NETTUR TECHNICAL TRAINING FOUNDATION

POST DIPLOMA IN TOOL DESIGN - CP05

Syllabus
For
SEMESTER - I

Issued & Verified By

Syllabus & Infrastructure Department

Syllabus Effective from

16/08/2022

Rev No: 04
Released Date: 16/08/2022
S/CP05/8305
 LIST OF SUBJECTS WITH TIME ALLOCATION PER SEMESTER

1. THEORY

HOURS
SL. SUBJECT
NO.
SUBJECT NAME
CODE HOUR / SEMESTER
WEEK HOUR

1 CP05101T Metrology 2 40

2 CP05102T Material Technology & Heat Treatment 1.5 30

3 CP05103T Mould Technology 4 80

4 CP05104T Press Tool Technology 4 80

5 CP05105T Gauges, Jigs & Fixtures 2 40

TOTAL 270

2. PRACTICAL

HOURS
SL. SUBJECT
NO.
SUBJECT NAME
CODE HOUR / SEMESTER
WEEK HOUR

1 CP05106P Engineering Drawing & CAD 5 100

2 CP05107P Gauges, Jigs & Fixtures - Practical 10 200

3 CP05108P Workshop Practice 5.5 110

4 CP05109P Computer Aided Machining 4 80

TOTAL 490

MODULAR SUBJECT:
CP05110M - English Communication: 40 hour / semester.

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 TIME DISTRIBUTION FOR SEMESTER - 1

Code Activity Hours

C (P) Rope In Programme 32

C (P) Shop Talk (Trainees) 10
C (P) Quality Circle -
C (P) Technical Enrichment 10
C (P) Study Tour -
C (P) Practical 490
C (P) Technical Seminar 20
C (T) Theory 270
EC Mentoring/Cultural Activity /Sports 20
EC Green / Red rack presentation -
EC Guest lecture + Ind. visits + Seminar -
EC Week Celebration 4
EX (P) Practical Test 16
EX (T) Theory Test / Examination 56
Total 928
GN Leave / Holidays / vacations 112

Total hours per Semester 1040

GN - General
C (T) - Curriculum Theory
C (P) - Curriculum Practical
EX (T) - Curriculum Exam Theory
EX (P) - Curriculum Exam Practical
EC - Extra curricular

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 METROLOGY

SUBJECT CODE CP05101T

SEMESTER I
SEMESTER HOUR 40 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Familiarise with different measuring instruments and their working principles.
2.0 To make the trainee learn about the tolerancing systems and its applications.
3.0 Highlight the bore measuring methods.
4.0 To impart knowledge on different types of gauges.
5.0 Understand the common measuring errors and the need for calibration of instruments.
6.0 To make the trainee learn about slip gauge and its applications.
7.0 To impart knowledge on tapers and angle measuring tools, to make the trainees learn
about angular measuring tools.
8.0 Highlight form and position features and its measuring methods.
9.0 To impart knowledge on comparators and different magnification methods adopted in it.
10.0 To familiarise the measuring methods of angle of taper
11.0 To familiarise about surface texture and its measurement.
12.0 To familiarise about measuring machines.
13.0 To impart knowledge on different methods of hardness checking.
14.0 To familiarise about SQC.

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 Topics:

Sl. No. Major Topics Hours Allotted

1.0 Linear Measurements 03
2.0 Limits, Fits and Engineering tolerances 05
3.0 Bore measuring instruments 02
4.0 Gauges 02
5.0 Errors in measurements and calibration of instruments 02
6.0 Slip Gauge 02
7.0 Taper and angular measurements 02
8.0 Form and Position features 03
9.0 Comparators 02
10.0 Miscellaneous measurement 02
11.0 Surface texture measurement 03
12.0 Measuring Machines 04
13.0 Hardness Checking 02
14.0 Statistical Quality Control (SQC) 06
Total 40 h

DETAILED SYLLABUS:
1.0 Linear Measurements
1.1 Principle of vernier
1.2 Vernier - Least count 0.1, 0.5 and 0.02
1.3 Vernier caliper, Vernier depth gauge, Vernier height gauge, Digital Vernier
1.4 Micrometer - principle, parts. Types: outside, inside, depth, screw thread, dial
indicating, V -anvil, other types
1.5 Error on micrometer.

2.0 Limits, Fits and Engineering Tolerances

2.1 Limit systems - advantages
2.2 Interchangeability
2.3 Elements of limit system : Nominal size, Basic size, Actual size, Allowance, Limits-
Upper, Lower, Tolerance - Unilateral, Bilateral
2.4 Fit : hole and shaft:
Types of Fits: Clearance Fit, Interference Fit, Transition Fit ISO 286
2.5 IS 919 - 28 Fundamental deviation - 18 Tolerance grades -symbols - numeral - letter -
terminology - zero line - deviation - upper - lower
2.6 Symbols for Tolerance deviation and fit - hole basis and shaft basis system -
practice problems - guidelines for selection of fits
2.7 Selective Assembly

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 3.0 Bore Measuring Instruments
3.1 Bore gauge
3.2 Telescopic gauge

4.0 Gauges
4.1 Classification: According to type - standard and limit, According to purpose-
workshop, Inspection, Reference. According to the elements to be checked -
gauge for checking holes, shafts, tapers, threads, forms.
4.2 Plug gauge, Snap gauge, Taper gauge, Thread gauge, Profile gauge, Radius
gauge, Feeler gauge, Plate and Wire gauge

5.0 Errors in measurements and calibration of instruments

5.1 Measurement error - types
5.2 Controllable and systematic error, Calibration error - due to ambient conditions -
stylus pressure, avoidable error
5.3 Random error
5.4 Calibration - Need for Calibration, Calibration Procedure
5.5 Calibration of Vernier Caliper and Micrometers

