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Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 1
GOVT.TOOL ROOM & TRAINING CENTRE
SEMESTER: FOURTH
Course: DIPLOMA IN PRECISION MANUFACTURING
Syllabus -Theory and practical Subjects
SL. NO
CODE SUBJECTS Contact
Hours/Week Contact Hours/Semester
1 DPM401 Production Technology – IV (Grinding)
3 60
2 DPM402 Fluid Mechanics 3 60
3 DPM403 CNC Technology 2 40
4 DPM404 Mechatronics 2 40
5 DPM405 Manufacturing Process 2 40
6 DPM406 Jigs & Fixture Design 4 80
Practical
7 DPM407 Work Shop – IV 28.5 570
8 DPM408 CAD Lab - II 3 60
Scheme of Examination
Course: DIPLOMA IN PRECISION MANUFACTURING
SI. No
Sub. Code
Subjects Contact Hours
per Week
Exam. Duration
Scheme of Examination
Total Marks
Min marks
for passing
Exam Internal
Assessment
Theory Max Min Max Min
Marks Marks Marks Marks
1 DPM401 Production Technology – IV (Grinding)
3 3 100 50 20 10 120 60
2 DPM402 Fluid Mechanics 3 3 100 50 20 10 120 60
3 DPM403 CNC Technology 2 3 100 50 20 10 120 60
4 DPM404 Mechatronics 2 3 100 50 20 10 120 60
5 DPM405 Manufacturing Process
2 3 100 50 20 10 120 60
6 DPM406 Jigs & Fixture Design
4 4 100 50 20 10 120 60
Practical
7 DPM407 Work Shop – IV 28.5 10 900 540 100 60 1000 600
8 DPM408 CAD Lab - II 3 3 100 50 20 10 120 60
Total 47.5
1600 890 240 130 1840 1020
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 2
PRODUCTION TECHNOLOGY-IV (GRINDING)
SUBJECT CODE: DPM 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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 3
PRODUCTION TECHNOLOGY-IV (GRINDING)
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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 4
PRODUCTION TECHNOLOGY-IV (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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 5
WEEKLY PLAN FOR
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
12-14 JIG GRINDING
Jig grinding – principle of operation, construction of machine,
applications
OD and ID grinding Safety precautions in jig grinding
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 6
WEEKLY PLAN FOR
PRODUCTION TECHNOLOGY-IV(GRINDING)
WEEK NO
CHAPTER TITLE CONTENTS OF TOPICS
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.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 7
FLUID MECHANICS
SUBJECT CODE: DPM 402
Learning goals for FLUID MECHANICS
On completion of this subject, the trainees will be able to:
Understand the basic of fluid mechanics.
Understand the basic principles of fluid statics.
Understand the basic principle of fluid kinematics.
Understand the principles of fluid dynamics and its applications.
Understand the principles of fluid flow through pipes.
Understand the working of hydraulic turbines.
Understand the working of Centrifugal Pumps.
Understand the working of Reciprocating pumps & special purpose pumps.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 8
FLUID MECHANICS
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. UNDERSTAND THE BASIC OF FLUID MECHANICS
- Explain scope of the subject. - Define fluid. - Classify fluid. - Define fluid mechanics. - Classify fluid mechanics. - Define statics, kinematics and dynamics. - Mention various properties of fluids. - Define density, specific volume, specific gravity and solve simple problems. - Define viscosity, dynamic viscosity, kinematics viscosity and their units. - Define surface tension, capillarity, compressibility, bulk modulus and their units. - Define fluid pressure and its units. - Explain the difference between absolute pressure, atmospheric pressure, and gauge.
Pressure and vacuum pressure. - Explain pressure head of a liquid. - State Pascal’s law. - Classify pressure measuring instruments. - Explain simple and differential manometers with sketches and state their advantages
and limitations. - Explain the construction and working principle of Bourdon tube and diaphragm
gauges. - Explain briefly vacuum gauges and mention their types.
2. UNDERSTAND THE BASIC PRINCIPLES OF FLUID STATICS
- Define total pressure, centre of pressure, buoyancy, metacentre and metacentric height.
- State Archimedes principle of buoyancy. - State types of equilibrium of floating bodies and explain stable, unstable and neutral
equilibrium.
