ITI's which provides courses for Tool & Die Maker (Dies & Moulds)

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. Occupational Safety & Health Importance of housekeeping & good shop floor practices.

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. Soft Skills: its importance and Job area after completion of training.

2

Bench Work: Identification of tools & equipments as per desired specifications for marking & sawing.

Bench vice construction –types, uses, care and maintenance. Hacksaw frames – its types, hacksaw blade – description, material, specifications and uses.

3

Identification of tools & equipments as per desired specifications for drilling and tapping. Making rectangular parallel block and drilling practice for through holes, blind holes, Counter drilling, Counter sinking, chain drilling and taping.

Drilling  machine  description  –  its  types, Selection  of  cutting  speed  for  different materials. Calculation of rotation per minute (rpm), drilling time for drilling. Description of twist drill, counter boring tool, counter sinking tool.

4

Practice of step fitting having curvature/radius fitting

Vernier  caliper,  micrometer  (inside  & outside),  height  gauge,  bevel  protector  –working principle – construction, graduations, calculation of least count, readings-uses and care

5

Practice of Chipping & Scraping

Study of tools used in chipping and scraping. Introduction between Metal and Non Metal, properties of metal, Classification of metals and its applications.

6

Prepare three piece Assembly fitting with Filing flat and radius, drilling, countersinking, counter boring and tapping.

Manufacturing process of ferrous metals and its classification, uses of wrought iron, cast iron and steel.

7

Dressing of grinding wheels. Grinding of chisel, punch in Pedestal Grinder. Practice of twist drill grinding. Practice of single point turning tools grinding.                     

Description of pedestal grinder, procedure for mounting the grinding wheel and its application. Introduction to dressing and its importance.

8

Lathe: Setting of job in four jaws chuck, truing. Setting of cutting tool on tool post, at centre height. And its effect on metal cutting.

Lathe: Introduction to lathe machine and its types, specifications, description of main parts – bed, headstock, carriage, tail-stock, feed mechanism and thread cutting mechanisms.

9

Lathe operations - step turning, shouldering, undercut, chamfering, grooving, fillet radius within  an  accuracy  of  ±0.1mm  and  its checking  of  squareness,  diameter,  length, chamfer,  fillets  radius  using  micrometer, vernier caliper and gauges.           

Lathe accessories and attachments. Chuck –its types, face plates, lathe dogs, lathe centers - its types, and lathe steady. Coolants and lubricants-its difference and use.

10

Lathe operations – drilling, boring, counter boring, thread making using die and tap.

Nomenclature  of  Lathe  cutting  tool  -  its shapes  cutting  angles  for  different  lathe operations.

11

Practice of eccentric turning.

Different simple lathe operations

12

Practice of different taper turning methods on lathe (internal and external).

Different taper turning methods and its calculations.

13

Practice screw thread cutting – whit worth/metric (Internal & external)

Definition of screw thread, types, forms and its applications. Calculation of gear train for screw thread cutting on lathe. Change gear and its calculation.

Sem. II

Trade Practical

Trade Theory

1

Preparation of rectangular block by milling – selection of cutters for plain milling, mounting of milling cutters. Milling a block within an accuracy of ± 0.2 mm and check the dimensions. 

Introduction to milling machine, construction, types. Safety precaution followed during milling operation.

2

Step milling operation within an accuracy of ± 0.2mm

Milling machine attachments – vertical milling attachment, universal milling attachment, circular milling attachment, dividing head attachment etc.

3

Angular milling

Nomenclature of milling cutters, different milling cutter angles, Milling cutter materials.

4

Dovetail milling

Milling cutter holding devices, work holding devices, milling process – Up milling and Down milling.

5

Milling Operation using rotary table. T- Slot Milling. Basic programming of CNC Milling

Dividing head – Introduction, construction, types. Simple and universal dividing head. G code M code, co-ordinates, basic programming for CNC

6

Concave and convex radius milling.

Indexing methods – direct indexing, simple indexing, angular indexing, differential indexing and its calculations.

7

Milling key ways or spline

Gears – types, calculation for spur, helical and bevel gears. Holding of gear blanks. Setting method of cutters and gear blanks.

