Scheme of Examination - karunadu.karnataka.gov.in Term Courses... · Design -II 4 4 100 50 20 10...
Transcript of Scheme of Examination - karunadu.karnataka.gov.in Term Courses... · Design -II 4 4 100 50 20 10...
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 1
GOVT.TOOL ROOM & TRAINING CENTRE
SEMESTER: SIXTH
Course: DIPLOMA IN TOOL & DIE MAKING
Syllabus -Theory and practical Subjects
Scheme of Examination
Course: DIPLOMA IN TOOL & DIE MAKING
SI.
No
Sub.
Code
Subjects
Contact
Hours
per
Week
Exam
Scheme of Examination
Total Marks
Min
marks
for
passing
Duration Exam
Internal
Assessment
Theory Max Min Max Min
Marks Marks Marks Marks
1 TDM601 Press Tool
Design -II 4 4 100 50 20 10 120 60
2 TDM602 Mould
Design -II 4 4 100 50 20 10 120 60
3 TDM603 Die Casting
Theory 3 3 100 50 20 10 120 60
4 TDM604 Industrial
Management 2 3 100 50 20 10 120 60
5 TDM605 Total Quality
Management 2 3 100 50 20 10 120 60
Practical’s
6 TDM606 Work
Shop – VI 26.5 10 900 540 100 60 1000 600
7 TDM607 CAD
Lab - III 3 3 100 50 20 10 120 60
8 TDM608 ISAP Lab 3 3 100 50 20 10 120 60
Total 47.5
1600 890 240 130 1840 1020
SL.
NO CODE SUBJECTS
Contact
Hours/Week
Contact
Hours/Semester
1 TDM601 Press Tool Design -II 4 80
2 TDM602 Mould Design -II 4 80
3 TDM603 Die-casting Theory 3 60
4 TDM604 Industrial Management 2 40
5 TDM605 Total Quality Management 2 40
Practical’s
6 TDM606 Work Shop – VI 26.5 530
7 TDM607 CAD Lab - III 3 60
8 TDM608 ISAP Lab 3 60
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 2
PRESS TOOL DESIGN-II
SUBJECT CODE: TDM 601
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
Learning goals for PRESS TOOL DESIGN-II
On completion of this subject, the trainees will be able to:
Calculation of Blank Diameter, Drawing force.
Calculation of Bend Allowance, Bending force.
Single Stage ‘U ‘Bending, V Bending, & Wiping Tool.
Design progressive bending tool with Floating type strippers.
Design progressive bending tool with Cut off & Part off operations.
Design multiple bends progressive tool.
Design progressive bending tool with Ball Cage in three views.
Design a combination tool assembly with part list.
Design a drawing tool assembly with part list.
Design & structure of a complete Project on Press Tool with reference to Component assigned.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 3
PRESS TOOL DESIGN-II
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. DESIGNING CONCEPT OF NON-CUTTING OPERATIONAL PRESS TOOLS
- DESIGN ANALYSES - Punch & Die Radius - Nesting - Pressure Pad ( Blank Holding Pressure) - Die Cushion construction - Ejector / Knockout Pins - Corner Setting Design on Punches (To minimize spring back) Stop Pin (to control the downward movement of the Moving Half)
2. BLANK DEVELOPED SIZE
- Calculation of Bend Allowance( Bending) - Calculation of Blank Diameter(Drawing)
3. SINGLE STAGE ‘U ‘BENDING TOOL ON REAR PILLAR DIES SET - Calculation of size of tool elements - Developed Blank Size Calculation - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
4. SINGLE STAGE “WIPING TOOL” ON DIAGONAL PILLAR DIE SET
- Calculation of size of tool elements - Developed Blank Size Calculation - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
5. “V “BEND DIES FOR PRESS BRAKES (OPEN TOOL)
- Calculation of size of tool elements - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
6. SINGLE STAGE INVERTED DRAW DIE WITH CENTRE PILLAR DIE SET
- Calculation of size of tool elements - Developed Blank Size Calculation - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material
Detail Part Drawings
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PRESS TOOL DESIGN -II
7. SINGLE STAGE RE-DRAW DIE WITH CENTRE PILLAR DIE SET
- Calculation of size of tool elements - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
8. FOUR STAGES PROGRESSIVE CUT & CARRY TOOL WITH FLOATING STRIPPER, PITCH PUNCH & PILOTS ON
A REAR PILLAR DIE SET
- Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
9. PROGRESSIVE BENDING TOOL WITH PITCH PUNCH & PILOTS ON A DIAGONAL PILLAR DIE SET (CONSTRUCTION TO SUIT DOWNWARD BENDING)
- Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
10. PROGRESSIVE BENDING TOOL WITH PITCH PUNCH & PILOTS ON A REAR PILLAR DIE SET (CONSTRUCTION TO SUIT UPWARD BENDING)
- Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
11. PROGRESSIVE BENDING TOOL WITH PITCH PUNCH & PILOTS ON A REAR PILLAR DIE SET
(CONSTRUCTION TO SUIT UPWARD BENDING)
- Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
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PRESS TOOL DESIGN –II
12. COMBINATION TOOL CENTRE PILLAR DIE SET (BLANK & DRAW) - Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
13. CASE STUDY (REPORT TO BE SUBMITTED WITH SPIRAL BINDING ALONG WITH DRAWN
DESIGNS)
- Component Analysis - Designing of Tool with BOM - Manufacturing & Heat Treatment - Try outs, Defects & Remedy - Estimation & Costing
14. DESIGN HANDS ON SOFTWARE
1. Seven Stages Progressive Bending Cutting Tool with Floating Stripper, Cut-off arrangement on four Pillar Die set.
2. Fine Blanking Tool - Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View - Assembly Side view - Bill of Material - Detail Part Drawings
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 6
WEEK PLAN FOR
PRESS TOOL DESIGN -II
WEEK No.
CHAPTER TOPICS ACTIVITY
1
Designing Concept of
Non-Cutting Operational
Press Tools
1. DESIGN ANALYSES
- Punch & Die Radius - Nesting - Pressure Pad ( Blank Holding
Pressure) - Die Cushion construction - Ejector / Knockout Pins - Corner Setting Design on
Punches ( To minimize Spring back) - Stop Pin (to control the
downward movement of the Moving Half)
Ask students to get different Components (Bend, Drawn, and Forming) before commencement of the Design Classes.
Show the animated Function of Single stage Bending Tools, Draw Tools & Forming Tools.
2 & 3 Blank Developed Size
- Calculation of Bend Allowance( Bending)
- Calculation of Blank Diameter(Drawing)
Explain one each Component of Bend & Draw How a Pre-Cut Blank can be
developed then ask students to Draw Blank drawing with dimensions for Bend
10 Components & Draw 10 Components.
4 Single Stage „ U „ Bending Tool on Rear Pillar Die Set
- Calculation of size of tool elements
- Developed Blank Size Calculation
- Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Display Bending Tool Chart. High light the Importance of Nesting & Stop Pin to
Control the Bending Depth
2 Components
6
Single Stage “Wiping
Tool” on Diagonal Pillar
Die Set
- Calculation of size of tool elements
- Developed Blank Size Calculation
- Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Create the Importance & Awareness about Edge Bending Die , Punch Profile &
Support Block 2 Components
7
“ V “ Bend Dies
for Press Brakes ( Open
Tool)
- Calculation of size of tool elements
- Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Create the Awareness about Air Bending & Press Breaks. Explain the Process planning of Designing Multi Bends dies in Press Breaks
2 Components
8
Single Stage Inverted
Draw Die with Centre
Pillar Die Set
- Calculation of size of tool elements
- Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Similar to the Compound Tool Construction. Highlight the Importance of Pressure Pad with Nesting & Shedder
2 Components
9
Single Stage Re-Draw
Die with Centre Pillar Die
Set
- Calculation of size of tool elements
- Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Highlight the importance in the following areas. 1. Fixed Stripper & its Construction. 2.Nesting
2 Components
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 7
WEEK PLAN FOR
PRESS TOOL DESIGN -II
10 & 11
Four Stages Progressive
Cut & Carry Tool with
Floating Stripper, Pitch
Punch & Pilots on a Rear
Pillar Die Set
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Highlight the Importance of Floating stripper, Guiding Arrangement & Ejector
in the Die Block 2 Components
12 & 13
Progressive Bending Tool
with Pitch Punch & Pilots
on a Diagonal Pillar Die
Set (Construction to Suit
Downward Bending)
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Highlight the Importance of following areas. 1.Pitch Punch Design 2.Pilot Design 3. Die Design with Cut-off arrangement.
