ITI's which provides courses for Machinist (Grinder)

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Importance of trade training, List of tools & Machinery used in the trade. Health & Safety: Introduction to safety equipments and their uses. Introduction of first aid, operation of Electrical mains.

Importance of safety and general precautions observed in the in the industry/shop floor. All necessary guidance to be provided to the new comers to become familiar with the working of Industrial Training Institute system including stores procedures.

2

Identification of tools & equipments as per desired specifications for marking & sawing( Hand tools , Fitting tools & Measuring tools) Selection of material as per application Visual inspection of raw material for rusting, scaling, corrosion etc.

Description of hand tools, Safety precautions, care and maintenance and material from which they are made. Ferrous and nonferrous metal and their identification by different methods. Application and use of pedestal grinder.

3

Grinding of Chisels, Hack sawing, Measuring different types of jobs by steel rule caliper etc

Theory of Semi precision instruments.

4

Drilling, reaming, tapping and threading with dies and use of coolants.

Relation between drill & tap sizes, care of taps and dies and their correct use

5

Drilling different sizes of holes by hand and machine.

Brief description of drilling machine use and care

6

Filling practice, simple fitting

Heat treatment of metals, its importance, various methods of heat treatment

7

Centre lathe and parts, setting of jobs and tools grinding of lathe tools of various angles

Brief description of a Centre lathe, its use

8

Parallel turning, taper turning and boring. Using compound rest and TT attachment.

Lathe tools and their uses taper and its types and problems on taper.

9

Simple screw cutting (External and Internal)

Method of screw cutting simple calculation.

10

Simple plain turning

Thread and its element types.

11

Safety rule on shop floor maintenance and control of grinding machines oiling cleaning etc.

Introduction to Grinding trade and machine safety precautions according to IS: 1991-1962.

12

Measurement of different types of job by steel rule, caliper etc. Taper by angular protractor.

General measuring tools (used in grinding shop) their description, use care and maintenance

13

Setting grinding wheel on wheel flange, truing and balancing of wheels.

General dressing tools used in grinding section such as wheel, diamond dresser, steel type dresser, abrasive dresser and nonferrous dresser

14

Checking measuring various types of jobs using micrometers, Vernier caliper, Vernier  Height gauge etc

Precision instruments English and metric micrometer, vernier caliper, dial test indicator etc. their description and uses

15

Grinding practice on surface and cylindrical grinding machine (Grinding should be performed both on soft and hardened materials).

Principle and value of grinding in finishing process, various types of grinding wheels their construction and characteristic glazed and loaded wheels.

16

Grinding practice on surface and cylindrical grinding machine.

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17

Rough and finish grinding of surface and cylindrical job according to drawings.

Different types of abrasive, manufacture of grinding wheels, their grades.

18

Demonstration on selection of grinding wheels for grinding different metals, selection of suitable wheel to obtain rough and IS: 1249- 1958.

Factors effecting selection of wheels, identification of wheel, marking system of grinding wheels IS: 551- 1966.

19

Grinding different metals with suitable grinding wheels.

Grit and different types of bonds, such as vitrified, resinoid, rubber etc.

20

Externals and internal grinding operation, changing the wheel speed, obtain recommended wheel and controlling depth.

Grinding wheel speed, surface speed per minute conversion of peripheral speed to r.p.m. Depth of cut and range at usefulness.

Sem. II

Trade Practical

Trade Theory

1

Introduction Training- Revision of previous works. Machine setting for automatic movements and parallel grinding on cylindrical grinder.

Introduction Training- Revision of previous works. Common types of grinding machines. Plain cylindrical external and internal cylindrical grinder and universal grinder.

2

Testing and mounting wheels sleeves, truing and rebalancing and grinding parallel mandrel.

Test for alignment and checking, balancing at wheel, dressing different types of wheel, dressers, their description and uses

3

Wheel balance and dressing grinding long bar using steady rest.

Test for alignment and checking, balancing of wheel, dressing different types of wheel, dressers their description and uses.

4

Grinding different types of jobs using machine chuck, face angle plate collets.

Holding devices such as Magnetic chuck, chucks and face plates collets their description and uses.

5

Table alignment with the help of test bar and dial test indicator parallel grinding and taper grinding (by swiveling machine table)

External grinding operational steps in external grinding of a job and precautions to be taken.

6

Grinding of eccentric job and different types of jobs using jigs and fixtures angle plates

Holding devices such as jig and fixture angle plates 'V' blocks etc. their description and uses.

