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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

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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.