cutting parameters and machining time on the above

machines

Explain the use of appropriate tool and work holding devices, auxiliary attachments

for the above machines

Explain and select proper cutting tools for a particular operation on the above

machines



Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. GRINDING

- Types and part description, specification

- Grinding wheels – abrasives, bonds (silicate, vitrified, shellac), grit, grade, structure and

specification, super abrasives like CBN, Ceramic grinding wheels

- Wheel selection – types of wheels, work material, surface finish, profile, machine type,

coolant

- Wheel shapes – straight, cup, saucer, flange cup, cutting off, dish, tapered, double cup

etc

- Wheel mounting – sound check, preparation of wheel, requirement of flanges, flange

diameter, tightening wheel on flange, cardboard, rubber, compressive washers, safety

precautions

- Wheel balancing – reason for balancing, methods, static and dynamic balancing

- Wheel dressing – purpose of dressing, types of dressers, cooling during dressing, depth

of cut, RPM of wheel, selection of dressers and their speed.

- Use of coolant – purpose, types, filtering of coolants, requirements of a good coolant

- Auxiliary equipment – Magnetic bed, laminated blocks, V block, sine bar, sine table,

demagnetizing unit

- Surface grinding operations – wheel selection, cutting parameters, right angle grinding,

grinding of thin components and edges

- Cylindrical grinding – wheel selection, guidelines for OD, ID and plunge cut grinding

- Profile grinding operations – selection of wheels, radius dressing, tangent dresser, sine

dresser, double sided dresser, optical dresser, pantograph dresser etc

- Cutting speed, rpm, feed, depth of cut, machining time, different units, calculations

and problems

- Safety precautions in grinding

2. JIG GRINDING

- Jig grinding machine and its construction, applications of JG, OD and ID grinding, profile

grinding

- Safety precautions in jig grinding

3. TOOL AND CUTTER GRINDING

- Tool and cutter grinding machine – construction and applications, various spindles,

spindle head, tail stock, OD and ID grinding, spiral grinding

- Safety precautions in tool and cutter grinding



4. ELECTRIC DISCHARGE MACHINING

- Concept of EDM

- Application and principles

- Advantages and disadvantages

- Electrode- metallic and non-metallic materials, requirements of a good electrode

material

- Dielectric fluid – need and their requirements

- Process description, material removal rate, polarity of work and electrode, pulse time

and temperatures, voltage and current during sparking, their effects on the surface

and MRR

- Spark gap and its importance, determination of spark gaps for roughing and finishing

operations, factors on which the spark depends

- General problems and trouble shooting in EDM.

- EDM machine – construction, table, working head, motors, spindle, dielectric tank

- Electrode clamping – fixing with screws, glue, soldering etc

- Flushing – purpose and methods of flushing

- Safety precautions in EDM.

REFERANCE BOOKS:

1. Basic machine shop practice by Tejwani

2. Workshop technology by Chapman

3. Technology of Machine tools by Krar and Oswald

4. Westermann tables

5. All about machine tools by Gerling

6. Production Technology by Hazra Choudhary

7. Production technology by R.K.Jain


WEEKLY PLAN

PRODUCTION TECHNOLOGY-IV(GRINDING)

WEEK NO

CHAPTER TITLE CONTENTS OF TOPICS

General Safety Safety precautions

1-11 GRINDING

Types of grinding machines, part description, specification

Grinding wheels – abrasives, bonds (silicate, vitrified, shellac), grit, grade, structure and specification, Super abrasives like CBN, Ceramic grinding wheels

Wheel selection – Factors that affect the selection of wheel like work material, surface finish, profile, machine type, coolant

Wheel shapes – straight, cup, saucer, flange cup, cutting off, dish,

tapered, double cup etc

Wheel mounting – sound check, preparation of wheel, requirement of flanges, flange diameter, tightening wheel on flange, cardboard, rubber, compressive washers, safety precautions

Wheel balancing – reason for balancing, methods, static and

dynamic balancing

Wheel dressing – purpose of dressing, types of dressers, cooling during dressing, depth of cut, RPM of wheel, selection of dressers and their speed.