3. UNDERSTAND THE BASIC PRINCIPLE OF FLUID KINEMATICS
- Importance of fluid flow and types of fluid flow.
- Define steady flow and unsteady flow.
- Define uniform flow and non- uniform flow.
- Define rotational and irrotational flow.
- Define compressible and incompressible flows.
- Define rate of flow or discharge.
- State law of continuity and explain continuity equation.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 9
FLUID MECHANICS
4. UNDERSTAND THE PRINCIPLES OF FLUID DYNAMICS AND ITS APPLICATIONS
- Mention and explain potential energy, kinetic energy, pressure energy and total head and its importance.
- State Bernoulli’s theorem. - Explain Bernoulli’s equation (without proof) - State the assumptions made in Bernoulli’s theorem. - Solve simple problems on Bernoulli’s theorem. - Mention the practical applications of Bernoulli’s theorem. - Explain horizontal Venturimeter, flow nozzle, orifice meter and Pitot’s tube with
expressions for discharge. - Solve simple problems on the above.
5. Understand the principles of fluid flow through pipes
- Define loss of head in pipes due to friction. - Mention major energy losses and minor energy losses. - State the Darcy- Weisbach’s formula (without derivation) - State the Chezy’s formula (without derivation) - Explain Hydraulic gradient and total energy lines. - Explain principle of working of 9siphon system. - Explain nozzles and its applications. - State the condition for maximum transmission of power in nozzles (without proof) - Explain the maximum efficiency of transmission of power through nozzle. - Explain water hammer in pipes.
6. UNDERSTAND THE WORKING OF HYDRAULIC TURBINES
- Explain the scope of hydraulic turbines. - Define hydraulic turbines. - Classify hydraulic turbines. - Explain working principle of impulse turbine. - Describe the construction and explain the working principle of pelton wheel. - State the formulae for work done and efficiency Pf pelton wheel. - State the different types head. - Define gross head and state its formula. - Define net or effective head and state its formula. - State the different types of efficiencies of peloton wheel. - Define hydraulic, mechanical, volumetric and overall efficiencies and mention their
formulae and solve simple problems. - Explain the principle of reaction turbines. - Describe the construction and working of Francis turbine. - Define and state formulae for Work done and efficiency of Francis turbine (without
derivation)
- Explain penstock, Anchor block, surge tank and draft tube. - Define Unit power, unit speed and unit discharge- Specific speed and mention their
significance. - Explain the following –Performance Characteristics of turbines-main or constant head,
operating or constant speed, constant efficiency or Iso efficiency or Muschel curves - Explain criteria for Selection of turbines – viz, based on specific speed and head of
water. - Compare impulse and reaction turbines.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 10
FLUID MECHANICS
7. UNDERSTAND THE WORKING OF CENTRIFUGAL PUMPS
- Definitions- pumps and centrifugal Pumps. - Explain Scope of pumps. - Classify pumps. - Explain the Principle of operation and constructional details of a centrifugal pump. - Define Work done by a centrifugal pump and state the formula without proof. - State the various Heads of centrifugal pumps. - Explain the Efficiency, Discharge and Power required in a centrifugal pump with
formulae. - Explain Priming of centrifugal pump. - Explain cavitations and its effects in centrifugal pump. - Explain the criteria for Selection of pumps.
- Explain the operational difficulties in centrifugal pumps.
8. UNDERSTAND THE WORKING OF RECIPROCATING PUMPS
- Definition of Reciprocating pumps and its applications. - Classify reciprocating pumps. - Explain the Principle of operation, Constructional details and working reciprocating
pumps. - Derive on expression for discharge, work done and Power required to drive a
reciprocating pump. - Differentiate between centrifugal and reciprocating pumps. - Special purpose pumps-Construction, working and uses of submersible pump, Jet
pump, Air lift pump.
Text Books: 1. Fluid Mechanics and Machinery by R K Hegde & Neeranjan Murthy, Sapna
Publishers.
BOOKS FOR REFERENCE
1) Fluid Mechanics and Machinery-BCS Rao-2nd Edn.-Tata McGraw Hill Publ., 2010.
2) Fluid Mechanics and Hydraulic Machines-R.K.Bansal-Laxmi Publications (P) Ltd., New Delhi,
2003.