6.0 Slip gauge

6.1 Description of slip gauge - Number of blocks in Standard Sets, Wringing Property
6.2 Grades - Reference grade, Inspection grade, Calibration grade, Workshop grade

7.0 Taper and angular measurement

7.1 Standard Tapers, Morse Taper, Metric Taper, ISO Taper, Brown and Sharp Taper
7.2 Angle gauges - Use, Number of gauge blocks in standard set, Addition and
Subtraction of Angles
7.3 Sine Bar - Construction, Method of checking
7.4 Sine Plate - Construction, Method of checking
7.5 Sine Centre - Use
7.6 Auto Collimator - Principle

8.0 Form and Position features

8.1 Straightness - definition
8.2 Measurement - Height master, Straight Edge Method, Auto Collimator Method
8.3 Flatness - definition, Testing - Surface Plate, Straight Edge method
8.4 Parallelism - Dial Indicator, use, Types - Plunger Type - Working Principle,
Precautions. Universal dial indicator - Working Principle, Precautions
8.5 Parallelism of 2 axes- parallelism of 2 planes-parallelism of axis to a plane
8.6 Squareness - Try Square, Indicator Method
8.7 Measurement of circularity, Ovality, Lobbing, Use of Dial Indicator and V block,
Taly Rond (Roundness measuring instrument)
8.8 Concentricity
8.9 Run out - checking

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 9.0 Comparators
9.1 What is a comparator - classification based on method of magnification -
Advantages and dis advantages
9.2 Mechanical comparator - reed type comparator - working principle - reed mechanism
9.3 Optical projector - parts - working principle

10.0 Miscellaneous measurement

10.1 Checking the angle of a piece tapered at one end
10.2 To check the angle of a tapered hole
10.3 Checking of dovetail

11.0 Surface texture measurement

11.1 Meaning of surface texture - difference between length measurement and surface
texture measurement.
11.2 Definition - primary texture - secondary texture - lay - sampling length - meanline of
profile - centre line of profile
11.3 Direct instrument measurement - stylus probe instruments - essential parts
11.4 Talysurf (Surface roughness tester)

12.0 Measuring machines :

12.1 Toolmaker's microscope - parts - protractor eye piece - radius measuring head -
thread template unit - projection attachment - Profile Projector
12.2 Co-ordinate measuring machine - X Y Z co-ordinates - CNC controls with CMM

13.0 Hardness checking

13.1 Hardness - property
13.2 Checking methods - Brinnel - indentor used - load - method
13.3 Rockwell principle - RA,RB and RC - indentor used - lead for different scales
13.4 Vicker's principle - indentor used - load
13.5 Shore Scleroscope hardness test

14.0 Statistical Quality Control (SQC)

14.1 Introduction - advantages - final concepts - variability in Measurement
14.2 Acceptance criteria - process capability - special characteristic - USL & LSL- introduction
14.3 Process capability in terms of Cp, Cpk - introduction only.

Reference books:
1. Engineering Metrology - R.K Jain
2. Mechanical and Industrial measurements - R.K Jain
3. Dimensional Metrology - M.K Khare
4. Engineering Metrology - K.J Hume
5. Hand book on Industrial Metrology - John W Greeve
6. Quality Control - M V V Raman
7. Workshop Technology Part III - Chapman
8. Industrial Engineering -Parameshwaran

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 MATERIAL TECHNOLOGY AND HEAT TREATMENT

SUBJECT CODE CP05102T

SEMESTER I
SEMESTER HOUR 30 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Awareness of steel
2.0 Awareness of alloying elements in steel
3.0 Awareness of different steels and uses
4.0 Highlight the properties and uses of non-ferrous metals and alloys
5.0 Familiarise with the scope of organic materials in engineering field
6.0 Highlight heat treatment terms
7.0 Awareness of surface hardening
8.0 Awareness of carburizing medium
9.0 Awareness of post heat treatment
10.0 Awareness of equipment’s used for heat treatment
11.0 Highlight the necessity of proper planning for heat treatment
12.0 Awareness on powder metallurgy
13.0 Highlight the importance of surface treatment

Topics:
Sl. Hours
Major Topics
No. Allotted
1.0 Steel 03
2.0 Alloying Elements 03
3.0 Non-ferrous metals and alloys 04
4.0 Different Steels and Uses 06
5.0 Organic Materials 03
6.0 Heat Treatment 04
7.0 Surface Hardening 03
8.0 Post Heat Treatment 02
9.0 Equipment’s, Tools required for heat treatment 02
Total 30 h

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DETAILED SYLLABUS:

1.0 Steel
1.1 Composition of steel and other elements.
1.2 Influence of following constituents: carbon-silicon - manganese-sulphur -phosphorous.
1.3 Classification of steel according to: carbon contents - purpose. Plain carbon steel.
1.4 Composition and application: low carbon steel- medium carbon steel - high carbon steel -
tool steel.

2.0 Alloying elements

1.5 Alloying elements - classification of alloy steel: chemical composition - purpose - types of
steel - alloy structural steel - alloy tool steel - alloy steel with special physical properties.
1.6 Effects of different alloying elements: chromium - nickel - manganese - vanadium -
molybdenum - silicon - tungsten - sulphur - copper - cobalt.
1.7 Composition properties and uses of alloy steel: nickel steel - chromium steel - nickel
chrome steel - molybdenum steel - chromium molybdenum steel - nickel chrome -
molybdenum steel - manganese steel - silicon steel.
1.8 Special alloy steel - composition properties and uses: heat resisting steel
1.9 Magnet steel, shock resisting steel - stainless steel - high speed steel - ISI Specification:
Plain carbon steel, alloy steel - Tool steel