Use of coolant – purpose, types, filtering of coolants, requirements

of a good coolant

Auxiliary equipment – Magnetic bed, laminated blocks, V block, sine bar, sine table, demagnetizing unit

Surface grinding operations – wheel selection, cutting parameters, right angle grinding, grinding of thin components and edges

Cylindrical grinding – wheel selection, guidelines for OD, ID and plunge cut grinding

Profile grinding operations – selection of wheels, radius dressing,

tangent dresser, sine dresser, double sided dresser, optical dresser,

pantograph dresser etc

Cutting speed, rpm, feed, depth of cut, machining time, different units, calculations and problems Safety precautions in grinding


WEEKLY PLAN

PRODUCTION TECHNOLOGY-IV(GRINDING)

WEEK NO

CHAPTER TITLE

CONTENTS OF TOPICS

12-14 JIG GRINDING

Jig grinding – principle of operation, construction of machine,

applications

OD and ID grinding Safety precautions in jig grinding

15-17

TOOL AND

CUTTER

GRINDING

Tool and cutter grinding machine – construction and applications,

various spindles, spindle head, tail stock, OD and ID grinding, spiral

grinding

Safety precautions in tool and cutter grinding

17-20 ELECTRIC

DISCHARGE MACHINING

Concept of EDM

Application and principles

Advantages and disadvantages

Electrode- metallic and non-metallic materials, requirements of a

good electrode material

-

-

-

- requirements of a good electrode material

Dielectric fluid – need and their requirements

Process description,

material removal rate, polarity of work and electrode, pulse time and

temperatures, voltage and current during sparking, their effects on

the surface and MRR

Spark gap and its importance, determination of spark gaps for

roughing and finishing operations, factors on which the spark

depends.

General problems and trouble shooting in EDM.

EDM machine – construction, table, working head, motors, spindle,

Dielectric tank

Electrode clamping – fixing with screws, glue, soldering etc

Flushing – purpose and methods of flushing

Safety precautions in EDM.


PRESS TOOL THEORY – II


Learning goals for Press Tool Theory: On completion of this subject, the trainees will be able to:

Explain different types of non-cutting operations

Explain the behaviour of material during deformation

Specifying proper stock materials for non-cutting operations

Understand the significance of fine blanking operation

Select proper materials for punch and die and recommend suitable heat treatment

operations

Understand the importance of a combination tool

Understand the theory of bending and calculate all the required parameters

Understand the theory of drawing and calculate all the required parameters

Understand the application of each element in a bending and drawing tool

Select proper lubricants

Select a proper press machine for a required operation





1. INTRODUCTION TO NON-CUTTING OPERATIONS

- Introduction - Purpose and applications - Advantages - Types of non-cutting operations - Types of non-cutting press tools - Behaviour of material during deformation - Stock material for non-cutting operations

2. FINE BLANKING

- Introduction - Construction - Functions - Operational sequences - Applications and advantages - Press selection for fine blanking

3. PUNCH AND DIE

- Materials for punch and die - Heat treatment of punch and die - Methods of manufacturing punch and die

4. COMBINATION DIE

- Introduction - Construction - Functions - Advantages and disadvantages - Manufacturing methods

5. BENDING

- Theory of bending - Bend elements - Neutral axis and its importance - Blank development calculation - V-bending procedure and force calculation - U-bending theory and force calculation - Calculation of bend allowance - Bending pressure - Spring back - Methods of avoiding spring back in U and V bending - Bending tool – constructional features - Defects and remedies of bent component and bending tool


PRESS TOOL THEORY - II

6. LUBRICATION

- Purpose of lubricants - Types of lubricants

7. FORMING OPERATIONS

- Introduction - Theory of forming - Types of forming dies - Purpose and application

8. DRAWING

- Introduction - Metal flow during drawing - Calculations – flat blank diameter, draw reductions, number of draws required, draw force - Variables that affect metal flow during drawing - Types of draw dies

9. PRESS MACHINE

- Introduction - Specification - Classification - Types of presses - Power source - Attachments for presses - Selection of a press - Feeding system – purpose, types, advantages

REFERENCE BOOKS:

1. Tool and die maker by Mahajan

2. Design fundamentals by Pacquin

3. Tool design by Donaldson

4. Basic die design by Osterguard

5. Advanced die design by Osterguard

6. Fundamentals of Tool Design By SME

7. Press Tools and Press Work By Waller


WEEKLY PLAN FOR


WEEK NO


1-2 INTRODUCTION TO NON-CUTTING OPERATIONS

Introduction Purpose and applications Advantages Types of non-cutting operations

Types of non-cutting press tools Behaviour of material during deformation Stock material for non-cutting operations

3-4

FINE BLANKING

Introduction Construction Functions

Operational sequences Applications and advantages Press selection for fine blanking

5-6 PUNCH AND

DIE

Materials for punch and die Heat treatment of punch and die Methods of manufacturing punch and die

7-8 COMBINATION

DIE

Introduction Construction Functions Advantages and disadvantages Manufacturing methods

9-11 BENDING

Theory of bending Bend elements Neutral axis and its importance Blank development calculation V-bending procedure and force calculation

U-bending theory and force calculation

Calculation of bend allowance

Bending pressure

Spring back

Methods of avoiding spring back in U and V bending

Bending tool – constructional features

Defects and remedies of bent component and bending tool

12 LUBRICATION

Purpose of lubricants Types of lubricants

13-14 FORMING

OPERATIONS

Introduction Theory of forming

Types of forming dies Purpose and application

15-16 DRAWING Introduction Metal flow during drawing


WEEKLY PLAN FOR


WEEK NO


17 DRAWING

Calculations – flat blank diameter, draw reductions, number of draws required, draw force Variables that affect metal flow during drawing Types of draw dies 18-20

PRESS MACHINE

Introduction Specification Classification Types of presses Power source

Attachments for presses Selection of a press Feeding system – purpose, types, advantages


MOULD THEORY-I


Learning goals for Mould Theory-I


Define mould and moulding and various types of moulds.

