Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 1
GOVT.TOOL ROOM & TRAINING CENTRE
SEMESTER: THIRD
Course: DIPLOMA IN TOOL & DIE MAKING
Syllabus -Theory and practical Subjects
SL. CODE SUBJECTS
Contact
Hours/Week
Contact
Hours/Semester NO
1 TDM301 Production Technology – III (Milling) 3 60 0 940 260 140 1960 1080
2 TDM302 E M & SOM 3 60
3 TDM303 Engineering Drawing –III(Assembly) 4 80
4 TDM304 Engineering Metrology 2 40
5 TDM305 Press Tool Theory-I 2 40
6 TDM306 Jigs & Fixtures (Theory) 2 40
Practical
7 TDM307 Work Shop – III 28.5 570
8 TDM308 CAD Lab – I (Solid Works) 3 60
Scheme of Examination
Course: DIPLOMA IN TOOL & DIE MAKING
SI.
No
Sub.
Code
Subjects Contact
Hours
per
Week
Exam
Duration
Scheme of Examination Total
Marks
Min
marks
for
passing
Exam Internal
Assessment
Theory Max Min Max Min
Marks Marks Marks Marks
1 TDM301 Production Technology – III (Milling)
3 3 100 50 20 10 120 60
2 TDM302 E M & SOM 3 3 100 50 20 10 120 60
3 TDM303 Engineering Drawing –III(Assembly)
4 4 100 50 20 10 120 60
4 TDM304 Engineering Metrology 2 3 100 50 20 10 120 60
5 TDM305 Press Tool Theory-I 2 3 100 50 20 10 120 60
6 TDM306 Jigs & Fixtures
(Theory) 2 3 100 50 20 10 120 60
Practical
7 TDM307 Work Shop – III 28.5 10 900 540 100 60 1000 600
8 TDM308 CAD Lab – I
(Solid Works) 3 3 100 50 20 10 120 60
Total 47.5
1600 890 240 130 1840 1020
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 2
PRODUCTION TECHNOLOGY-III (MILLING)
SUBJECT CODE: TDM 301
Learning goals for Production Technology-
On completion of this subject, the trainees will be able to:
Define milling and various types of milling machines and their parts description
Explain the specification of milling and work holding devices and their applications
Identify various types of milling cutters and classifications & explain cutter
geometry
Explain about tool holding devices
Define various types of milling operations and their working procedure and boring
Explain about Dividing Head and Rotary table
Define Indexing and Explain methods of Indexing with their examples
Explain about milling attachments and their usage
Define speed, feed, and depth of cut and calculations on machining time
Explain the necessity of coolant and mixing ratio
Explain the safety precautions of milling
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 3
PRODUCTION TECHNOLOGY-III (MILLING)
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. General safety
- Safety precautions
2. Classifications of Milling
- Definition
- Types and parts description
3. Specification and Work Holding devices
- Specification and example
- Work Holding Devices
- T- bolts and clamps
- Angle plates
- V-blocks
- Vices
- Special fixtures
4. Milling cutters
- Definition
- Types of cutters
- Cutters geometry
- Nomenclature of plain milling cutter
- Nomenclature of side milling cutter
5. Tool holding device
- Arber
- collets
- Adaptor
- Spring collets
- Bolted cutters
6. Milling operations
- Plain milling and Face milling
- Side milling and Straddle milling
- Angular milling and Gang milling
- Form milling and Profile milling
- End milling and Saw milling
- Milling key ways , grooves and slots
- Gear cutting and Helical milling
- Cam milling and Thread milling
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 4
PRODUCTION TECHNOLOGY-III (MILLING)
7. Dividing Head and Rotary table
- Definition
- Working process and applications of dividing head
- Definition of rotary table
- Working process and applications of rotary table
8. Indexing and methods of indexing
- Definition
- Direct or rapid indexing
- Plane or simple indexing
- Compound indexing
- Differential indexing
- Angular indexing
9. Milling attachment
- Vertical milling attachment
- Universal milling attachment
- High speed milling attachment
- Slotting attachment
- Universal spiral milling attachment
- Rack milling attachment
- Circular milling attachment
- Dividing head milling attachment
10. Problems and Machining time calculations