3.0 Non Ferrous metals and alloys

3.1 Need - Different non-ferrous metals - Uses. Aluminum: Uses - Aluminum alloy - Cast
aluminium - Application
3.2 Copper: Uses - Copper Zinc alloy - Copper Tin alloy - Copper Aluminum alloy -
Copper Nickel alloy - Copper Nickel Zinc alloy - Applications.
3.3 Materials used for EDM Electrodes

NOTE: Above Topics are for Reference, Handout to be given

4.0 Different Steels and Uses

4.1 Metals used for: Press tool - jigs and fixtures - Moulds
4.2 AISI Steels - Awareness on other international equivalents.
4.3 EN Specification of steels
4.4 Comparison of different standards

5.0 Organic materials

5.1 Introduction to organic material: Application -Different materials used in engineering:
Natural materials -synthetics
5.2 Polymers: Monomers and polymers- Types: Naturally occurring-Synthetic polymers.
5.3 Mechanism of Polymerization: Describe - Types: Additional polymerization -
Condensation.
5.4 Additives to Polymers: Uses - Advantage - Types: Plasticizer - Fillers - Catalysts -
Initiators - Dyes - Pigments - Master Batch

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 6.0 Heat Treatment
6.1 Iron Carbon Equilibrium Diagram
6.2 Interpretation of iron carbon equilibrium diagram and its role in heat treatment of steel
6.3 T-T-T Diagram
6.4 Introduction to common heat treatment terms : annealing-stress relieving-normalizing -
hardening- tempering
6.5 Vacuum heat treatment - Process and Advantages

7.0 Surface Hardening Processes

7.1 Difference between Surface hardening and Case hardening
7.2 Case Hardening - Carburizing - Nitriding
7.3 Surface Hardening - Induction hardening, Flame hardening, Hard Chrome
7.4 Partial Hardening Electric contact resistance hardening
7.5 Surface treatment including CVD, PVD, coating

8.0 Post Heat Treatment

8.1 Treatment of heat treated items. Surface treatment- Sub Zero treatment-Hard
chroming - Nitriding- Advantages- Application.
8.2 Removal of scale - pickling
8.3 Cleaning of heat treatment items: alkaline -detergents-degreasing.

9.0 Equipments, Tools required for Heat Treatment

9.1 Quenching media - fixtures for holding - safety Precautions - care to be taken while
quenching
9.2 Introduction to types of Heat Treatment Furnaces

Reference Books

1. Material Science and Processes - S. K. Hajra Choudhury

2. Material and Metallurgy - V.K Manchanda
3. Material Science - R.S Khurmi
4. Engineering Materials - Surendar Singh
5. Materials for Engineering (Part 1&2)- P. S Houghton
6 Heat Treatment of Steels - Edwin George & Eric N Simons
7. Heat treatment of metals - B Zakharov
8. Hints of Hardening - Bohler
9. Metals And Heat Treatment - Guptha
10. Heat Treatment Fundamentals - S Rolland Churchill

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 MOULD TECHNOLOGY
SUBJECT CODE CP05103T
SEMESTER I
SEMESTER HOUR 80 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Familirisation in the use of plastics in moulding industry.
2.0 Familirisation of the working of injection moulding machine
3.0 Ability to determine the number of cavities of an injection mould when provided with
component and machine details.
4.0 Awareness of basic terminology of injection moulds.
5.0 Highlight the importance of elements of feed system in an injection mould and to select
appropriate feed system.
6.0 Ability to select the ejection system in an injection mould.
7.0 Determination of appropriate parting surface for a mould.
8.0 Determination of core and cavity dimension.
9.0 Appreciation of the need for controlling temperature of injection mould.
10.0 Highlight the design of the mould with split cavities.
11.0 Highlight the design of moulds with side cores and side cavities.
12.0 Appreciation of design of moulds for components with internal undercuts and threads.
13.0 Understand the design of multiday light moulds.

Topics:
Sl. No. Major Topics Hours Allotted
1.0 Plastics in Moulding industry 08
2.0 Introduction to Moulding Process 08
3.0 Number of cavities 06
4.0 Feed system 04
5.0 Ejection system 06
6.0 Parting surface 08
7.0 Core and Cavity dimension 06
8.0 Temperature Controlling for Moulds 08
9.0 Types of Moulds 06
10.0 Moulds with side core and side cavity 08
11.0 Moulds for Internal undercuts and threads 06
12.0 Multi daylight Moulds 06
Total 80 h

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 DETAILED SYLLABUS:
1.0 Plastics in Moulding industry
1.1 Thermo plastics and Thermoset plastics: Types –Property-Application.
1.2 Fillers and Additives: Varieties - effect
1.3 Plastic Blends
1.4 Identification of plastics: simple tests.

2.0 Introduction to Moulding Process

2.1 Basic Terminology.
2.2 Elements of mould-Function-Fixed half-moving half-Impression-cavity-core - sprue
bush-register ring -runner - gate - guide pillars and bushes - heel blocks -rest button-
sprue breaker-ejector- ejector retainer-push back pin.
2.3 Injection Moulding Machine
2.3.1 Introduction - Function, Plasticising, Injection, Clamping
2.3.2 Major Parts of Injection Moulding Machine - Hooper, Plasticizing Unit, Screws,
Nozzle, Fixed and Moving Platens, Tie rods, Clamping Mechanism
2.3.3 Types of Injection Moulding Machine - Plunger Type, Screw Type, Advantage of Screw
Plasticising, Vertical, Horizontal, Multi Spindle / Multi Cooler, Microprocessor based
Moulding, CNC Moulding Machine
2.3.4 Machine Accessories - Pre Plasticizer, De-humidifier
2.3.5 Machine Specification -Shot Capacity, Plasticizing Capacity, Clamping Tonnage,
Injection Pressure, Maximum / Minimum Daylight
2.3.6 Purging - Need of Purging
2.3.7 Drooling

3.0 Number of cavities

Determining number of Cavities of Mould considering
3.1 Shot Capacity
3.2 Plasticising Capacity
3.3 Cycle Time
3.4 Clamping Force

4.0 Feed system

4.1 Parts of feed system
4.2 Runner- Function-runner cross section shape - runner size
4.3 Gates-Function of gates-position of gates-balanced gates-types of gates -
advantages of different types of gates-disadvantages of different types of gates.
4.4 Runner diameter calculation - Gate calculation.