3) Fluid Mechanics and Hydraulic Machines-R.K.Rajput-S.Chand and Co., 4th Revised Edn. 2010.
4) Fluid Mechanics and Hydraulic Machines-R.S.Khurmi- S.Chand and Co, 19th Edn, 2010.
5) Hydraulic Engg – Roberson Cassidy & Choudhary, Jaico Publishing House.
6) Engineering Fluid Mechanics – T. Al-Shemmeri.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 11
WEEKLY PLAN FOR
FLUID MECHANICS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
1-2 UNDERSTAND THE BASIC OF FLUID
MECHANICS
Explain scope of the subject Define fluid Classify fluid Define fluid mechanics Classify fluid mechanics Define statics, kinematics and dynamics Mention various properties of fluids Define density, specific volume, specific gravity and solve simple Problems. Define viscosity, dynamic viscosity, kinematics viscosity and their units Define surface tension, capillarity, compressibility, bulk modulus and their units
3-4
UNDERSTAND THE BASIC OF FLUID MECHANICS
Define fluid pressure and its units Explain the difference between absolute pressure, atmospheric pressure, gauge pressure and vacuum pressure Explain pressure head of a liquid State Pascal’s law Classify pressure measuring instruments Explain simple and differential manometers with sketches and state their advantages and limitations Explain the construction and working principle of Bourdon tube and diaphragm gauges Explain briefly vacuum gauges and mention their types
5-6 UNDERSTAND THE BASIC
PRINCIPLES OF FLUID STATICS
Define total pressure, centre of pressure, buoyancy, metacentre and metacentric height State Archimedes principle of buoyancy State types of equilibrium of floating bodies and explain stable, unstable and neutral equilibrium
7-8 UNDERSTAND THE BASIC
PRINCIPLE OF FLUID KINEMATICS
Define rotational and irrotational flow Define compressible and incompressible flows Define rate of flow or discharge State law of continuity and explain continuity equation
8-10 UNDERSTAND THE PRINCIPLES
OF FLUID DYNAMICS AND ITS APPLICATIONS
Mention and explain potential energy, kinetic energy, pressure energy and Total head and its importance. State Bernoulli’s theorem Explain Bernoulli’s equation (without proof) State the assumptions made in Bernoulli’s theorem
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 12
WEEKLY PLAN FOR
FLUID MECHANICS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
11-12 UNDERSTAND THE PRINCIPLES OF FLUID DYNAMICS AND ITS
APPLICATIONS
Solve simple problems on Bernoulli’s theorem Mention the practical applications of Bernoulli’s theorem Explain horizontal Venturimeter, flow nozzle, orifice meter and Pitot’s tube with expressions for discharge Solve simple problems on the above
13-15
UNDERSTAND THE PRINCIPLES OF FLUID FLOW THROUGH PIPES
Define loss of head in pipes due to friction Mention major energy losses and minor energy losses State the Darcy- Weisbach’s formula (without derivation) State the Chezy’s formula (without derivation) Explain Hydraulic gradient and total energy lines
Explain principle of working of syphon system Explain nozzles and its applications State the condition for maximum transmission of power in nozzles (without proof) Explain the maximum efficiency of transmission of power through nozzle Explain water hammer in pipes
16-18
UNDERSTAND THE WORKING OF
HYDRAULIC TURBINES
Explain the scope of hydraulic turbines Define hydraulic turbines Classify hydraulic turbines Explain working principle of impulse turbine Describe the construction and explain the working principle of peloton wheel State the formulae for work done and efficiency pf peloton wheel State the different types head
Define gross head and state its formula Define net or effective head and state its formula State the different types of efficiencies of peloton wheel Define hydraulic, mechanical, volumetric and overall efficiencies and mention their formulae and solve simple problems Explain the principle of reaction turbines
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 13
WEEKLY PLAN
FLUID MECHANICS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
19 UNDERSTAND THE
WORKING OF HYDRAULIC TURBINES
Describe the construction and working of Francis turbine Define and state formulae for Work done and efficiency of Francis turbine (without derivation) Explain penstock, Anchor block, surge tank and draft tube Define Unit power, unit speed and unit discharge- Specific speed and mention their significance Explain the following –Performance Characteristics of turbines main or constant head, operating or constant speed, constant efficiency or ISO efficiency or Muschel curves Explain criteria for Selection of turbines – viz, based on specific speed and head of Water. Compare impulse and reaction turbines
20-21 UNDERSTAND THE WORKING
OF CENTRIFUGAL PUMPS