- Definition of speed, feed and Depth of cut
- Machining time calculations
11. Coolant
- Necessity of coolant
- Mixing ratio
12. Safety
- Safety precautions
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 5
WEEKLY PLAN FOR PRODUCTION TECHNOLOGY-III (MILLING )
WEEK
NO CHAPTER TITLE CONTENTS OF TOPICS
1
2
General safety Safety precautions
2 Classifications of Milling
Definition
Types and parts description
3-4
Specification and Work
Holding devices
Specification and example
Work Holding Devices
T- bolts and clamps
Angle plates
V-blocks
Vices
Special fixtures
5-6
Milling cutters
Definition
Types of cutters
Cutters geometry
Nomenclature of plain milling cutter
Nomenclature of side milling cutter
7
Tool holding device
Arber
collets
Adaptor
Spring collets
Bolted cutters
8-10
Milling operations
Plain milling and Face milling
Side milling and Straddle milling
Angular milling and Gang milling
Form milling and Profile milling
End milling and Saw milling
Milling key ways , grooves and slots
Gear cutting and Helical milling
Cam milling and Thread milling
11
Dividing Head and Rotary
table
Definition
Working process and applications of dividing head
Definition of rotary table
Working process and applications of rotary table
12-14
Indexing and methods of
indexing
Definition Direct or rapid indexing
Plane or simple indexing
Compound indexing
Differential indexing
Angular indexing
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 6
WEEKLY PLAN FOR PRODUCTION TECHNOLOGY-III (MILLING)
15-16
Milling attachment
Vertical milling attachment
Universal milling attachment
High speed milling attachment
Slotting attachment
Universal spiral milling attachment
Rack milling attachment
Circular milling attachment
Dividing head milling attachment
17
Problems and Machining
time calculations
Definition of speed, feed and Depth of cut
Machining time calculations
18
Coolant
Necessity of coolant
Mixing ratio
20 Safety
Safety precautions
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 7
ENGINEERING MECHANICS & STRENGTH OF MATERIALS
SUBJECT CODE: TDM 302
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60
Learning goals for EM&SOM -
On completion of the course the students should be able to…
Understand the Basics of Engineering Mechanics & SOM
Understand the force analysis and moment of a force.
Understand the concept of centre of gravity
Understand the concept of simple stresses & strains.
Understand strain energy & impact loading.
Understand the concept of thick & thin cylinders.
Understand the concept of Torsion and its applications.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 8
ENGINEERING MECHANICS & STRENGTH OF MATERIALS
SUBJECT CODE: TDM 302
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. INTRODUCTION TO ENGINEERING MECHANICS AND STRENGTH OF
MATERIALS
1.1 Introduction to Engineering Mechanics & SOM
1.2 Scalar & Vector quantities.
2. FORCE ANALYSIS
2.1 Composition & Resolution of forces – Force, examples of force, effect, characteristics
of a force, system of forces, Resultant force, methods for the resultant force and
simple problems.
2.2 Parallelogram law of forces and simple problems.
2.3 Triangle law of forces
2.4 Polygon law of forces2.5 Equilibrium of forces – Introduction, principles of
equilibrium, lami’s theorem, (with proof) Types of equilibrium.
3. CENTRE OF GRAVITY
3.1 Centre of gravity, methods of finding centre of gravity and axis of reference.
3.2 Centre of gravity of symmetrical unsymmetrical plane figures & cut out hole sections.
3.3 Simple problems.
4. SIMPLE STRESSES & STRAINS
4.1 Elasticity, stress, types of stress, strain.
4.2 Elastic limit, Hooke’s law, modulus of elasticity, factor of safety, working stress &
ultimate stress. With stress-strain Diagram.
4.3 Deformation of a body due to force acting on it.
4.4 Simple problems.
4.5 Volumetric strain of a rectangular body subjected to an axial force and 3 mutually
perpendicular forces.