2 Components
14 & 15
Progressive Bending Tool
with Pitch Punch & Pilots
on a Rear Pillar Die Set
(Construction to Suit
upward Bending)
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Highlight the Importance of following areas. 1.Pitch Punch Design 2.Pilot Design 3. Die Design with Cut-off arrangement.
2 Components
16
Progressive Bending Tool
with Notching Punch &
Pilots on a Diagonal Pillar
Die Set with Ball Caged
(Construction to Suit
three sides upward
Bending)
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Display to the students about BALL CAGES BUSH Explain their application & function in the Die Set
1 Component
17
Combination Tool Centre
Pillar Die Set (Blank &
Draw)
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Similar to the Compound Tool Construction. Highlight the Importance
of Pressure Pad, Shedder & Die Construction (Cutting & Non
Cutting) 1 Component
18 & 19
CASE STUDY
(Report to be Submit with
spiral binding along with
drawn Designs)
- Component Analysis - Designing of Tool with BOM - Manufacturing & Heat
Treatment - Try outs, Defects & Remedy - Estimation & Costing
Ask each student to get a component for
designing Progressive Bending Tool. (Allot 25% of sessional Marks by this
Report)
DESIGN HANDS ON SOFTWARE
20 to 22
1. Seven Stages
Progressive Bending
Cutting Tool With Floating
Stripper, Cut-off
arrangement on four
Pillar Die set.
2. Fine Blanking Tool
- Calculation of size of tool elements
- Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front
View
- Assembly Side view - Bill of Material - Detail Part Drawings
Designing to be done using Software‟s
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 8
MOULD DESIGN -II
SUBJECT CODE: TDM 602
Learning goals for MOULD DESIGN -II
On completion of this subject, the trainees will be able to:
Manufacturing methods for thermo plastic Components.
Design concept for split cavity/side core moulds.
Design concept in split actuation methods.
Design concept for three plate mould.
Design concept for simple hot runner moulds.
Design concept for simple die-casting Components.
Shrinkage calculation and there importance for core cavity dimension, and draft for core
and cavity.
Core and cavity Design concept.
Design concept for hand mould.
Design concept for two plate mould.
Design concept for different feed systems.
Design concept for different ejection system.
Design concept for different cooling system.
Design concept for different types parting surface component.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 9
MOULD DESIGN –II
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. INTRODUCTION TO DIFFERENT THERMO PLASTIC MATERIALS, AND MOULDING METHODS.1.COMPONENT ANALYSES.
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. - Core and cavity concept.
2. DESIGN: HAND INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. - Production rate. 2. DESIGN ANALYSES. - Core cavity concept. - Ejection method. - Core cavity design. - Assemble Drawing. - Detailed drawing of core and cavity. - Dimensioning of core cavity with shrinkage.
3. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods
2. DESIGN ANALYSES.
- Number of cavity: - Single cavity. - Type of gate:-sprue gate. - Type of Ejection:-pin ejection. - Cooling system:-Parallel/U-circuit. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC] - Detailed drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
4. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES - Component application. - Type of materials. - Type of moulding methods
2. DESIGN ANALYSES. - Number of cavity: single cavity. - Type of gate:-Spoke gate - Type of ejection:-Sleeve ejection. - Cooling system:-Annular cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD
- Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 10
MOULD DESIGN -II
5. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods 2. DESIGN ANALYSES. - Number of cavity: Two cavities. - Type of gate:-Ring gate. - Type of ejection:-Sleeve ejection. - Cooling system:-Annular cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
6. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. 2. DESIGN ANALYSES. - Number of cavity: Four cavities. - Type of Gate & Runner:-Rectangular edge gate with half round runner. - Type of ejection:-pin ejection. - Cooling system:-Annular cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
7. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. 2. DESIGN ANALYSES. - Number of cavity: Four cavities. - Type of gate & Runner:-Rectangular edge gate with half round runner. - Type of ejection:-Blade ejection. - Cooling system:-Annular cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
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MOULD DESIGN –II
8. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four cavities. - Type of gate & Runner:-Submarine gate with modified trapezoidal round runner. - Type of ejection:-Blade ejection. - Cooling system: - Parallel/U-circuit. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
9. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Eight cavities. - Type of gate & Runner:-Submarine gate with modified trapezoidal round runner. - Type of ejection:-Stripper plate ejection. - Cooling system: - Baffle cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
10. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring ejection. - Cooling system: - Bubbler cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 12