5.0 Ejection system

5.1 Ejection - Purpose, Ejection Grid - Types of Grid, Ejector Plate, Retainer Plate,
Assembly of Ejection System - Guiding and Supporting elements, Rest Buttons / Stop
Buttons / Stop Pins, Push back Pin and its function, Ejector Rod and Ejector Bush
5.2 Types of Ejection Methods - Pin Ejection - Plain Diameter Pin, Stepped Ejector Pin,
D-Shaped Ejector Pin, Blade Ejection, Sleeve Ejection, Valve Ejection / Air Ejection,
Stripper Bar / Plate / Ring, Ejection from fixed half
5.3 Ejection Force Calculation
5.4 Support Pillar requirement for Ejection System
5.5 Sprue Puller - Function, Different Types and Applications.

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 6.0 Parting surface
6.1 Choosing parting surface for different components - Relief of parting - Reason for
relief for parting surface
6.2 Venting: Function of air vents - position of air vents for different components.

7.0 Core and Cavity Dimension

7.1 Shrinkage-Explain shrinkage
7.2 Types of Shrinkage
7.3 Factors governing shrinkage
7.4 Values of shrinkage
7.5 Effect of Shrinkage on Core and Cavity - Determining core and cavity dimensions -
by Calculation and Through Software

8.0 Temperature Controlling for Moulds

8.1 Need of Temperature controlling for Moulds
8.2 Methods of Core and Cavity Cooling
8.2.1 Baffle Cooling, Bubblers, Thermal Pins etc.
8.2.2 Traditional / Standard Cooling, Conformal Cooling
8.3 Cooling time, How to reduce Cooling time
8.4 Water Connection - Adapters for Connectors, Plugs - Application, Selection

9.0 Types of Moulds

9.1 Single Cavity-Multi Cavity
9.2 Two Plate Mould- Three Plate Mould
9.3 Mould with Split Cavities.
9.4 Selection of splits - Design of moulds with splits - External undercut components -
Position of joint line – Splits - sliding splits - guiding and retention of splits - mould
plate designs - split designs.
9.5 Operation of Splits - Finger cam actuation - Dog leg actuation - Cam track actuation -
spring actuation - Hydraulic actuation
9.6 Split locking method - Open channel type - Closed channel type.
9.7 Split safety arrangement - spring detente method-spring loaded method.

10.0 Moulds with Side core and side cavity

10.1 Selection of side core and side cavity design for the required components -Integral
side core or side cavity.
10.2 Assembly details - Construction - guiding arrangement.
10.3 Method of actuation of side core and side cavity.

11.0 Moulds for Internal under cuts and threads.

11.1 Different methods used in moulding internal undercuts-form pin-straight action form
pin - angled action form pin-split cores-split core with straight and angled action-side
cores
11.2 Stripping internal undercut.
11.3 Mould for threaded components-Methods used-Fixed thread core design
11.4 Stripping threaded components-Loose thread core-Unscrewing mould-rotating cavity
- moulding for external threaded component.

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 12.0 Multi-daylight moulds.
12.1 Differentiating single daylight mould and multi-daylight mould.
12.2 Under feed moulds - Function of under feed mould - operation cycle.
12.3 Types of feed: Secondary sprue gate - Reverse taper secondary sprue -
Undercut runner system - runner stripper plate design - design feature.
12.4 Triple daylight mould - Selection Criteria for Triple daylight mould.

Reference Books:
1. Introduction to Injection - Pye Moulding Design
2. American Society of Metals - Hand Book 8th edition
3. Die Moulds and Jigs - V. Vladimirov
4. Refresher Course in - CIPET Injection Moulding
5. Plastic Material & Processes - Schwartz
6. Plastic Engineering hand Book - Joel Frados
7. Design and Manufacture of - R.L.E. Brown Plastic parts
8. Plastics - J. Harry Dubias & Frederic W. John

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 PRESS TOOL TECHNOLOGY

SUBJECT CODE CP05104T

SEMESTER I
SEMESTER HOUR 80 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Awareness of different types of sheet metal processing using press tools and
familiarization with general press tool construction and features.
2.0 Familiarise with theory of shearing.
3.0 Ability to determine cutting force.
4.0 Recognition of the effect and determination of cutting clearance.
5.0 Familiarisation with land and angular clearance.
6.0 Awareness of basic design of press tools.
7.0 Familiarisation with type of stock materials.
8.0 Ability to design a strip lay out.
9.0 Familiarisation of different types of punch.
10.0 Recognition of the effect of buckling of punches.
11.0 Ability to design of a die block.
12.0 Recognition of the function and design of stoppers.
13.0 Recognition of the function and design of stripper.
14.0 Recognition of the function and design of gauge.
15.0 Familiarisation with the function and design of the pilots.
16.0 Ability to design side cutter for a tool
17.0 Recognition of the use of ejectors and shedders in a press tool.
18.0 Recognition of the use of fasteners and dowel in a press tool.
19.0 Familiarisation with the shank location.
20.0 Ability to select the right die set.
21.0 Ability to design a progressive tool.