4.6 Elastic constants, linear strain, lateral strain, volumetric strain & Poisson’s ratio.
4.7 Bulk modulus, relation between bulk modulus & young’s modulus (with proof).
4.8 Shear stress, shear strain & modulus of rigidity.
4.9 Relation between modulus of elasticity & modulus of rigidity (with proof).
4.10 Simple problems.
4.11 Stresses in Bars of varying Cross sections & Simple Problems.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 9
ENGINEERING MECHANICS & STRENGTH OF MATERIALS
5. STRAIN ENERGY & IMPACT LOADING
5.1 Introduction, resilience, proof resilience and modulus of resilience.
5.2 Types of loading.
5.3 Equation for strain energy stored in a body when the load is gradually applied.
5.4 Simple problems.
5.5 Equation for strain energy stored in a body when the load is suddenly applied.
5.6 Simple problems.
6. THICK AND THIN CYLINDERS
6.1 Introduction to thin cylinders, stresses in thin cylindrical shells.
6.2 Expression for circumferential stress & longitudinal stresses (without proof).
6.3 Simple problems.
6.4 Design of thin cylinders with simple problems.
6.5 Simple problems.
7. TORSION:
7.1 Torsion stress and strain 7.2 Theory of pure torsion
7.3 Angle of twist and shear strain – formulas 7.4 Equation for the strength of a shaft 7.5 Polar moment of inertia 7.6 Power transmitted by a shaft
7.7 Simple problems REFERENCE BOOKS
1. Engineering mechanics by R.S.Khurmi. 2. Strength of materials by R.S.Khurmi.
3. Applied Mechanics by S.S.Bhavikatti.
4. Strength of Materials by S.S.Bhavikatti.
5. Applied Mechanics & Strength of Materials by S.Ramamrutham.
6. Applied Mechanics & Strength of Materials by I.B.Prasad.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 10
WEEKLY PLAN FOR EM&SOM
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
1
INTRODUCTION TO
ENGINEERING
MECHANICS AND
STRENGTH OF
MATERIALS
Introduction to Engineering Mechanics & SOM
Scalar & Vector quantities.
2-5
FORCE ANALYSIS
Composition & Resolution of forces – Force,
examples of force, effect, characteristics of a force,
system of forces,
Resultant force, methods for the resultant force and
simple problems.
Parallelogram law of forces and simple problems.
Triangle law of forces
Polygon law of forces
Equilibrium of forces – Introduction, principles of
equilibrium, lami’s theorem,(with proof)
Types of equilibrium
6-7 CENTRE OF
GRAVITY
Centre of gravity, methods of finding centre of
gravity and axis of reference.
Centre of gravity of symmetrical unsymmetrical
plane figures & cut out hole sections.
Simple problems.
8-10
SIMPLE STRESSES &
STRAINS
Elasticity, stress, types of stress, strain.
Elastic limit, Hooke’s law, modulus of elasticity,
factor of safety, working stress & ultimate stress.
With stress-strain diagram.
Deformation of a body due to force acting on it.
Simple problems.
11-14
Volumetric strain of a rectangular body subjected to
an axial force and 3 mutually perpendicular forces.
Elastic constants, linear strain, lateral strain,
volumetric strain & Poisson’s ratio.
Bulk modulus, relation between bulk modulus &
young’s modulus (with proof).
Shear stress, shear strain & modulus of rigidity.
Relation between modulus of elasticity & modulus of
rigidity (with proof).
Simple problems.
Stresses in Bars of varying Cross sections & Simple
Problems.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 11
WEEKLY PLAN FOR EM&SOM
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS
15-17
STRAIN ENERGY &
IMPACT LOADING
Introduction, resilience, proof resilience and modulus
of resilience.
Types of loading.
Equation for strain energy stored in a body when the
load is gradually applied.
Simple problems.
Equation for strain energy stored in a body when the
load is suddenly applied.
Simple problems.
WEEKLY PLAN FOR
EM&SOM
18
THICK AND THIN
CYLINDERS
Introduction to thin cylinders, stresses in thin
cylindrical shells.
Expression for circumferential stress & longitudinal
stresses (without proof).
Simple problems.
Design of thin cylinders with simple problems.
Simple problems.