Explain Thermo plastic moulding methods and thermosest moulding methods.

Define Injection moulding.

Explain about Blow moulding, working process and their Importance.

Define Extrusion moulding and working method.

Explain about Rotational moulding and working concept.

Define Thermo forming, Importance and working process.

Explain about calendaring and working concept.

Define compression mould and explain working process and construction.

Explain in brief about Types of compression mould.

Define bulk factor, Shrinkage allowance, flash thickness allowance.

Calculations on Loading well Height.

Explain the factors that influencing on compression moulding.

Explain the Importance of Heating in compression moulding and Heaters.

Explain the Defects and Remedies of compression mould.

Define Transfer mould and List out their advantages and disadvantages.

Explain types of Transfer mould, pot and plunger type.

Explain transfer moulding cycle.

Calculations on transfer pot (Design Data)


MOULD THEORY-I



1. INTRODUCTION

- Definition of mould

2. TYPES

-Thermoplastic moulding methods - Injection moulding - Blow moulding - Extrusion moulding - Thermo forming - Rotational moulding - Calendaring

Thermo set moulding methods - Compression moulding - Transfer moulding

3. INJECTION MOULD

- Introduction

4. BLOW MOULDING

- Definition - Construction - Working process - Importance and examples

5. EXTRUSION MOULDING


6. ROTATIONAL MOULDING


7. THERMOFORMING



MOULD THEORY-I

8. CALENDARING


9. COMPRESSION MOULD

- Introduction - construction - working process - Types - Hand mould - Semi Automatic mould - Fully Automatic mould - Split Cavity mould - Gang mould - Calculation of mould cavity Dimension - Bulk factor - Shrinkage Allowance - Flash Thickness Allowance - Calculation on loading well Height - Factors Influencing on compression mould - Temperature - Pressure - Curing time - Venting - Heating of compression mould - Importance - Types of Heaters - Pre heating - Defects and Remedies

10. TRANSFER MOULD

- Introduction - Advantages and Disadvantages - Types - Pot - Plunger - Transfer moulding cycle - Transfer pot calculation(Design Data)


WEEKLY PLAN FOR

MOULD THEORY-I

WEEK NO


1-2

Introduction

Definition, General concepts of mould and moulding, Plastic components Importance

Types Thermoplastic moulding methods

Thermo set moulding methods

3-4

Injection mould and

Blow moulding

Definition

Construction

Working process

Importance and examples

5-6

Extrusion moulding and

Rotational moulding

Definition

Construction

Working process


7

Thermoforming

Definition

Construction

Working process


8-9

Calendaring

Definition

Construction

Working process


10

Compression mould

Introduction

Construction

working process

Types

11-12

13

Hand mould

Semi Automatic mould

Fully Automatic mould

Split Cavity mould

13 Gang mould


WEEKLY PLAN FOR

MOULD THEORY-I

WEEK NO


14-17

Compression mould

Calculation of mould cavity Dimension

Bulk factor

Shrinkage Allowance

Flash Thickness Allowance

Calculation on loading well Height

Factors Influencing on compression mould

Temperature

Pressure

Curing time

Venting

Heating of compression mould

Importance

Types of Heaters

Pre heating

Defects and Remedies

18-20

Transfer mould

Introduction

Advantages and Disadvantages

Types

Pot

Plunger

Transfer moulding cycle

Transfer pot calculation(Design Data)


MECHATRONICS



Learning goals for MECHATRONICS


Scope of Mechatronics

Sensors & Transducers

Electrical actuation systems

Microprocessor systems and its applications

Advanced Manufacturing systems

Programmable Logic Controllers

Overview of robots


MECHATRONICS



SPECIFIC INSTRUCTIONAL OBJECTIVES

1. INTRODUCTION

- What is Mechatronics?