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 Topics:

Sl. No. Major Topics Hours Allotted

1.0 Different Press Tool Operations 04
2.0 Types of Press Tools 03
3.0 Shearing Theory 02
4.0 Cutting force 03
5.0 Cutting clearance 03
6.0 Land and Angular clearance 02
7.0 Basic design of Press Tool 04
8.0 Stock Material 02
9.0 Strip layout 12
10.0 Punches 04
11.0 Buckling of punches 02
12.0 Die Blocks 04
13.0 Stoppers 02
14.0 Strippers 02
15.0 Gauges 02
16.0 Pilots 03
17.0 Side cutters 04
18.0 Ejectors and Shedders 02
19.0 Fasteners and Dowels 02
20.0 Shank 06
21.0 Die Sets 04
22.0 Progressive Tool 08
Total 80 h

DETAILED SYLLABUS:
1.0 Different Press Tool Operations
1.1 Piercing - blanking - cut off - parting off - notching - trimming - shaving - perforating -
lancing - dinking - broaching - extrusion - planishing - embossing - coining - bending -
forming - drawing - flaring - curling - bulging - swaging
1.2 Differentiating between different press tool operations.

2.0 Types of Press Tools

2.1 Guide Plate Tool - Blanking Tool - Piercing Tool - Progressive Tool - Compound Tool -
Inverted Tool - Side Cam Tool - Bending Tool - Drawing Tool etc.
2.2 Construction of basic press tools - Elements and Functions.

3.0 Shearing Theory

3.1 Critical stage of shearing.

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 4.0 Cutting Force
4.1 Calculation of cutting force
4.2 Selection of press with respect to Cutting Force
4.3 Methods for reducing cutting force

5.0 Cutting clearance

5.1 Determination of Cutting clearance - Importance of cutting clearance.
5.2 Cut Edge Characteristics of Components - Optimum clearance - Excessive Clearance
- Insufficient clearance - Misalignment of Punch and Die
5.3 Relationship between piece part size to punch and die size.
5.4 Determining punch and die dimension.

6.0 Land and Angular Clearance

6.1 Land - Amount of Land on Die
6.2 Importance of angular clearance
6.3 Methods used in providing Angular Clearance - Straight Relief - Angular Relief
6.4 Exceptional Cases for not providing Land and Angular clearance

7.0 Basic design of Press Tool

Working principle of guide plate tool - when to adopt guide plate tool - Importance
of each part of the tool - Design of guide plate tool - Selecting material.

8.0 Stock Material

8.1 Types of Stock Materials - Unit Stock- Stock Strip-Coil - Specification
8.2 Material- Stock materials used in press tool operations–mechanical properties of
different stock material - choosing material for the required press operation -
preparation of stock material-Standards.

9.0 Strip Layout

9.1 Importance of strip lay out.
9.2 Different types of strip lay out:-narrow run - wide run -single row - two pass-double
row lay out-gang dies-angular lay out
9.3 Strip Layout with respect to Shape of the blank- production requirement grain
direction - burr side - stock material.
9.3.1 Strip lay out for blanking tool- Cut off-parting - notching-trimming- progressive tools.
9.4 Economy factor-Calculate the percentage of utilization of the strip - most economical
layout.

10.0 Punches
10.1 Types of punches - Cutting punches - non cutting punches - hybrid punches.
10.2 Classification of Punches based on mounting methods - Plain punches - pedestal
punches - offset pedestal punches - bossed punches - flanged punches - headless
punches - step head punches -beveled head punches - clamped punches - floating
punches - quilled punches - perforators.
10.3 Selection of punches depending on the work - material of the punch.

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 11.0 Buckling of Punches
Buckling theorem - problems - types of loads coming on a punch - determining the
size of the punch.

12.0 Die Blocks

12.1 Function of Die in Press Tool
12.2 Types of Die Blocks - Solid Die, Split Die or Sectional Die
12.3 Condition at which Solid Die and Split Die are preferred
12.4 Construction of Split Die
12.5 Nesting - Purpose and Methods
12.6 Selection of Die Plate - Size of Plate, Die Plate Material and Heat Treatment Method.

13.0 Stoppers
13.1 Function of Stopper
13.2 Categories of Stopper
13.2.1 Position - Stop categories - Primary - Secondary - Final
13.2.2 Construction of different types of stoppers - plain pin stop - headed pin stop -
disappearing pin stop - finger stop - operation - pusher stop

14.0 Strippers
14.1 Function of a stripper
14.2 Types of stripper - hook pin stripper - box stripper - fixed stripper - travelling stripper
14.3 Constructional details of stripper - spring strippers - clamping spring stripper - non
clamping spring stripper - piloting through spring stripper - compensating washer -
spring stripper bolts - stripper bolt suspension.
14.4 Stripping force - Stripping force for blanking and piercing
14.5 Types and Selection of Stripper Springs - Coil - PUR - Nitrogen gas Strippers

15.0 Gauges
15.1 Function of gauges in a press tool - dimensional aspect of gauge.
15.2 Types of gauges - Back gauge- Front gauge -Bulge clearance- size of back gauge
and front gauge - extended back gauge- Strip support - Pushers
15.3 Nesting gauges -Requirement of nest gauge -types of nest gauge - accuracy - easy
and quick loading and unloading - fool proofing - Different types of nest gauges - pin
types nest gauges - plate type nest gauge
15.4 Strip lifters.

16.0 Pilots
16.1 Purpose of pilots.
16.2 Differentiating between Stop Position and Registry Position.
16.3 Pilot size - Pilot length -Pilot opening in die -Pilot opening in bottom plate.
16.4 Types of pilots-Function of different types of pilots-retractable pilots - removable type
pilots-pilot in punch-Pilot nose profile-Bullet nose- 45 degree conical stub nose pilot -
30 degree conical stub nose pilots -15 degree angular nose - function of pilot nose.
16.5 Different methods of piloting.
16.6 Differentiating between direct piloting and indirect piloting

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 17.0 Side Cutters
17.1 Function of side cutters
17.2 Advantages of side cutter

18.0 Ejectors and Shedders

18.1 Ejector - Function of ejector - Application
18.2 Shedder - Function of shedder - Types of shedders - Positive shedder -
Compression shedder - Shedding pins.
18.3 Knock outs - Function-Distinguishing between direct knockout and indirect knock out.