MOULD DESIGN -II
11. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring ejection. - Cooling system: - Helical cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
12. DESIGN: TWO PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring ejection. - Cooling system: - Angle hole cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
13. DESIGN: TWO PLATE MOULD INJECTION (SPLIT CAVITY)
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Two cavities. - Type of gate: - edge Gate. - Type of ejection:-pin ejection. - Cooling system: -Baffle cooling. - Split Activation: - Finger Cam. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
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MOULD DESIGN -II
14. DESIGN: TWO PLATE INJECTION MOULD (SPLIT CAVITY / SIDE CORE)
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Two cavities. - Type of gate: - edge Gate. - Type of ejection:-pin ejection. - Cooling system: -Baffle cooling. - Split Activation: - Dog leg Cam. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
15. DESIGN: THREE PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-pin ejection. - Cooling system: -Annular cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
16. DESIGN: THREE PLATE INJECTION MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Eight cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-Stripper plate ejection. - Cooling system: -Annular cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
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MOULD DESIGN -II
17. DESIGN: HOT RUNNER MOULD
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-Stripper plate ejection. - Cooling system: -Annular cooling. - Core cavity concept. - Core cavity design. - Hot runner Manifold design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
18. DESIGN: DIE CASING
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single cavity. - Type of gate: - rectangular Gate. - Type of ejection:-pin ejection. - Core cavity concept. - Core cavity design. - Assembly drawing with STD Mould base [DME/GTTC]. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.
19. DESIGN HANDS ON SOFTWARE - Basic rules. - Component design. - Core cavity design. - Tool design. - Detail drawings. - Electrode design. - Dimensioning with shrinkage.
- Bill of material.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 15
WEEK PLAN FOR
MOULD DESIGN -II
WEEK No.
CHAPTER TOPICS ACTIVITY
1
Introduction to
different thermo
plastic materials, and
moulding methods.
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. - Core and cavity concept.
Ask students to get different plastic materials before commencement of the design class.
Ask the application to student for their collected components.
Segregate the components like heat, wear resistance, toughness, aesthetic look and application components etc.
2 Design:
Hand injection mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. - Production rate.
2. DESIGN ANALYSES. - Core cavity concept. - Ejection method. - Core cavity design. - Assemble Drawing. - Detailed drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage.
Ask the student to identify the placement of component.
Ask the students to identify core cavity surface.
Ask the students type ejection to be used.
Core cavity Design for 05 different types of components.
Example/assignment: Design No: 01.
3
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods
2. DESIGN ANALYSES. - Number of cavity: - Single
cavity. - Type of gate:-sprue gate. - Type of Ejection:-pin ejection. - Cooling system:-Parallel/U-
circuit. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC] - Detailed drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:02
4
Design:
Two plate injection
mould
1. COMPONENT ANALYSES - Component application. - Type of materials. - Type of moulding methods
2. DESIGN ANALYSES. - Number of cavity: single cavity. - Type of gate:-Spoke gate - Type of ejection:-Sleeve
ejection. - Cooling system:-Annular
cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:03
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 16
WEEK PLAN FOR
MOULD DESIGN -II
5
Design:
Two plate injection
mould
- Base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage.
- Bill of material.
6
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four
cavities. - Type of Gate & Runner:-
Rectangular edge gate with half round runner.
- Type of ejection:-pin ejection. - Cooling system:-Annular
cooling - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:05
7
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four
cavities. - Type of gate & Runner:-
Rectangular edge gate with half round runner.
- Type of ejection:-Blade ejection.
- Cooling system:-Annular cooling
- Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:06
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WEEK PLAN FOR
MOULD DESIGN -II
8
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four
cavities. - Type of gate & Runner:-
Submarine gate with modified trapezoidal round runner.
- Type of ejection:-Blade ejection.
- Cooling system: - Parallel/ U-circuit.
- Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:06
9
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Eight
cavities. - Type of gate & Runner:-
Submarine gate with modified trapezoidal round runner.
- Type of ejection:-Stripper plate ejection.
- Cooling system: - Baffle cooling.
- Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:07
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WEEK PLAN FOR
MOULD DESIGN -II
10
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single
cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring
ejection. - Cooling system: - Bubbler
cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:08
11
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single
cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring
ejection. - Cooling system: - Helical
cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:09
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 19
WEEK PLAN FOR
MOULD DESIGN -II
12
Design:
Two plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single
cavity. - Type of gate: - Sprue Gate. - Type of ejection:-Stripper ring
ejection. - Cooling system: - Angle hole
cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:10
13
Design:
Two plate mould
injection (Split Cavity)
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Two
cavities. - Type of gate: - edge Gate. - Type of ejection:-pin ejection. - Cooling system: -Baffle cooling. - Split Activation: - Finger Cam. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:11
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 20
WEEK PLAN FOR
MOULD DESIGN -II
14
Design:
Two plate injection
mould
(Split Cavity / side
core)
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Two
cavities. - Type of gate: - edge Gate. - Type of ejection:-pin ejection. - Cooling system: -Baffle cooling. - Split Activation: - Dog leg Cam. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:12
15
Design:
Three plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Four
cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-pin ejection. - Cooling system: -Annular
cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:13
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 21
WEEK PLAN FOR
MOULD DESIGN -II
16
Design:
Three plate injection
mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Eight
cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-Stripper plate
ejection. - Cooling system: -Annular
cooling. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment:
Design No:14
17
Design:
Hot runner mould
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods. 2. DESIGN ANALYSES. - Number of cavity: Four
cavities. - Type of gate: - pinpoint Gate. - Type of ejection:-Stripper plate
ejection. - Cooling system: -Annular
cooling. - Core cavity concept. - Core cavity design. - Hot runner Manifold design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection, type of cooling.
Size of mould base. Example/assignment: Design No:15
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WEEK PLAN FOR
MOULD DESIGN -II
18 Design:
Die casing
1. COMPONENT ANALYSES. - Component application. - Type of materials. - Type of moulding methods.
2. DESIGN ANALYSES. - Number of cavity: Single
cavity. - Type of gate: - rectangular
Gate. - Type of ejection:-pin ejection. - Core cavity concept. - Core cavity design. - Assembly drawing with STD
Mould base [DME/GTTC]. - Detail drawing of core and
cavity. - Dimensioning of core cavity
with shrinkage. - Bill of material.
Justification for type of mould, type of gate, type of ejection.
Size of mould base. Example/assignment:
Design No:16
DESIGN HANDS ON SOFTWARE
WEEK No.
CHAPTER TOPICS ACTIVITY
19 to 22
1. Hand mould.
2. Two plate injection
mould.
3. Split Cavity design.
4. Three Plate Mould.
- Basic rules. - Component design. - Core cavity design. - Tool design. - Detail drawings. - Electrode design. - Dimensioning with shrinkage. - Bill of material.
Designing to be done using Software‟s Auto Cad/Solid works/Pro-e/UG/Catia
Note:
After evaluating the design a similar component with different shape, size & Dimension
may given to the trainee as Assignment for practice and to gain knowledge in designing.
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DIE CASTING (THEORY)
SUBJECT CODE: TDM 603
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60
Learning goals for DIE CASTING (THEORY)
On completion of this subject, the trainees will be able to:
Define Die casting, give Introduction on Die casting.
Explain classifications of die casting.
Define Gravity die casting, list out applications, advantages and disadvantages.
Define Pressure die casting, list out applications, advantages and disadvantages
Explain brief on Centrifugal Casting.
Explain die casting Alloys: - High fusion and Low fusion.
Explain requirements of Die casting Machines.
Explain the classifications of Die casting machines.
Explain brief on hot chamber and Cold chamber Die casting Machines.
Explain about die locking mechanisms.
Explain ejector system of die casting.
Define feed system, explain brief on feed system.
Define over flow and importance of over flow.
Explain about air vents and importance.
Explain cooling system and their types used in die casting.
Explain the defects and remedies of die casting.