8

Gear Cutting (spur) Carryout housekeeping work

-do-

9

Grinding: Procedure for holding of job, setting of machine stroke length. Practice of wheel balancing.

Grinding: Grinding machine – introduction, description, types – surface grinding and cylindrical grinding machines.

10

Grinding of angular surfaces within an accuracy of ± 5 arc minutes using universal vice

Grinding wheels – abrasives, bond and bonding process, grit, grade, and structure of grinding wheels.

11

Setting of machine for internal & external cylindrical grinding surfaces within an accuracy of ±0.02mm.

Grinding wheel shapes and sizes. Standard marking system. Selection of grinding wheel.

12

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

13

EDM: Machining practice / observation on EDM Machine (Spark Erosion m/c) Preparing simple electrodes from Copper, Graphite.

EDM: Electrical discharge machining (EDM) – Introduction, principle of operation, advantages & disadvantages and its applications.

14

Welding: Introduction to gas welding equipment/arc welding equipment, Simple welding practice. Practice on brazing. Practice on die welding. Welding on Hard die block as well as on die casting.

Welding: Explanation of gas welding and arc welding techniques. Description of welding equipment, types of welding joints. Knowledge about flux, filler rod material. Die welding techniques.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Pantograph machine: Practice for setting of job on machine vice, setting of cutter, setting of stylus, master and template, depth of cut. Practice of removing material from work piece i.e. from - Engraving, sunk and raised letters, die sinking

Pantograph machine: Introduction, types, parts, working principle, advantages for using of pantograph milling m/c, its applications. Setting of enlarging and reducing ratios between master/template and work piece for Engraving, sunk and raised letters, die sinking.

2

Wire Cut: Machining practice / observation on machine

Wire Cut: Electrical wire cut machining – Introduction, principle of operation, advantages & disadvantages and its applications

3

Hand Injection Mould: Manufacture of Hand Injection Mould.

Hand Injection Mould: Constructional details of a basic injection mould (Hand injection mould). Constructional details of a single cavity two plate injection mould.

4

Two cavity injection Mould: Manufacture of two cavity injection mould.

Constructional features of injection moulding machine. Specification of injection moulding machine. Calculation of shot weight. Plasticising capacity, minimum cycle time Clamping.

5

Single Compression Mould Manufacture of single compression mould.

Types of parting surface. Selection of parting surface shrink-age factors, governing shrinkage determination of core and cavity dimensions Importance of temperature controlling in moulds.

6

Plunger Type Transfer Mould: Manufacture of plunger type transfer mould.

Different methods used in moulding internal undercuts. Factors to be considered while designing moulds for components with threads. Methods employed in the removal of internally and externally threaded components.

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Tool & Cutter Grinder: Grinding of single point cutting tool blank. Grinding of plain and face milling cutter

Tool & Cutter Grinder: Description of tool and cutter grinding machine. Work (cutting tool) holding device for tool & cutter grinder machine. Setting process of cutting tools and grinding wheel on tool & cutter grinding machine.

2

Manufacture of two cavity injection mould with side cores. Ensure that total range of checks are regularly and consistently perform Identify potential causes for non conformities to quality assurance standards

Identification of common moulding defects that occur during injection moulding, reasons for defect in the component. Compression moulding process. Procedure of compression moulding. Identification of common defect that occur during compression moulding Transfer moulding process, advantages of transfer moulding.

3

Manufacture of pressure die casting die.

Die casting, hot chamber process and cold chamber process. Basic designs of a die casting die. Effect of metal on die casting process. Effect of die casting machine on process. Effect of die in process.

4

Hydraulics & Pneumatics: Identification and familiarisation of various types of hydraulic & pneumatic elements such as cylinder, valves, actuators and filters.

Hydraulics & Pneumatics: Basic principles of Hydraulic Pneumatic system. Advantages & disadvantages of hydraulic and pneumatic system.

5

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.

6

Program generation & Simulation with CAD/CAM software for dies & moulds.

Concepts of CAD/CAM Basic concepts of inspection of 3D surfaces. Part program generation and setting up the machine for producing punch/dies.

Project Work