GOVT.

TOOL ROOM & TRAINING CENTRE

SEMESTER: THIRD
Course: DIPLOMA IN TOOL & DIE MAKING

Syllabus -Theory and practical Subjects

SL. Contact Contact

NO CODE SUBJECTS
Hours/Week Hours/Semester
Production Technology (Milling-
1 20TD31T 3 64
Grinding)
20TD32T
2 E M & SOM 3 64
20TD33T
3 Engineering Metrology 3 64
20TD34T
4 Material Technology-1 3 64
20TD35T Engineering Drawing –III
5 4 94
(Assembly)
Practical
6 20TD31P CAD Lab – I (Solid Works) 2 64
7 20TD32P Work Shop – III 20 386
AUDIT SUBJECTS
8 20TD31A Koushalya Kaipidi 2 64

Scheme of Examination

Scheme of Examination
Contact Internal Min
Subjects
SI. Sub. Hours Exam Exam marks
Theory Assessment Total
No Code per Duration for
Week Max Min Max Min Marks passing
Marks Marks Marks Marks
Production Technology – III
1 20TD31T 3 3 100 50 20 10 120 60
(Milling)
20TD32T
2 E M & SOM 3 3 100 50 20 10 120 60
20TD33T
3 Engineering Metrology 3 3 100 50 20 10 120 60
20TD34T
4 Material Technology-1 3 3 100 50 20 10 120 60
20TD35T Engineering Drawing –
5 4 4 100 50 20 10 120 60
III(Assembly)
Practical
6 20TD31P CAD Lab – I (Solid Works) 2 3 100 50 20 10 120 60
7 20TD32P Work Shop – III 20 10 900 540 100 60 1000 600
Audit Subject
8 20TD31A Koushalya kaipidi 2 3 100 50 20 10 120 60
Total 40 --- 1600 890 240 130 1840 1020
 PRODUCTION TECHNOLOGY (MILLING)

SUBJECT CODE: 20TD31T

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

PRODUCTION TECHNOLOGY (MILLING)

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

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

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
 PRODUCTION TECHNOLOGY (GRINDING)

Learning goals for Production Technology-IV

On completion of this subject, the trainees will be able to:

 Explain the operations on various types of grinding machines, Tool and Cutter
Grinder and non-conventional machines like Electric discharge machines, Jig
grinding machines etc.
 Explain safety precautions to be followed on the above machines

 Calculate the various cutting parameters and machining time on the above
machines
 Explain the use of appropriate tool and work holding devices, auxiliary attachments
for the above machines
 Explain and select proper cutting tools for a particular operation on the above
machines

REFERANCE BOOKS:

1. Basic machine shop practice by Tejwani

2. Workshop technology by Chapman
3. Technology of Machine tools by Krar and Oswald
4. Westermann tables
5. All about machine tools by Gerling
6. Production Technology by Hazra Choudhary
7. Production technology by R.K.Jain

PRODUCTION TECHNOLOGY(GRINDING)

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. GRINDING
- Types and part description, specification
- Grinding wheels – abrasives, bonds (silicate, vitrified, shellac), grit, grade,
structure and specification, super abrasives like CBN, Ceramic grinding wheels
- Wheel selection – types of wheels, work material, surface finish, profile,
machine type, coolant
- Wheel shapes – straight, cup, saucer, flange cup, cutting off, dish, tapered,
double cup etc
 - Wheel mounting – sound check, preparation of wheel, requirement of flanges,
flange diameter, tightening wheel on flange, cardboard, rubber, compressive
washers, safety precautions
- Wheel balancing – reason for balancing, methods, static and dynamic balancing
- Wheel dressing – purpose of dressing, types of dressers, cooling during
dressing, depth of cut, RPM of wheel, selection of dressers and their speed.
- Use of coolant – purpose, types, filtering of coolants, requirements of a good
coolant
- Auxiliary equipment – Magnetic bed, laminated blocks, V block, sine bar, sine
table, demagnetizing unit
- Surface grinding operations – wheel selection, cutting parameters, right angle
grinding, grinding of thin components and edges
- Cylindrical grinding – wheel selection, guidelines for OD, ID and plunge cut
grinding
- Profile grinding operations – selection of wheels, radius dressing, tangent
dresser, sine dresser, double sided dresser, optical dresser, pantograph dresser
etc
- Cutting speed, rpm, feed, depth of cut, machining time, different units,
calculations and problems
- Safety precautions in grinding

2. JIG GRINDING
- Jig grinding machine and its construction, applications of JG, OD and ID
grinding, profile grinding
- Safety precautions in jig grinding

3. TOOL AND CUTTER GRINDING

- Tool and cutter grinding machine – construction and applications, various
spindles, spindle head, tail stock, OD and ID grinding, spiral grinding
- Safety precautions in tool and cutter grinding
4. ELECTRIC DISCHARGE MACHINING
- Concept of EDM
- Application and principles
- Advantages and disadvantages
- Electrode- metallic and non-metallic materials, requirements of a good electrode
material
- Dielectric fluid – need and their requirements
- Process description, material removal rate, polarity of work and electrode, pulse
time and temperatures, voltage and current during sparking, their effects on the
surface and MRR
- Spark gap and its importance, determination of spark gaps for roughing and
finishing operations, factors on which the spark depends
- General problems and trouble shooting in EDM.
- EDM machine – construction, table, working head, motors, spindle, dielectric
tank
- Electrode clamping – fixing with screws, glue, soldering etc
- Flushing – purpose and methods of flushing
 - Safety precautions in EDM

ENGINEERING MECHANICS & STRENGTH OF MATERIALS

SUBJECT CODE: 20TD32T

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

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.