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 24
DIE CASTING (THEORY)
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60
SPECIFIC INSTRUCTIONAL OBJECTIVES: 1. Introduction
- Definition of die casting
2. Classifications
- Gravity dies casting - Definition - Application - Advantages & Disadvantages
- Pressure die casting - Definition - Application - Advantages & Disadvantages - Centrifugal die casting
3. Die casting Alloys
- High fusion alloys - Low fusion alloys
4. REQUIREMENTS OF DIE CASTING MACHINES
- To hold die casting die - To inject the molten metal under pressure into die - To close die with required locking force against the applied injection pressure. - To open the die casting die and eject the component
5. CLASSIFICATIONS OF DIE CASTING MACHINES
- Hot Chamber Die casting Machines - Cold Chamber Die Casting Machines - Horizontal Cold Chamber Casting Machine - Vertical Cold Chamber Casting Machine - Disadvantage of cold chamber die casting - Machine specification
6. DIE LOCKING MECHANISM
- Hydraulic and toggle locking - Straight hydraulic locking system
7. EJECTOR SYSTEM
- Mechanical actuation - Rack and pinion ejection system - Hydraulic actuation
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DIE CASTING (THEORY)
8. FEED SYSTEM
- Runner - Gate construction - Types of gate - Calculation to find runner and gate
9. OVER FLOW
- Define over flow and their importance
10. AIR VENTS AND COOLING SYSTEM
- Define air vents and their importance - Define cooling and types of cooling method
11. DIE CASTING DEFECTS AND REMEDIES
- Surface finish - Cold shots , incomplete filling of cavity - Heat waves - Blisters - Sinks - Lamination - Soldering - Dragging - Die erosion - Sounders - Dimensional reproducibility - Metal dribble from sprue hole
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WEEKLY PLAN FOR
DIE CASTING (THEORY)
WEEK NO
CHAPTER TITLE CONTENTS OF TOPICS
1-4
INTRODUCTION Definition of die casting
CLASSIFICATIONS
Gravity die casting Definition Application Advantages & Disadvantages Pressure die casting Definition Application Advantages & Disadvantages centrifugal die casting
4-7
DIE CASTING ALLOYS High fusion alloys Low fusion alloys
REQUIREMENTS OF DIE CASTING MACHINES
To hold die casting die To inject the molten metal under pressure into die To close die with required locking force against the applied injection pressure. To open the die casting die and eject the component
8-10 CLASSIFICATIONS OF DIE
CASTING MACHINES
Hot Chamber Die casting Machines Cold Chamber Die Casting Machines Horizontal Cold Chamber Casting Machine Vertical Cold Chamber Casting Machine Disadvantage of cold chamber die casting Machine specification
11-12 DIE LOCKING MECHANISM Hydraulic and toggle locking Straight hydraulic locking system
13-14 EJECTOR SYSTEM
Mechanical actuation Rack and pinion ejection system Hydraulic actuation
15-16 FEED SYSTEM
Runner Gate construction Types of gate Calculation to find runner and gate
17-18
OVER FLOW Define over flow and their importance
AIR VENTS AND COOLING SYSTEM
Define air vents and their importance Define cooling and types of cooling method
19-20 DIE CASTING DEFECTS AND
REMEDIES
Surface finish Cold shots , incomplete filling of cavity Heat waves Blisters Sinks Lamination Soldering Dragging Die erosion Sounders Dimensional reproducibility Metal dribble from sprue hole
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INDUSTRIAL MANAGEMENT
SUBJECT CODE: TDM 604
Learning goals for INDUSTRIAL MANAGEMENT
On completion of this subject, the trainees will be able to:
Understand the estimation and costing procedure in industries
Know the actual costing process and calculation of selling prices
Understand the depreciation of equipments, plants and to know the different methods of
calculating depreciation
Know the procedure for calculating material cost of various components
Understand the procedure for estimation of various shops
Know the labour wages and incentives
Know about basics of financial management
Understand the concepts of project planning and breakeven analysis
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INDUSTRIAL MANAGEMENT (THEORY)
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES: 1. INTRODUCTION TO ESTIMATION AND COSTING
- Estimation - Definition, Importance and Aims - Qualities and functions of an Estimator - Source of errors in estimation - Constituents of Estimation - Costing - Definition and Aims - Standard cost and its Advantages - Difference between estimation and costing - Advantages of efficient costing
2. ELEMENTS OF COST
- Elements of cost- material, labour, expenses - Material - Direct material, indirect material and examples - Calculation of Material cost - Labour - direct, indirect labour and examples - Calculation of labour cost - Expenses - direct, indirect expenses and examples - Classification of expenses - factory, administrative, selling and distribution expenses and examples - Fixed and variable expenses and examples - Components of cost - prime cost, factory cost, office cost, total cost - Selling price - Block diagram to show the relationship between elements and components of cost - Simple problems on above - Allocation of on-cost - methods and simple problems