TORSION Torsion stress and strain
19-20
Theory of pure torsion
Angle of twist and shear strain – formulas
Equation for the strength of a shaft
Polar moment of inertia
Power transmitted by a shaft Simple problems
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 12
ENGINEERING DRAWING (ASSEMBLY)
SUBJECT CODE: TDM 303
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
Learning goals of Engineering Drawing (Assembly):
Draw the sectional views and interpret them correctly.
Prepare the assembly drawing with the help of the given detail drawings.
Prepare the assembly drawing with the help of given details for blanking tool
and progressive tool with all the parts.
Prepare the bill of materials.
Decide dimensions for all mating parts.
Interpret special views.
Interpret the symbols for surface finish.
Interpret tolerances and fits correctly.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 13
ENGINEERING DRAWING (ASSEMBLY)
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. ASSEMBLY AND DETAIL DRAWINGS
- Review previously done assemblies. - Concept of assembly drawings from the given part drawings. - Indication and interpretation of surface roughness symbols as per IS
696:1972. - Indication of fits and tolerances in assembly drawings.
2. Preparation of assembly drawings and parts list for the following:
Leaf Drill Jig
Universal Coupling
Tool Head of shaping Machine
Lathe slide rest
Tail Stock
Machine Swivel Vice
Machine Vice
Swivel Bearing
Knuckle Joint
2 Stage Progressive Tool
Blanking Tool
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 14
WEEKLY PLAN FOR ENGINEERING DRAWING (ASSEMBLY)
Week No. Topics
1 DETAIL DWG - PARTS OF LEAF JIG 2 LEAF JIG ASSEMBLY
3 & 4 UNIVERSAL COUPLING - Part & Assembly
5 & 6 KNUCKLE JOINT - Part & Assembly 7 TOOL HEAD OF SHAPING MACHINE 8 LATHE SLIDE REST 9 TAIL STOCK 10 I - INTERNALS 11 MINI VICE ASSEMBLY 12 MACHINE SWIVEL VICE 13 SWIVEL BEARING 14 PLUMMER BLOCK 15 & 16 BLANKING TOOL - Part & Assembly
17 & 18 PRESS TOOL (3rd YEAR PRACTICAL) - Part & Assembly
19
HAND INJECTION MOULD - Part & Assembly
20 II - INTERNALS
INSTRUCTIONS TO THE FACULTY 1. The above assemblies are framed for III Semester. 2. The assemblies have to be explained in detail before drawing.
3. Explain each part for material, quantity, manufacturing, fits, tolerance, functionality & purpose. 4. Explain about selection of cutting plane, sectioning, number of views, part list & title block.
5. Standard sizes for relief holes, counter bore, counter sink, chamfers, importance of reamed holes, Hole & shaft basis system, conventions.
6. Selection criteria of standard parts. 7. Script & Line standards, Dimensioning standards - zero line, chain line & Ordinate dimensioning.
8.Dimensioning standards - aligned & unidirectional methods, zero & chain line, Ordinate dimensioning
Reference books – Machine Drawing by KRG & N D Bhatt, Engineering Drawing by KRG & N D Bhatt. Engineering drawing with problems & solutions by K R Hart, Engineering drawing
for mechanical trades by K L Narayana, P Kannaiah, K Venkata Reddy. Fundamentals of Engineering drawing by Warren J Luzadder, Jon M Duff
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 15
ENGINEERING METROLOGY
SUBJECT CODE: TDM 304
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
Learning goals for Engineering Metrology
Explain the various standards of measurement
Define different types of tolerances
Explain & use tolerances disposition chart
Define various types of gauges & state the applications
Define comparators & explain the working principles
Explain the different options for angle measurement
Define surface roughness & explain inspection methods
Explain the function & application measuring machines
Explain the basics of statistical quality control
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 16
ENGINEERING METROLOGY
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. STANDARDS OF MEASUREMENT
1.1 Definition of Metrology
1.2 Objectives of Metrology
1.3 Definition of a standard
1.4 Need for standards
1.5 Imperial standard Yard
1.6 Airy points
1.7 International Prototype Meter
1.8 Types of Standards-Line, End and Wavelength standards
1.9 Subdivision of standards
1.10 Standardization and standardizing organizations
2. LIMITS,FITS AND TOLERANCES
2.1 Concept of tolerances 2.2 Need for tolerances 2.3 Types of tolerances- Unilateral and Bilateral 2.4 Analysis of tolerances- Addition & Subtraction of tolerances 2.5 Accuracy & Precision 2.6 Interchangeability & Selective assembly 2.7 ISO representation of holes & shafts & basic terminology 2.8 Classes & grades of tolerances 2.9 Fits and types of fits 2.10 Hole basis and Shaft basis system 2.11 Gauges- plug & snap/ring gauges, Go & NOGO gauges 2.12 Maximum & Minimum metal condition 2.13 Taylors principle, Wear allowance and limitation of gauges