Definitions- pumps and centrifugal Pumps Explain Scope of pumps Classify pumps Explain the Principle of operation and constructional details of a Centrifugal pump Define Work done by a centrifugal pump and state the formula without proof State the various Heads of centrifugal pumps
Explain the Efficiency, Discharge and Power required in a Centrifugal pump with formulae. Explain Priming of centrifugal pump. Explain cavitations and its effects in centrifugal pump Explain the criteria for Selection of pumps Explain the operational difficulties in centrifugal pumps
22 UNDERSTAND THE WORKING OF RECIPROCATING PUMPS
Definition of Reciprocating pumps and its applications Classify reciprocating pumps Explain the Principle of operation, Constructional details and working reciprocating pumps Derive on expression for discharge, work done and Power required to drive a reciprocating pump Differentiate between centrifugal and reciprocating pumps Special purpose pumps-Construction, working and uses of submersible pump, Jet pump, Air lift pump
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 14
CNC TECHNOLOGY
SUBJECT CODE: DPM 403
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES
1.0 Introduction to CNC
- Definition of CNC
- Function of CNC
- Comparison between NC and CNC
- Direct numerical control
- Advantages of CNC
- Disadvantages of CNC
- Application of CNC
- Parts suitable for CNC Machines
2.0 Components of numerical control system
- Introduction
- Basic components of numerical control system
- Functions of machine control unit (MCU)
- Programming Instruction
- NC Coding
- Machine Tool
3.0 Classification of numerical control machine
- Introduction
- Classifications Based on feedback control
- Open loop control
- Closed loop control
- Classification based on control system features
- Point to Point control system
- Straight line control system
- Contouring control system
- Classification based on coordinate systems
- Cartesian coordinate system
- Cylindrical coordinate system
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 15
CNC TECHNOLOGY
4.0 Tooling for CNC Machines
- Introduction
- Cutting Tools
- Index able inserts
- Tool holders
- Work holding devices in CNC
5.0 Tool changing and Pallet changing
- Tool changes
- Automatic tool changers
- Tool storage
- Tool length
- Tool length offset
- Automatic Pallet changers
6.0 Part Programming for Turning
- Introduction
- Programming coordinates
- Mixing Absolute and Incremental Positioning
- Metric coordinates
- Two axis programming
- Turning Programs
- Step turning Programs
- Taper turning Programs
- Knurling and Program
- Canned programs
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 16
CNC TECHNOLOGY
7.0 Part Programming for Milling
- Two axis programming
- Rectangular milling Programs
- Circular milling Programs
- Contour milling Programs
- Drilling examples-Incremental Positioning
- Milling examples-Absolute Positioning
- Milling examples-Incremental Positioning
- Linear and circular interpolation
- Cutter diameter compensation
- Tool offset and sub programs
- Canned Programs
REFERENCE BOOKS
1. CNC Machine – B S Pabla, M Adithan
2. Computer numerical control concepts & programming 4th Edition – Warren S. Seames
3. Programming of CNC Machines – Ken Evans
4. CNC Machines – K Adinarayana
5. Computer numerical control machines – P Radhakrishnan
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 17
WEEKLY PLAN FOR
CNC TECHNOLOGY
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
1-3 Introduction to CNC
- Definition of CNC - Function of CNC - Comparison between NC and CNC - Direct numerical control - Advantages of CNC - Disadvantages of CNC - Application of CNC - Parts suitable for CNC Machines
4-7
Components of numerical control system
- Introduction - Basic components of numerical
control system - Functions of machine control unit
(MCU) - Programming Instruction - NC Coding - Machine Tool
8-11
Classification of numerical control machine
- Introduction - classifications Based on feedback control - Open loop control - Closed loop control - Classification based on control system
features - Point to Point control system - Straight line control system - Contouring control - Classification based on coordinate
systems - Cartesian coordinate system - Cylindrical coordinate system
12-14 Tooling for CNC Machines
- Introduction - Cutting Tools - Index able inserts - Tool holders - Work holding devices in CNC
15-16 Tool changing and Pallet changing
- Tool changes - Automatic tool changers - Tool storage - Tool length - Tool length offset - Automatic Pallet changers
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 18
WEEKLY PLAN FOR
CNC TECHNOLOGY
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
17-18 Part Programming for Turning