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.
 ENGINEERING MECHANICS & STRENGTH OF MATERIALS

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.

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

ENGINEERING METROLOGY

SUBJECT CODE: 20TD33T

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

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
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.
9. Total Quality Management by NVR Naidu
10. Total Quality Management By S D Ramachandra
11. Statistics by Mahajan
12. Statistics by Raj Mohan –volume 1 & 2

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 Interchange ability & 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

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)

7. TOTAL QUALITY MANAGEMENT [TQM]

7.1 Definition of TQM
7.2 Definition of quality and its characteristics
7.3 TQM concepts
7.4 Deming’s philosophy
7.5 Principles of TQM
7.6 Benefits of TQM
7.7 TQM organization

8. LEADERSHIP
8.1 Characteristics of TQM leaders
8.2 Role of TQM leadership
8.3 Continuous process improvement
8.4 The PDSA (Plan-Do-Study-Act) cycle
8.5 Six sigma (6σ) quality

9. STATISTICAL PROCESS CONTROL

9.1 Seven quality control tools
9.2 Process Capability
9.3 Defect v/s defective

10. RELIABILITY AND LIFE TESTING

10.1Definitions of Reliability, Life testing and Redundancy
10.2 Failure rate curve
10.3 Systems reliability – series and parallel configuration
10.4 Improvement factor
 MATERIAL TECHNOLOGY - I

SUBJECT CODE: 20TD34T

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

Learning goals for Material Technology

On completion of this subject, the trainees will be able to:

 Explain nature & fractures of Pig Iron
 Explain composition, properties & use of cast iron
 State the manufacturing process of steel
 Explain the mechanical properties of steel
 Classify steel types
 Explain the constituents of steel
 State the effect of carbon content in steel

REFERANCE BOOKS:
1 Heat treatment – Principles and techniques By T.V.Rajan, C.P.Sharma, Ashok
Sharma
1. Material Science By R.B.Gupta
2. Material Science and processes By S.K.Hazra Chowdhary
3. Material Science and Metallurgy By O.P.Khanna
4. Westermann tables

MATERIAL TECHNOLOGY – I

1. INTRODUCTION TO METAL PROPERTIES & APPLICATION

1.1. Definition of Material Technology, Classes of engineering materials – Metals &

alloys, ceramics, organic substances
1.2. Metals – ferrous and non-ferrous metals
1.3. Different properties & behaviour of materials, Mechanical properties of materials –
strength,
1.4. Elasticity, plasticity, ductility, malleability, brittleness, hardness, toughness,
resilience, stiffness, fatigue
1.5. Crystalline structure of metal. Meaning of Structure
1.6. Crystal and crystallization
1.7. Space lattice and unit cell
1.8. Crystalline structure of metals – BCC, FCC, and HCP

2. FERROUS METAL & ITS MANUFACTURING PROCESS

2.1. Pig iron – composition and structure
2.2. Allotropic changes of pure iron, Iron ore, Manufacture in blast furnace
2.3. Composition, fracture, properties and uses of pig iron
2.4. Cast Iron - composition and structure manufacture in cupola furnace
2.5. Composition, fracture, properties and uses of cast iron
2.6. Types of cast iron, Grey cast iron – properties and applications
2.7. White cast iron – properties and applications,
 2.8. Malleable cast iron – properties and application
2.9. Alloy cast iron – need for alloying, properties and applications
2.10 Ductile cast iron – properties and applications
2.11 Wrought iron – composition and structure, properties and application

3. STEEL AND IT’S MANUFACTURING PROCESS

3.1. Introduction to Steel, Application of Steel, Difference between cast iron and steel.
3.2. Manufacture of steel – Bessemer converter, open hearth furnace, electric arc
furnace, high frequency induction furnace, crucible process, L-D process

4. CLASSIFICATION AND STRUCTURE OF STEEL

4.1 Classification of steels – plain carbon and alloy steels, Plain carbon steels –
properties,
4.2 Classification based on carbon content and their applications.
4.2 Effects of carbon on the mechanical properties
4.3 Derivation of Alloy steels, alloying elements & its effects,
4.4 Types of alloys steels – properties, applications of nickel steels, chromium steels,
nickel-
Chrome steels, vanadium steels, manganese steels, tungsten steels, silicon steels
4.5 Stainless steels.
4.6 Structure of steel – fractures of ferrite, pearlite and cementite

5. PLASTICS
5.1 Definition of plastics
5.2 Monomers
5.3 Polymers
5.4 Polymerization
5.5 Advantages & disadvantages of plastics
5.6 Thermo setting
5.7 Thermo plastics
5.9 Transparent plastics

KOUSHALYA KAIPIDI

SUBJECT CODE: 20TD31A

 KOUSHALYA KAIPIDI SYLLABUS AS PER GTTC TEXT BOOK

 ENGINEERING DRAWING – III (ASSEMBLY)

SUBJECT CODE: 20TD35T

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.

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

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
Note: There is no change in contents of CAD lab and Workshop