Design problems 2.14 Brief description of form & positional tolerances
3. COMPARATORS
3.1 Definition
3.2 Difference between comparators & measuring instruments
3.3 Mechanical comparators – Dial indicators & its advantages & disadvantages
3.4 General working principle of pneumatic comparators, advantages &
disadvantages
3.5 Optical ,Electrical & Electronic comparators
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 17
ENGINEERING METROLOGY
4. ANGULAR MEASUREMENTS
4.1 Concept of Sine bars 4.2 Applications & limitations of sine bars 4.3 Sine table 4.4 Sine centre 4.5 Angle gauges 4.6 Problems on sine bar & Angle gauges
5. SURFACE ROUGHNESS
5.1 Surface irregularities 5.2 Profile geometry 5.3 Terminology of a surface – Real surface, nominal surface, roughness, waviness, sampling length, lay, central line of profile, Ra value, RMS value 5.4 Indication of surface roughness 5.5 Measurement of surface finish by Tomlinson surface tester
5.6 Indirect inspection methods – Touch inspection, Visual inspection, Scratch inspection, Surface photographs, Microscopic inspection
6. MEASURING MACHINES
6.1 Working principle of
6.2 Tool makers Microscope
6.3 Coordinate Measuring machines(CMM)
REFERENCE BOOKS:
1. Engineering Metrology – R.K.Jain
2. A text book of Metrology – M.Mahajan
3. Engineering metrology –K.J. Hume
4. Engineering Metrology & Instrumentation –R.K.Rajput
5. Metrology & Quality control – P.G.Deshpande
6. Mechanical measurements – BeckwithMarangoni & Lienhard,Pearson
Education,6th
Ed,2006
7. Engineering Metrology – I.C. Gupta, Dhanpat Rai Publications,Delhi
8. Measurements Systems Application & Design – Ernest O, Doblin, Mc Graw
hill book Co.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 18
WEKLY PLAN FOR
ENGINEERING METROLOGY
Week
No Chapter Topics to be covered
1-4 STANDARDS OF
MEASUREMENT
Definition of Metrology
Objectives of Metrology
Definition of a standard
Need for standards
Imperial standard Yard
Airy points
International Prototype Meter
Types of Standards-Line, End and Wavelength
standards
Subdivision of standards
Standardization and standardizing organizations
5-10
LIMITS,FITS AND
TOLERANCES
Concept of tolerances
Need for tolerances
Types of tolerances- Unilateral and Bilateral
Analysis of tolerances- Addition & Subtraction of
tolerances
Accuracy & Precision
Interchange ability & Selective assembly
ISO representation of holes & shafts & basic
terminology
Classes & grades of tolerances
Fits and types of fits
Hole basis and Shaft basis system
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 19
WEKLY PLAN FOR
ENGINEERING METROLOGY Week
No Chapter Topics to be covered
11-14 COMPARATORS
Definition
Difference between comparators & measuring
instruments
Mechanical comparators – Dial indicators & its
advantages & disadvantages
General working principle of pneumatic
comparators, advantages & disadvantages
Optical ,Electrical & Electronic comparators
15-17 ANGULAR MEASUREMENTS
Concept of Sine bars
Applications & limitations of sine bars
Sine table
Sine centre
Angle gauges
Problems on sine bar & Angle gauges
18-19 SURFACE ROUGHNESS
Surface irregularities
Profile geometry
Terminology of a surface – Real surface ,nominal
surface, roughness, waviness, sampling length,
lay, central line of profile, Ra value, RMS value
Indication of surface roughness
Measurement of surface finish by Tomlinson
surface tester
Indirect inspection methods – Touch inspection,
Visual inspection, Scratch inspection, Surface
photographs, Microscopic inspection
20 MEASURING MACHINES Tool makers Microscope
Coordinate Measuring machines(CMM)
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 20
PRESS TOOL THEORY – I
SUBJECT CODE: TDM 305
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
Learning goals Press Tool Theory- I:
At the end of the subject, the trainee will be able to know:
Explain the different types of press tool operations
Explain shearing theory and action
Describe and calculate cutting clearance between punch and die
Calculate cutting and stripping force and methods to reduce them
Explain the principles of fine blanking
Design and draw an optimum strip lay out for the given component drawing
Explain the materials, calculations and specifications of various elements of a press
tool and their functions
Explain the mounting methods of punches
Describe different types of strippers, stoppers and pilots
Calculate centre of pressure
Explain progressive, compound, fine blanking, combination, shaving, lancing and
trimming tools and their applications
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 21
PRESS TOOL THEORY – I
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. INTROCUTION TO TOOLING.