- Scope of Mechatronics

- Key Issues

- Systems

- Measurement systems

- Control Systems

- Microprocessor based controller

- Response of a system

- Mechatronics approach

2. SENSORS & TRANSDUCERS

- Sensors & Transducers

- Performance terminology

- Displacement, position, & Proximity

- Velocity and motion

- Force

- Fluid pressure

- Liquid flow

- Liquid levels

- Light sensors

- Selection of sensors

- Data i/p using switches

3. ELECTRICAL ACTUATION SYSTEMS

- Electrical systems: Relays

- Solid state switches

- Solenoid

4. MICROPROCESSORS - Control

- Microprocessor systems

- Microcontrollers

- Applications

- Programming


MECHATRONICS

5. INTRODUCTION TO MODERN CNC MACHINE & MANUFACTURING

SYSTEMS - Introduction

- Advantages of CNC Machines

- CNC Machining centre developments

- Turning centre developments

- Tool monitoring on CNC Machines

- Other CNC developments

- Advanced Manufacturing systems

- Benefits of FMS

- Trends in adoption of FMS

6. PROGRAMMABLE LOGIC CONTROLLERS - Programmable Logic Controllers

- Basic structures

- I/O Processing

- Programming

7. Robots & Other Motion Control Systems - Overview of robots

- Types of robots

- Types of robot controls

- Types of robot programs

- Basic parts of robot systems

- Other types of robot actuators

- I/O signals for robots

- I/O circuits for robot signals

- I/O modules

- Robots in typical work and manufacturing cells

Text Books

1. MECHATRONICS, Bolton, Pearson Publication [LPE]

2. MECHATRONICS, HMT Ltd., TMH Publication

3. Industrial Electronics, Kissel


WEEKLY PLAN FOR

MECHATRONICS

WEEK NO


1-2 INTRODUCTION

What is Mechatronics? Scope of Mechatronics Key Issues Systems Measurement systems Control Systems Microprocessor based controller Response of a system Mechatronics approach

3-6 SENSORS &

TRANSDUCERS

Sensors & Transducers Performance terminology Displacement, position, & Proximity

Velocity and motion Force Fluid Pressure Liquid flow Liquid levels Light sensors Selection of sensors

Data i/p using switches

7-8

ELECTRICAL

ACTUATION

SYSTEMS

Electrical systems: Relays Solid state switches Solenoid

10-11 MICROPROCESSORS

Control Microprocessor systems Microcontrollers Applications Programming

12-14

INTRODUCTION TO

MODERN CNC

MACHINE &

MANUFACTURING

SYSTEMS

Introduction Advantages of CNC Machines CNC Machining centre developments

Turning centre developments Tool monitoring on CNC Machine Other CNC developments Advanced Manufacturing systems Benefits of FMS Trends in adoption of FMS

15-16

PROGRAMMABLE

LOGIC

CONTROLLERS

Programmable Logic Controllers Basic structures I/O Processing Programming


WEEKLY PLAN FOR

MECHATRONICS

WEEK NO


17-20

ROBOTS & OTHER

MOTION CONTROL

SYSTEMS

Overview of robots Types of robots

Types of robot controls Types of robot programs

Basic parts of robot systems Other types of robot actuators

I/O signals for robots I/O circuits for robot signals

cel I/O modules Robots in typical work and manufacturing cells


JIGS & FIXTURE DESIGN




1. Design of locating elements

2. Design of Tool guiding devices like Drill Bushes for different types of jigs (fixed, Renewable and slip renewable bushes

3. Design of Drill Jigs (min 4 types

a) Plate/template jig b) Angle plate jig c) Box Jig d) Leaf Jig e) Indexing jig

4. Design of Clamps

5. Milling Fixture (different types for horizontal & vertical milling)

6. Turning fixture,

7. Welding fixtures, (for Laser and Arc welding)

8. Grinding fixture (2 types for surface grinding)

9. Broaching fixture.

REFERENCE BOOKS:

1. Introduction to jig and Tool Design - M H A KEMPSTER 2. Jigs and fixtures – T M H GRANT 3. Hand Book of Fixture Design – FRANK W WILSON 4. Jigs and Fixture and gauges for Limited Production 5. Hand Book of Jigs & Fixture Design - BOYES 6. Jigs and fixture – JOSHI.


WEEKLY PLAN FOR

JIGS & FIXTURE DESIGN

WEEK NO CHAPTER TITLE CONTENTS OF TOPICS

1-2 Design of locating

elements

Various Types of locating elements

3-4 Design of Tool

guiding devices

like Drill Bushes for different types of jigs (fixed, Renewable and slip renewable bushes

5-10 Design of Drill Jigs

(min 4 types)

Plate/template jig

Angle plate jig

Box Jig

Leaf Jig

Indexing jig

11-12 Design of Clamps Various Types of Clamps

13-15 Milling Fixture

Different types for horizontal & vertical milling

16-17 Turning fixture Various Types of Turning fixture

18 Welding fixtures For Laser and Arc welding

19 Grinding fixture 2 types for surface grinding

20 Broaching fixture. Various Types of Broaching fixture.

govt.tool room & training centre semester: … term courses/diploma in... · 4 tdm404...

Documents