3. INDIRECT EXPENSES AND DEPRECIATION
- Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance - Depreciation - causes, methods of calculating depreciation
4. MENSURATION AND ESTIMATION OF MATERIAL COST
- Area of regular plane figures - Volume and surface area of solids (formulae only) - Estimation of material costs of tool elements and total cost of tool. - Mechanical Estimation - Estimation in machine shop - Definition of cutting speed, feed, depth of cut - Estimation of time for various operations like Turning, Knurling, Facing, Drilling, Boring,
Reaming, Threading, Tapping, Milling, Grinding, Shaping and Planning - Estimation in sheet metal shop - Sheet material and gauge number, Select suitable formula for
Estimation
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INDUSTRIAL MANAGEMENT
5. WAGES AND INCENTIVES
- Definition of wages, normal wages, real wages, living wages, fair wages - Minimum wages, methods of wage payment - Incentives - definition of incentive, types of incentives, examples - Characteristics of a good wage and incentive systems - Standard time - work measurement - Bonus system - collective bonus system, group bonus system
6. INTRODUCTION TO FINANCIAL MANAGEMENT
- Definition of terms such as assets, liabilities, current and long term assets and liabilities, capital, income, expenses, gain
- Working capital - definition - net and gross working capital - factors affecting working capital. - Maintenance of accounts through journal ledger, cash book, balance sheet. - Transaction with bank - credits, payments overdraft, current account, securities.
7. PROJECT PLANNING AND BREAK EVEN ANALYSIS
- Concept of project work. - Project planning like market survey, project capacity, selection of site, plant Layout, product design, drawing, specification, material requirement operation planning, - Break even analysis - break event chart, diagram to illustrate break event point, Simple
problems on break even analysis
8. OPERATION RESEARCH
- Game theory: definitions- strategy, saddle point, two person zero sum game, dominance property, problems
- Transportation problem: NW corner rule, Least cost method (simple problems) - Assignment problem (balanced problems only)
REFERENCE BOOKS 1. Mechanical estimation and costing- T.R.Banga and S.C.Sharma
2. Estimation and costing – by Acharya and Narang
3. Industrial Organisation and Engineering Economics by Banga and Sharma
4. Mechanical Estimation by Malhotra
5. Operations research by S D Sharma
6. Operations research by Phaneesh
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WEEKLY PLAN FOR
INDUSTRIAL MANAGEMENT
WEEK
NO CHAPTER TITLE CONTENTS OF TOPICS
1-3
INTRODUCTION TO ESTIMATION
AND COSTING
Estimation - Definition, Importance and Aims Qualities and functions of an Estimator Source of errors in estimation Constituents of Estimation Costing - Definition and Aims Standard cost and its Advantages Difference between estimation and costing Advantages of efficient costing
4-6 ELEMENTS OF COSTS
Elements of cost- material, labour, expenses Material - Direct material, indirect material and examples Calculation of Material cost Labour - direct, indirect labour and examples Calculation of labour cost Expenses - direct, indirect expenses and examples Classification of expenses - factory, administrative, selling and distribution expenses and examples Fixed and variable expenses and examples Components of cost - prime cost, factory cost, office cost, total cost Selling price Block diagram to show the relationship between elements and components of cost Simple problems on above Allocation of on-cost - methods and simple problems
7-9 INDIRECT EXPENSES AND
DEPRECIATION
Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance Depreciation - causes, methods of calculating depreciation
10-13
MENSURATION AND
ESTIMATION OF MATERIAL COST
Area of regular plane figures Volume and surface area of solids (formulae only) Estimation of material costs of tool elements and total cost of tool. Mechanical Estimation Estimation in machine shop - Definition of cutting speed, feed, depth of cut Estimation of time for various operations like Turning, Knurling, Facing, Drilling, Boring, Reaming, Threading, Tapping, Milling, Grinding, Shaping and Planning Estimation in sheet metal shop - Sheet material and gauge number, Select suitable formula for Estimation
14-16 WAGES AND INCENTIVES
Definition of wages, normal wages, real wages, living wages, fair wages Minimum wages, methods of wage payment Incentives - definition of incentive, types of incentives, examples Characteristics of a good wage and incentive systems Standard time - work measurement Bonus system - collective bonus system, group bonus system
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 31
WEEKLY PLAN FOR
INDUSTRIAL MANAGEMENT
WEEK
NO CHAPTER TITLE CONTENTS OF TOPICS
17-18
INTRODUCTION TO FINANCIAL
MANAGEMENT
Definition of terms such as assets, liabilities, current and long term assets and liabilities, capital, income, expenses, gain Working capital - definition - net and gross working capital - factors affecting working capital. Maintenance of accounts through journal ledger, cash book, balance sheet. Transaction with bank - credits, payments overdraft, current account, securities.