19.0 Fasteners and Dowels

19.1 Dowels: Function - Types of Dowels used in tooling - Fit between Dowel and Plate in
Assembly
19.2 Fasteners: Screws - Function - Types and Specification of screws -socket headed
cap screw - counter sunk screw - head screw-cheese head screw - set screw
19.3 Positioning of screws and Dowels.

20.0 Shank
20.1 Function of Shank
20.2 Different types of shanks.
20.3 Location of shank -Importance for locating shank in correct position
20.4 Shank point location -Arithmetical , graphical method

21.0 Die Sets

21.1 Different types of die sets - difference between precision and commercial.
21.2 Die set components - Top plate - Bottom plate - Guide pillar
21.3 Die set material
21.4 Types of Die set - Standard die set - Non-standard die set
21.5 Selection of Die Sets by referring Catalogues
21.6 Importance of Shut height

22.0 Progressive tool

22.1 Construction - Function of elements of Progressive Tool - related design of
progressive tool
22.2 Selecting Strip Layout for Progressive Tool

Reference Books:
1. Die Design Fundamentals - Paquin
2. Tool Design - Donaldoon
3. Basic Die Making - Ostergarrd
4. American Society of Metals - Hand Book 8th edition.
5. Advanced Die Making - Ostergarrd
6. Fundamentals of Tool Design - A.S.T.M.E
7. Tool Design - C.B Cole
8. Punches and Dies - Frank A Stanley
9. Tool Engineers hand book
10. Die Design Hand book
11. PSG Hand book
12. CMTI Hand book

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 GAUGES, JIGS AND FIXTURES

SUBJECT CODE CP05105T

SEMESTER I
SEMESTER HOUR 40 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Awareness of gauges
2.0 Familiarisation of types of jigs
3.0 Awareness on gauge tolerance
4.0 Highlight the importance of materials in gauges
5.0 Awareness on different use of jigs and fixtures
6.0 Awareness on different types of jigs and fixtures
7.0 General awareness of mounting jig/fixture on a machine tool
8.0 In-depth knowledge of elements of jig and fixture
9.0 Highlight the importance of cutting tool used with jig, fixture
10.0 Awareness of design of jig, fixture
11.0 General awareness of heat treatment of jig + fixture parts

TOPICS:
Sl.
Major Topics Hours Allotted
No.
1.0 Introduction to gauge 02
2.0 Types of gauges 04
3.0 Tolerance of gauges 04
4.0 Material for gauges 03
5.0 Introduction to Jigs and Fixtures 04
6.0 Types of Jigs and Fixtures 04
7.0 Machine relation 04
8.0 Elements of jigs and fixtures 05
9.0 Cutting Tools used for jig, fixture 02
10.0 Design steps 06
11.0 Effect of heat treatment on jig and fixture elements 02
Total 40 h

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 DETAILED SYLLABUS:
1.0 Introduction to gauges
1.1 Importance of gauge - gauging devices and gauging methods - standardization

2.0 Types of gauges

2.1 Fixed gauges - indicating gauges and combination gauges - its classification

3.0 Tolerance of gauges - Gauge limit - Application

4.0 Materials for Gauges - Properties - Advantages - Selection

5.0 Introduction to Jigs and Fixtures

5.1 Introduction - jig, fixture - function of jig, fixture - difference between jig and fixture -
Economic use of jig and fixture
5.2 Planes of movement - Principle of location - 12 freedom of movement of an object
5.3 Possible movements of work piece - Arresting the freedom of movement -
Clamps, Stoppers, in a jig & fixture
5.4 Location of work piece - Purpose of location - Fool proofing of work - Body, Feet of jig &
fixture, Chip control

6.0 Types of Jigs and Fixtures

6.1 Explain Template jig - Table jig - Plate jig - Angle plate jig - Modified angle plate jig -
Sandwich jig - Box jig - Channel jig - Leaf jig - Indexing jig
6.2 Explain Different types of fixture - Plate fixture - Angle plate fixture - Modified angle plate
fixture - Vice jaw fixture

7.0 Machine Relation

7.1 Fixture and machine relation - Explain: Turning fixture - Milling fixture - Grinding fixture
- Inspection fixture
7.2 Jig and machine - Explain: Drill jig - Marking jig

8.0 Elements of Jigs and Fixtures

Explain: Clamps - Stoppers - Supports - Plugs - Types of drill bushes

9.0 Cutting Tools used for Jig, Fixture

Types of tools - Cutting tool setting - Chip direction and Chip removal

10.0 Design steps to be followed

Design principles - care - procedure - Cutting forces for jig & fixture effect - force direction
- failure of jig & fixture - failure of elements - failure of clamping - discuss the above with
case study

11.0 Effect of heat treatment on jig and fixture elements - cutter setting block body feed.

Reference Books:
1. Jigs and Fixtures - Hiran E Grant
2. Jigs and Fixtures Design - Franklin D Jones
3. Jigs and Fixtures - Joshi
4. Jigs and Fixtures - Hiramegrant
5. Die Design Fundamentals - ASTME
6. P S G Hand book
7. CMTI Hand book

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 ENGINEERING DRAWING AND CAD