- Introduction - Programming coordinates - Mixing Absolute and Incremental
Positioning - Metric coordinates - Two axis programming - Turning Programs - Step turning Programs - Taper turning Programs - knurling and Program - Canned programs
19-20 Part Programming for Milling
- Programming for Milling - Two axis programming - Rectangular milling Programs - Circular milling Programs - Contour milling Programs - Drilling examples- Incremental
Positioning - Milling examples-Absolute Positioning - Milling examples-Incremental
Positioning - Linear and circular interpolation - Cutter diameter compensation - Tool offset and sub programs - Canned Programs
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 19
MECHATRONICS
SUBJECT CODE: TDM 404
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
Learning goals for MECHATRONICS
On completion of this subject, the trainees will be able to:
Scope of Mechatronics
Sensors & Transducers
Electrical actuation systems
Microprocessor systems and its applications
Advanced Manufacturing systems
Programmable Logic Controllers
Overview of robots
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 20
MECHATRONICS
SUBJECT CODE: DPM 404
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40 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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 21
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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 22
WEEKLY PLAN FOR
MECHATRONICS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 23
WEEKLY PLAN FOR
MECHATRONICS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
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
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 24
MANUFACTURING PROCESS
SUBJECT CODE: DPM 405
Learning goals for MANUFACTURING PROCESS
Identify the necessity of “Manufacturing”
Define with examples the concept of “Manufacturing”
List the main classifications of the “Manufacturing processes” with examples
State the main purposes of “Machining”
State with example the principles of “Machining”
State with examples the main functions of “Machine tools”
Define the concept of “Machine tools”
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 25
MANUFACTURING PROCESS
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. Module -Manufacturing Process
- Definition
- Need
- Concept
- Classification of engineering manufacturing process.
- Machining
- Purpose
- Principle
- Definition
- Machining requirements.
- Definition of Machine tool.
2. Module Casting Process
- Advantages
- Limitations
- Patterns
- Materials
- Allowances
- Classifications
3. Module Moulding Process
- Sand Moulding
- Shell Moulding
- Investment Casting
- Metal Moulding
- Gravity Moulding
- Pressure Die Casting
- Hot chamber and Cold Chamber
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 26
MANUFACTURING PROCESS
4. Module Welding Process
- Definition
- Classification
- Gas welding process
- Arc welding process
- Resistance welding process
- Explosive welding process
- Laser welding process
- Electron beam welding process.
- Soldering Definition
- Classification.
- Brazing – Definition
- Comparison of Soldering
- Welding and Brazing
5. Module Rivets & Joints
- Definitions
- Classification
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 27
WEEKLY PLAN FOR
MANUFACTURING PROCESS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
1-5 Module -Manufacturing
Process
Definition
Need
Concept
Classification of engineering manufacturing Process.
Machining
Purpose
Principle
Definition
Machining requirements.
Definition of Machine tool.
6-9 Module- Casting Process
Advantages
Limitations
Patterns
Materials
Allowances
Classifications
10-13 Module- Moulding
Process
Sand Moulding
Shell Moulding
Investment Casting
Metal Moulding
Gravity Moulding
Pressure Die Casting
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 28
WEEKLY PLAN FOR
MANUFACTURING PROCESS
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
14-18 Module- Welding
Process
Definition
Classification
Gas welding process
Arc welding process
Resistance welding process
Explosive welding process
Laser welding process
Electron beam welding process.
Soldering Definition
Classification.
Brazing – Definition
Comparison of Soldering
Welding and Brazing
19-20 Module - Rivets & Joints
Definition of Rivets & Joints
Classification of Rivets & Joints
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 29
JIGS & FIXTURE DESIGN
SUBJECT CODE: DPM 406
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
SPECIFIC INSTRUCTIONAL OBJECTIVES:
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.
Govt.Tool Room & Training Centre -Bangalore-10 IV-SEMESTER SYLLABUS DPM COURSE Page No: 30
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.