7

Grinding of job by using face plate angle plate etc

Internal grinding operational steps in internal grinding of a job precautions to be taken

8

Grinding of plain/slot milling cutter

Milling cutters and its nomenclature.

9

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Grinding of bushes and cylinders steps and precautions to be taken

10

Grinding bushes on mandrel within the close tolerance limits.

Rough and finish grinding limit fit and tolerances as per ISI: 919-1963. Basic size and its deviation, position of tolerances as per ISI: 919-1963.

11

Dry and wet grinding of different classes of metals such as cast iron, barzed carbide tip and different classes of steel.

Heat generated in grinding dry and wet grinding use of coolant, their composition and selection.

12

Grinding square block angle plate and angular block.

Grinding a square job grinding angular surface taker grinding by stane land taper and angle protractor

13

Grinding practice on drills reamers and taps.

Methods of grinding of drills reamers and taps.

14

Grinding slitting saw and side and face milling cutter.

Methods of grinding of milling cutters such as slitting saws, side and face milling cutter etc

15

Checking tapered or angular jobs with help of sine bar, Dial gauge.

Use of snap gauges, sine bar and slip gauges their description and uses. Polishing, lapping powder and emery clothes lapping flat surface.

16

Grinding milling cutter with straight flutes

Tools and cutter grinder their description, working principles, operations care and maintenance.

17

Grinding milling cutter with helical flutes

Special types of grinding machines and centreless grinders. T

18

Grinding internal bore of cylindrical job and use of telescopic gauge.

Grinding defects vibration, chattering, glazing and loading their causes and remedies.

19

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Grinding different defects and remedies on its

20

Grinding carbide tipped tools and gauges (rough and finish grinding using disc and diamond wheels)

Applications of diamond wheel in grinding and grinding of tipped tools.

21

Making simple utility jobs with surface and cylindrical grinders.

Preventive maintenance and its necessity. Mode of frequency of lubrication.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Cylindrical and surfaces grinding practice (Maintaining parallelism) on both soft and hard metals.

Cylindrical grinding machine, its parts, use care and maintenance surface grinding machine

2

Practice on tools and cutter grinding machine. Machine manipulation and control Mounting jobs on mandrel.

Tool and cutter grinding machine-parts and accessories, description use, care and maintenance, pedestal grinder and bench grinder-their description and uses.

3

Grinding practice on plain flat surface with close tolerances

Dial test indicators marking block, height gauge and surface plate their description

4

Grinding practice on angular surface like V block

Principle of vernier caliper, protractors, micrometers (O/S, I/S and depth) and other instruments having vernier graduations

5

6

Parallel block grinding on surface grinding machine within close limits.

Bonding materials their kinds description and uses.

7

Cylindrical bore grinding practice. Setting and turning of jobs on chucks and face plates.

Wheel marking system selection of wheels. Specification and types (shapes & size) of grinding wheels, diamond wheels and their uses

8

Balancing and mounting of grinding wheel Rt. angle grinding practice on surface grinding machine.

Mounting of grinding wheels, grinding wheels, collets and mandrels, balancing of grinding wheels by different methods

9

Wheels dressing for rough and finishing grinding. Grinding a cube to close limit.

Types of dresses-steel type, abrasive Diamond tool and rotary dresses abrasive bricks and sticks their description, use, care and maintenance

10

Shoulder grinding practice on cylinder-grinding machine to close limit h7.

Dressing and truing of grinding wheels advantage of balancing, inspections and care of grinding wheels. Wheel storage.

11

Slot grinding practice on surface grinding machines to close limits H7.

Heat generated in grinding dry and wet grinding, use of coolants their composition and selection, limit, fit and tolerances as per ISI: 919-1963.

12

Snap gauge grinding practice in close limit.

Gauges-feeler, taper gauge radius, plug, ring snap (fixed and adjustable) and slip their description use care and maintenance

13

Grinding practice on cylindrical taper using standards ring gauges.

Inside micrometer depth gauge, special types of micrometers, universal dial test indicator their construction and function

14

Grinding practice of ring gauge using plug gauge.

Special type of grinding machine centreless, thread crankshaft etc.

15

Grinding long cylindrical using steady rest to close limit h6.

Essential mechanism of grinding machines, wheel is guards to IS: 1991-1962 machine guards etc.

16

Grinding thin plates using coolants to close limits h6.

Principle types of grinding fluids importance of uniform temperature, selection and use at grinding fluids, method of supplying grinding fluids.