SUBJECT CODE CP05106P

SEMESTER I
SEMESTER HOUR 100 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Understand the importance of engineering drawing
2.0 Competency to writ engineering script.
3.0 Understand the importance of IS 696
4.0 Ability to construct standard geometrical shapes.
5.0 Ability to prepare 3 dimensional drawings of a given object
6.0 Indepth practice of Orthographic projection with example.
7.0 Ability to prepare dimensional drawing.
8.0 Ability to visualise sectional view and to draw them
9.0 Highlight the importance of geometrical tolerance
10.0 Apply the method of showing surface texture.
11.0 Ability to prepare Assembly and detail drawings
12.0 Skill on CAD- 2D and 3D

TOPICS:

Sl.
Major Topics Hours Allotted
No.
1.0 Engineering Drawing and Standards 01
2.0 Pictorial projection 01
3.0 Orthographic projection 01
4.0 Dimensioning and Tolerancing 02
5.0 Sectional views 02
Conventional Representation of Mechanical
6.0 02
Elements on Drawing
7.0 Surface texture 03
8.0 Geometric Dimensioning and Tolerancing (GD & T) 08
9.0 Assembly and detail drawing 30
10.0 CAD practice 50
Total 100 h

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 DETAILED SYLLABUS:

1.0 Engineering Drawing and Standards

1.1 Importance of Engineering Drawing
1.2 Standards - Introduction to IS 696: SP46
1.2.1 Drawing sheet sizes - drawing sheet layout - title block
1.2.2 Scales - full scale - enlarged scale - reduced scale
1.2.3 Lines - types of lines.

2.0 Pictorial Projection

2.1 Types of pictorial drawings -Isometric - oblique and perspective
2. 2 Isometric drawings-Isometric axes-angle between axes-steps involved in
Preparing-Isometric drawing-exercises on Isometric drawing

3.0 Orthographic Projection

3.1 Explanation- concept of front view - top view and side view Explanation of first
angle projection - symbol used
3.2 Third angle projection–positioning of three views in third angle projection
3.3 Exercises in sketching the three views of different types of objects in both third
angle and first angle
3.4 Auxiliary views.

4.0 Dimensioning and Tolerancing:

4.1 Principles of Dimensioning and Standards
4.2 Elements of dimensioning - Dimensions, Dimension line, Extension line,
Leader line - Termination
4.3 Orientation of Dimensions
Aligned method - Unidirectional method - Rules for dimensioning as per standards
4.4 Types of Dimensioning
Chain Dimensioning - Parallel Dimensioning - Superimposed Dimensioning -
Combined Dimensioning and Coordinate Dimensioning
4.5 Tolerances - Introduction about IS 919 - methods of placing tolerance - hole basis
system and shaft basis system
4.6 Indication of Tolerance on Drawings
4.7 Exercise on Dimensioning Practices
4.8 Exercise on indicating tolerances - by referring IS Tolerance Charts

5.0 Sectional Views:

5.1 Need for drawing sectional views - to show hidden details - explanation of the
term cutting plane - cut plane line - principle of selection of cutting plane to give
maximum information.
5.2 Meaning of full section - half section - revolved section - removed section - thin
section and local section
5.3 Conventional practice of showing sections of different materials asper IS 696
5.4 Exercise in drawing section views.

6.0 Conventional Representation of Mechanical Elements on Drawing

6.1 Conventional Representation of Threads and Threaded Parts - Springs - Welded
Joints - Gears - Bearings - Pins on Drawing

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 7.0 Surface Texture:
Introduction about IS 696 - symbols used for indication of surface texture -
indications added to the symbols - roughness grade number and roughness values
- symbols for the direction of lay - proportion and dimension of symbols - indications
on drawing.

8.0 Geometric Dimensioning and Tolerancing (GD & T):

8.1 Introduction to Geometrical Tolerance -need of geometrical tolerance in drawing -
method of Tolerancing
8.2 GD&T - Feature, Datum/Reference, Tolerance Zone, Control Frame
8.3 Types of Tolerances – SLOF, Form, Orientation, Location, Profile and run out
8.4 Symbols and Notations for Geometrical Tolerancing and their representation on the
drawing
8.5 Indication of GD & T Symbols and Notations on the drawing
8.6 Geometrical tolerances – Principle of Material Condition.
8.7 Exercise on Interpretation of GD & T

9.0 Assembly drawing - placing of views - selection of views - placing of position

9.1 Detail drawing - placing of views - selection of cutting plane - dimension and
Tolerancing - geometrical tolerances - roughness symbol
9.2 Parts list - preparation of parts list - both in assembly and detail drawing.

10.0 CAD Practice - both 2D and 3D

Note: Use Engineering Drawing Workbook

Reference books:
1. Technical drawing : W. Whott
2. ISO Engineering drawing Practice: SP 46(BIS)
3. Engineering Graphics : Narayana & Kannaih
4. Engineering Drawing : N.D. Bhatt
5. Theory of Machine :
6. IS 696 :
7. IS 8000 :
8. PSG Hand book : PSG
9. CMTI Hand book : CMTI

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 GAUGES, JIGS & FIXTURES - PRACTICAL

SUBJECT CODE CP05107P

SEMESTER I
SEMESTER HOUR 200 h
REV. NO. 4
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Training in the ability to design of gauge
2.0 Training in the ability to design different types of jigs
3.0 Training in the ability to design different types of fixtures

TOPICS:

Sl. No. Major Topics Hours Allotted

1.0 Design of Gauge 40
2.0 Design of Jigs 80
3.0 Design of fixture 80
Total 200 h

DETAILED SYLLABUS:

1.0 Design of Gauge

1.1 Design of plug gauge to check the holes
1.2 Design of flush pin gauge to check the depth of a slot
1.3 Design of a form gauge to check the angle of a work piece
1.4 Design of gauges - any three press tool components
1.5 Design of gauges - any three mould components

2.0 Design of jigs

2.1 Template jig
2.2 Box jig
2.3 Indexing jig
2.4 Angle plate jig

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 3.0 Design of fixture
3.1 Turning fixture
3.2 Grinding fixture
3.3 Milling fixture
3.4 Welding fixture
3.5 Cooling fixture
3.6 Assembly fixture