- Introduction
- Purpose, applications and advantages
- Types
2. TYPES OF PRESS TOOLS.
- Basic description of different types of press tools, their applications
3. ELEMENTS OF A PRESS TOOL.
- Different parts of a press tool
- Materials, functions and their importance
4. THEORY OF SHEARING.
- Shearing action on metal
- Plastic deformation
- Penetration
- Fracture
5. CUTTING CLEARANCE.
- Necessity of clearance
- Calculation of clearance
- Effects of insufficient, sufficient and optimum clearance
- Misalignment between punch and die
- Land and angular clearance
- Problems
6. CUTTING FORCE.
- Calculation of cutting force
- Methods of reducing the cutting force
7. STRIP LAYOUT.
- Unit stock and stock strip
- Types of strip layout
- Economic strip layout
- Problems
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 22
PRESS TOOL THEORY – I
8. PUNCH AND DIE.
- Introduction
- Basic requirement of a die
- Types of dies - solid and split type
- Types of punches
- Classification of punches
- Mounting of punches
- Materials for punches and dies
- Heat treatment methods
- Methods of manufacture of punch and die
9. STRIPPER.
- Functions
- Types and applications
10. STOPPER.
- Functions
- Types and applications
11. PILOT.
- Functions
- Types and applications
12. CENTRE OF PRESSURE.
- Meaning
- Importance in design
- Calculation of COP by analytical and graphical methods
13. DIE SETS.
- Elements of a die set
- Types of die sets
- Accuracy and manufacture
- Applications of different types
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 23
PRESS TOOL THEORY – I
14. PROGRESSIVE DIES.
- Introduction
- Pitch and pitch punch
- Advantages and disadvantages
- Classification
- Design considerations
15. COMPOUND DIES.
- Introduction
- Applications
- Construction
- Comparison with a progressive die
REFERANCE BOOKS:
1. Tool and die maker by Mahajan
2. Design fundamentals by Pacquin
3. Tool design by Donaldson
4. Basic die design by Osterguard
5. Advanced die design by Osterguard
6. Fundamentals of Tool Design By SME
7. Press Tools and Press Work By Waller
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 24
WEEKLY PLAN FOR PRESS TOOL THEORY – I
Week
No
Chapter Topics to be covered Remarks
1
INT
RO
DU
CT
ION
Introduction
Purpose of Tooling
Application of Tooling
Advantages of Tooling
Types of tooling (press tools, moulds,
die casting dies, jigs and fixtures)
Explanation and
demonstrate
different tools
2
Types
of
Pre
ss T
ools
Basic description of different types of a
press tool – blanking tool, piercing tool
and progressive tool
Compound Tool
Combination tool Brief explanation
and demonstrate the
products from each
tool
3
Coining tool
Bending tool
Embossing tool
Drawing tool
Flaring tool
Curling tool
Bulging tool
Swaging tool
4
Ele
men
ts o
f a
pre
ss t
ool
Different parts of a press tool and their
functions and importance
Top plate
Bottom plate Guide plate
Punch holder
Explain the
function, material,
requirements and
importance of each
element in detail.