19-20
PROJECT PLANNING AND BREAK
EVEN ANALYSIS
Concept of project work. Project planning like market survey, project capacity, selection of site, plant Layout, product design, drawing, specification, material requirement operation planning, Break even analysis - break event chart, diagram to illustrate break event point, Simple problems on break even analysis
OPERATION RESEARCH
Game theory: definitions- strategy, saddle point, two person zero sum game, dominance property, problems Transportation problem: NW corner rule, Least cost method (simple problems) Assignment problem (balanced problems only)
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 32
TOTAL QUALITY MANAGEMENT
SUBJECT CODE: TDM 605
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. OVERVIEW OF TQM
- Definition of TQM - Definition of quality and its characteristics - TQM concepts - Deming’s philosophy - Principles of TQM - Benefits of TQM - TQM organization
2. LEADERSHIP - Characteristics of TQM leaders - Role of TQM leadership - Continuous process improvement - The PDSA (Plan-Do-Study-Act) cycle - Six sigma (6σ) quality
3. QUALITY MANAGEMENT TOOLS - Nominal group technique - Affinity diagram - Inter relationship diagram - Tree diagram - Matrix diagram - Activity network diagram
4. STATISTICAL PROCESS CONTROL - Seven quality control tools - Process Capability - Defect v/s defective
5. FUNDAMENTAL STATISTICS AND PROBABILITY DISTRIBUTIONS - Measures of central tendency- mean mode, median, standard deviation Problems - Definition and Properties of Probability - Poisson distribution- simple problems - Binomial distribution -simple problems - Normal distribution- simple problems
6. DESIGNS FOR SIX SIGMA - Tools for concept and design development - Design optimization - Design verification
7. RELIABILITY AND LIFE TESTING - Definitions of Reliability, Life testing and Redundancy - Failure rate curve - MTBF, MTTR, MTTF (simple problems) - Systems reliability – series and parallel configuration - Improvement factor
REFERENCE BOOKS
1. Total Quality Management by NVR Naidu 2. Total Quality Management By S D Ramachandra 3. Statistics by Mahajan 4. Statistics by Raj Mohan –volume 1 & 2
Govt. Tool Room & Training Centre Bangalore -10 VI- SEMESTER DTDM COURSE P a g e | 33
WEEKLY PLAN FOR
TOTAL QUALITY MANAGEMENT
WEEK
NO CHAPTER TITLE CONTENTS OF TOPICS
1-3
OVERVIEW OF TQM
Definition of TQM Definition of quality and its characteristics TQM concepts Deming’s philosophy Principles of TQM Benefits of TQM TQM organization
4-6 LEADERSHIP
Characteristics of TQM leaders Role of TQM leadership Continuous process improvement The PDSA (Plan-Do-Study-Act) cycle Six sigma (6σ) quality
7-9
QUALITY MANAGEMENT
TOOLS
Nominal group technique Affinity diagram Inter relationship diagram Tree diagram Matrix diagram Activity network diagram
10-12 STATISTICAL PROCESS CONTROL
Seven quality control tools Process Capability Defect v/s defective
13-15 FUNDAMENTAL STATISTICS AND
PROBABILITY DISTRIBUTIONS
Measures of central tendency- mean mode, median, standard deviation Problems Definition and Properties of Probability Poisson distribution- simple problems Binomial distribution -simple problems Normal distribution- simple problems
16-18 DESIGNS FOR SIX SIGMA
Tools for concept and design development Design optimization Design verification
19-20 RELIABILITY AND LIFE
TESTING
Definitions of Reliability, Life testing and Redundancy Failure rate curve MTBF, MTTR, MTTF (simple problems) Systems reliability – series and parallel configuration Improvement factor