Reference Books
1. Jigs and Fixtures - Hiran E Grant
2. Jigs and Fixtures Design - Franklin D Jones
3. Jigs and Fixtures - Joshi
4. Jigs and Fixtures - Hiramegrant
5. Die Design Fundamentals - ASTME
6. P S G Hand book
7. CMTI Hand book
8. Tool Design - Donaldson

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 COMPUTER AIDED MACHINING

SUBJECT CODE CP05109P

SEMESTER I
SEMESTER HOUR 80 h
REV. NO. 0
REV. DATE 16/08/2022

GENERAL OBJECTIVES:
1.0 Awareness on CNC
2.0 Familiarise CNC Machine Hardware and its functions
3.0 Familiarise with Cutting Tools used in CNC
4.0 Awareness on Basic Operations of CNC Machine
5.0 Familiarise CNC Turning Operations
6.0 Familiarise CNC Milling Operations
7.0 Familiarise CNC Part Programming - Manual and Simulation
8.0 Ability to use MasterCAM Software for CAM

TOPICS:

Sl. Hours
Major Topics
No. Allotted
1.0 Introduction to CNC 02
2.0 CNC Hardware basics 04
3.0 Cutting Tool and Cutting Tool Parameters 04
4.0 CNC Operation 04
5.0 CNC Turning 03
6.0 CNC Milling 03
7.0 Part Programming - CNC Turning and CNC Milling 30
8.0 MasterCAM 30
Total 80 h

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 DETAILED SYLLABUS:

1.0 Introduction to CNC

1.1 Introduction, Application and Advantages of CNC
1.2 Classification of CNC Machine – Feedback System, Motion Control System

2.0 CNC Hardware basics

2.1 Spindle Drives (Servo motors, Stepper Motors)
2.2 Automatic Tool Changer
2.3 Automatic Pallet Changer
2.4 Automatic Swarf Removal Mechanism
2.5 Work Holding and Tool Holding Devices

3.0 Cutting Tool and Cutting Tool Parameters

3.1 Cutting Tool Parameters - Tool Dia, Surface Speed, Spindle Speed, Feed Rate and
Depth of Cut
3.2 Tool Selection Criteria for PMKNSH Materials - referring catalogues

4.0 CNC Operation

4.1 CNC Safety
4.2 Power ON / OFF
4.3 Emergency Stop – Reset
4.4 CNC Set up and Operation
4.5 Offset and Settings
4.5.1 Machine Offset
4.5.2 Tool Length Offset
4.5.3 Fixture Offset
4.6 Loading of Tools
4.7 Loading of CNC Program
4.8 Running of CNC Program

5.0 CNC Turning

5.1 Tools used in CNC Lathe
5.2 CNC Turning Operations

6.0 CNC Milling

6.1 Tools used in CNC Milling
6.2 CNC Milling Operations

7.0 Part Programming - CNC Turning and CNC Milling

7.1 Preparatory Codes
7.2 Miscellaneous Codes or Machine Codes
7.3 Programming exercises

8.0 MasterCAM
8.1 Introduction
8.2 Sketching Practice
8.3 3D Tools for Design
8.4 2D Part Programming - Contour Machining, Pocket Machining, Drilling
8.5 3D Part Programming

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 Modular Subject:

ENGLISH COMMUNICATION

SUBJECT CODE CP05110M

SEMESTER I
SEMESTER HOUR 40 h

GENERAL OBJECTIVES:
1.1 To sensitize students to their communicative behavior.
1.2 Considering the significance of English language as a tool for global Communication
the course aims to develop and enhance the linguistic and Communicative
competence of the trainees.
1.3 To enable them to reflect and improve on their communicative behavior /performance
1.4 To build capacities for self-criticism and facilitate growth The self-learning tasks
designed will facilitate to enhance effective communication skills in modern,
globalized context.

TOPICS:
Sl. No. Major Topics Hours Allotted
1.0 COMMUNICATION SKILLS IN ENGLISH 05
2.0 BASIC GRAMMER FOR COMMUNICATION 04
3.0 STRESS MANAGEMENT 04
4.0 BUSINESS CORRESPONDENCE 03
5.0 PRESENTATION SKILLS 07
6.0 REPORT WRITING 03
7.0 GROUP DISCUSSION 07
8.0 INTERVIEW SKILLS 07
TOTAL HOURS 40 h

DETAILED SYLLABUS:

1.0 Communication skills in English

1.1 The importance of English language
1.2 How to make effective English communication.

1.3 What are the problems in communicating in English and how to overcome
those problems?

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 2.0 Basic grammar used for communication
2.1 Sentence types
2.2 Verbs
2.3 Tense

3.0 Stress management

3.1 What is stress?
3.2 Causes of stress
3.3 Managing stress

4.0 Business correspondence

4.1 Letter Writing
4.2 Letter of Request
4.3 Leave letter
4.4 Letter of enquiry
4.5 Complaint letter
4.6 Writing Agenda and Minutes

5.0 Presentation skills

5.1 Oral presentation
5.2 Public speaking skills
5.3 Business presentation
5.4 Giving topics for presentation
a) Group presentation b) Individual presentation

6.0 Report writing

6.1 Memo report
6.2 Incident report
6.3 Accident report
6.4 Trip report

7.0 Group discussion

7.1 Difference between group discussion and debate
7.2 Ensuring success in GD Conducting GD by giving topics
Topics varies from social, political, serious and current

8.0 Interview skills

8.1 Types of interview
8.2 Ensuring success in job interviews.
8.3 Appropriate use of non-verbal communication

Reference books:
English Communication - TTTI, Madras
Developing Communication Skill - Krishna Mohan & Meera Baner

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