Demonstrate all the
elements 5
Punch back plate
Stripper
Die plate
Pillars and bushes
Shank
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 25
WEEKLY PLAN FOR PRESS TOOL THEORY – I
Week
No
Chapter Topics to be covered Remarks
6
Shea
ring t
heo
ry
Principle of shearing action between punch
and die
3 stages of shearing
Edge radius
Cut band
Fracture
Blank
Burrs
Explain with the
help of pressed
components
7
Cutt
ing c
lear
ance
Importance of cutting clearance between
punch and die
Effect of insufficient and excessive
clearance
Optimum clearance
Misalignment between punch and die
Explain with the
help of components
with insufficient,
excessive and
optimum clearance.
8
Calculation of cutting clearance
Factors on which the cutting clearance
depends
Relation between piece part and punch size
Problems
Both the
mathematical
formula and thumb
rule to be
explained.
9 Land and angular clearance
Purpose Explain in detail
10 Determination of the sizes of punch and die
by applying clearances on punch and die
properly
Solve problems
11
Cutt
ing f
orc
e
Calculation of cutting force
Problems
Methods of reducing the cutting force
Selection of press
and its relation
with cutting force
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 26
WEEKLY PLAN FOR PRESS TOOL THEORY – I
Week
No
Chapter Topics to be covered Remarks
12
Str
ip l
ayout
Unit stock and stock strip
Direction of material grain
Strip layout and its types
Problems for
determining the
economic strip
layout
Economic utilization of strip
Strip width and its importance
Blank positioning
13
Punch
and D
ie
Types of dies
Basic design requirement of a die
Solid dies
Split dies
Factors influencing the selection of die sets
14
Introduction
Cutting, non-cutting and hybrid punches
Segregated and integrated punches
Types of punches – Plain, pedestal, bossed
and flanged Mounting of punches peening,
by screws, cross pins, araldite
15
Advantages and disadvantages of each
Materials for punches
Materials for dies
Effects of important alloys
Heat treatment methods
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 27
WEEKLY PLAN FOR PRESS TOOL THEORY – I
Week
No
Chapter Topics to be covered Remarks
16
Manufacture of punch and die – Filing,
Conventional machining, CNC machining,
EDM and WEDM.
Application of
each method to
be explained
Str
ipper
Function
Types
Solid stripper
Floating stripper
Rubber stripper
17
S
topper
Function
Stop position and registry position
Position types
Primary and secondary stoppers Finger stop
End stopper
Button stopper
Nest gauges and its types
Auto stopper (trigger)
18
Pil
ots
Function
Types and construction
Direct and indirect pilots
Bullet nose pilot
Flat arrows
Spring loaded pilots
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 28
WEEKLY PLAN FOR PRESS TOOL THEORY – I
Week
No
Chapter Topics to be covered Remarks
19
Cen
tre
of
pre
ssure
Shank positioning and its importance
Meaning of COP
Calculation of COP – approximate moments
method, centre of gravity method and
graphical method
Problems on calculating COP
Die
set
s
Introduction
Day light and shut height
Elements of a die set
Die set standards
Die set material
Explanation and
demonstrate Die
sets
Types of die set
Applications of different types of die sets
Accuracy of die sets and factors affecting the
accuracy
Manufacture of die sets
21
Pro
gre
ssiv
e to
ols
Introduction
Selection criteria
Construction and applications
Pitch and pitch punch
Advantages and disadvantages of progressive
dies
Explanation and
demonstrate tools
Classification of a progressive die -
Progressive blank die, progressive cut off and
form die, progressive draw die, progressive
cut and carry die
Design considerations in a progressive die
Explanation and
demonstrate tools
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 29
WEEKLY PLAN FOR PRESS TOOL
THEORY – I
22
Com
pound T
ools
Definition
Selection criteria
Application
Construction Difference between progressive
and compound die
Advantages and disadvantages
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 30
JIGS & FIXTURES (THEORY)
SUBJECT CODE: TDM 306
Learning goals Jigs & Fixtures
Students demonstrate their knowledge in various Jigs and Fixtures,
its design, clamping methods and design and drawing of jigs and
fixtures.