17

Grinding practice on parallel and taper pins using chuck and collets-h6.

Types of holding devices methods of holding work, type of centres

18

Selection of grinding wheel and grinding practice on rectangular bar of non-ferrous metals.

Holding work on face plate, pneumatic chuck and magnetic chuck.

19

Grinding practice on machine centre to close limit h6 or H6.

Calculation at R.P.M. and S.F.P.M. of grinding wheels calculation of work speed for cylindrical grinding speed and feeds for cylindrical grinding speed and feeds for internal grinding.

20

Facing and Chamfering practice

Traverse and over run of traverse, width of wheel and depth of cut in different types of grinding achiness.

21

Step grinding practice on surface grinding machine to close limit h6 or H6.

Surface grinding methods of surface grinding by using periphery of grinding wheel and ring edge of grinding wheel.

22

V-block grinding practice.

Process of grinding angular surfaces. Grinding slots and grooves. Grinding "V" blocks. Recommended wheel speeds for surface grinding machines.

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Introduction to CNC machine operation like Jog, Reference Edit, MDI, Auto Mode Prog. Call & Entry, Simulation, Tool off-set & Tool changing /Orientation.

Introduction to CNC Technology CNC M/c. principle advantages classification, drives, and controls. Basic information on CNC machine & maintenance of CNC M/c. computer aided CNC Language.

2

Angular from grinding practice.

Cylindrical-types of cylindrical grinding operation traverse method, plunge cut method and form grinding method.

3

Grinding cylindrical steps with shoulder and chamfer.

Method of plain cylindrical surface grinding step-grinding and shoulder and face grinding.

4

Compound or double taper grinding practice on cylindrical grinder.

Method of grinding external and angle (simple) taper and steep. Taper double compound taper.

5

Steep taper, grinding practice on lathe centre.

Use of universal head for angular grinding. Measuring and checking of taper and angles

6

Morse taper-plug grinding metric tapers.

Taper and angle checking by using protractors, micrometer and rollers.

7

Taper grinding using sine bar D.T.I. and gauge blocks to close limit h6.

Use of sine bar and gauge block-taper checking by sine bar gauge block D.T.I. micrometer and rollers.

8

Prepare different types of documentation as per industrial need by different methods of recording information

Importance of Technical English terms used in industry –(in simple definition only)Technical forms, process charts, activity logs, in required formats of industry, estimation, cycle time, productivity reports, job cards

9

Grinding Taper up to close limit H6.Grinding lathe centre.

Centreless grinding process of holding job, and types of operations. Effect of setting work above and below wheel centre.

10

Internal step grinding to close limit, ring gauge, grinding to close limit

Internal centreless grinding methods of holding jobs and processes of grinding. Selection of wheels

11

Cylindrical slot grinding to close limit h5

Thread grinding method of holding jobs method of grinding threads and thread calculation

12

Grinding of angular cutter by using work head.

Various types of thread grinding wheels and their selection.

13

Lapping practice on flat surface. Lapping practice on cylindrical surface and buffing practice to close limits h5.

Laps and lapping material, types of laps lapping abrasives rotary diamond lap lapping lubricants lapping pressures wet and dry lapping.

14

Sharpening tools and drills, sharpening scrapers and chisels.

Grinding boring tools shaping tools, slotting tools, tools planning and drills, grinding of scrapers, chisels and carbide tipped tools.

15

Grinding of spiral path

Grinding defects and their corrections, inaccurate work out of round, out of parallel taper on and irregular marks spiral scratches, discoloured burnt surface etc

16

Form grinding radius angle, Grinding of concave & convex cutter.

Grinding defects and their correction.

17

Slitting saw sharpening practice using tooth rest.

Cutter grinding necessity of sharpening. General method of sharpening milling cutter

18

Side and face milling cutter sharpening practice.

Method of indexing direction of wheel rotation, wheel dressing. Types of cutter grinding wheels and their selection

19

Spiral milling cutter sharpening practice

Calculation of clearance angle. Setting for cup wheels and straight wheels.

20

Sharpening end mill cutter.

Sharpening of helical milling cutter using linear and angular setting methods.

21

Sharpening tap

Grinding flutes of form cutters, grinding taps, reamers, similar types of cutting tools, use of universal attachment. Hones and honing- Type of honing stones-their description and use. Amount and rate of stock removal. Adjustment for elementary honing condition, honing tolerances.

Project Work