Subject aims at making the students learn jigs and fixtures, Locating
methods, clamping methods and guiding elements etc.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 31
JIGS & FIXTURES (THEORY)
Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. INTRODUCTION
- Definition of jigs and fixtures and their importance in industry
- Interchangeability
- Difference between jigs and fixtures
- Design considerations for jigs and fixtures
- Elements of jigs & fixture
- Materials
- Advantages and disadvantages
- Applications
2. LOCATION
- Definition and choice of location
- Degrees of freedom, 3-2-1 principle
- Types of locators
Locating methods and chip removal
Locating by Flat surface , support pads & pins
Conical locators (Fixed & Adjustable)
Diamond locators
V Locators ( Fixed& Adjustable )
- Redundant location
Errors caused in locating
- Fool proofing
3. CLAMPING
- Definition and need
- Requirements of a good clamping system
- Types of clamping
Plate or strap clamp, Solid clamp with heel pin,
Sliding clamps, slotted clamp, pivoted clamps, latch
clamps, swing clamps, Quick action clamps, multiple
clamps & Power clamps.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 32
4. GUIDING ELEMENTS
- Introduction
- Classification of drill bushes
- Types of bushes
Fixed bush, Liner bush, Slip bush, Threaded bush
- Special bushes
Headed & Headless bushes, shaped bush, extended
bushes.
- Materials and hardness requirements
5. TYPES OF JIGS
- Introduction
- Constructional features
- Elements of a jigs
- Types of jigs
Solid jig
Post jig
Pot jig
Turn over jig
Latch jig
Box jig
- Indexing Device – Liner & Rotary indexing
- Design considerations
- Jigs design for some simple components
6. TYPES OF FIXTURES
- Introduction
- Constructional features
- Elements of a fixtures
- Setting blocks and tenons
- Types of fixtures
Milling fixtures – Indexing fixtures
Turning fixtures
* Grinding fixtures
- Design considerations
- Fixture design for some simple components
REFERENCE BOOKS:
1. Jigs & Fixtures by P.H. Joshi
2. An introduction to jig & Tool Design by M.H.A. Kempster.
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 33
WEKLY PLAN FOR
JIGS & FIXTURES (THEORY)
Week No
Chapter Topics to be covered
1-4
INTRODUCTION
- Definition and need
- Interchangeability
- Difference between jigs and
fixtures
- Elements of jigs & fixture
- Materials
- Advantages and
disadvantages
- Applications
5-9 LOCATION
- Definition and need
- Degrees of freedom, 3-2-1
principle
- Types of locators
- Locating by Flat surface ,
support pads & pins
- Conical locators (Fixed &
Adjustable)
- Diamond locators
- V Locators ( Fixed&
Adjustable )
- Redundant location
- Errors caused in locating
- Fool proofing
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 34
Week No
Chapter Topics to be covered
10-12 CLAMPING
- Definition and need
- Requirements of a good
clamping system
- Types of clamping
13
Plate or strap clamp, Solid clamp with heel
pin, Sliding clamps, slotted clamp, pivoted
clamps, latch clamps, swing clamps, Quick
action clamps, Multiple clamps & Power
clamps.
14-16 DRILL BUSHES
- Introduction
- Classification of drill bushes
- Types of bushes
- Fixed bush, Liner bush, Slip
bush, Threaded bush
- Special bushes
- Headed & Headless bushes,
Shaped bush, Extended
bushes.
17
JIGS
- Introduction
- Constructional features
- Elements of a jigs
- Types of jigs
- Solid jig
- Post jig
- Pot jig
- Turn over jig
-
Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 35
- Latch jig
- Box jig
- Indexing Device – Liner &
Rotary indexing
- Design considerations
18 - Jigs design for some simple
components
19-20 FIXTURES
- Introduction
- Constructional features
- Elements of a fixtures
- Setting blocks and tenons
- Types of fixtures
- Milling fixtures – Indexing
fixtures
- Turning fixtures
- Grinding fixtures
- Design considerations
- Fixture design for some
simple components
WEKLY PLAN FOR JIGS & FIXTURES (THEORY)
Week No
Chapter Topics to be covered
Top Related