ITI's which provides courses for Tool & Die Maker (Press Tools, Jig & Fixture)

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: Setting of job on machine vice, setting of cutter, stylus, master template, depth of cut. Practice for removing material from work piece (making a job on pantograph machine)

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.

2

Wire Cut: Machining practice / observation on Wire cut Machine.

Wire Cut: Wire cut machine – introduction, principle of operation, advantages & disadvantages and its applications

3

Jigs & fixtures: Manufacture of Drill Jig.

Jigs & fixture: Introduction, definitions, difference, advantages and disadvantages, and types of jigs & fixtures.

4

Manufacture of drill jig (indexing and other type) Designing of simple plate type drill jig.

Degree of freedom/possible direction of movement, method of restricting the possible movements (principle of 3 – 2 – 1 pin method), locating methods.

5

Manufacture of milling fixtures

Methods of removing chips from jigs & fixtures. Drill bushes such as- fixed bush, liner bush, slip bush. Bush materials and its heat treatment.

6

Press tool: Demonstrate about safety precautions followed during working on press machine. Demonstrate about fly and power press - its parts, function of each part, operating procedure of presses, mounting procedure of die set on press machine, alignment technique between punch and die assembly. 

Press tool: Press – Introduction of press machines, its types. Selection of presses, its specification, calculation of press capacities. Function of different parts of press tools. Mounting procedure of die set on press machine, alignment technique between punch and die assembly.

7

Manufacture of Blanking Die Manufacture of Blanking (simple) die set components.

Principle of metal cutting on press tool. Shearing theory, three stages of shearing and calculation of blanking/piercing pressure. Burrs and its effects on press working.

8

Manufacture of Piercing Die - Manufacture of Piercing (simple) die set components

Description about strip lay out - its advantages for press work, utilization of maximum strip material as piece part, positioning of press tools stopper

9

Manufacture of Progressive Die Manufacture of Progressive (simple) die set components.

Difference between solid die and split die, application of split die and factors for selecting the split die. Introduction to progressive tool, its parts, functions, materials and heat treatment. Calculation of die clearance

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 devices for tool & cutter grinder machine. Setting process of cutting tools and grinding wheel on tool & cutter grinding machine.

2

Manufacture of Compound Die: Manufacture of compound dies components

Compound Die: Introduction, description of different parts, their functions, materials and heat treatment.

3

Assembly, tryout & rectification of compound tool

Spring back and different methods of compensation for spring back in V- bending

4

Manufacture of ‘V’ Bending Die: Manufacturing of simple ‘V’ bending die components.

Introduction to drawing tool, different parts of drawing tool, their function, materials, heat treatment, calculation of clearances between draw die and draw tool, stages of drawing operation, draw clearance.

5

Manufacture of Drawing Die: Manufacture of Drawing die set components.

Redraw die – function, use and advantages over draw die. Ejectors, types, functions in press tool work. Pressure pad, types, functions, application procedure in press work.

6

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.

7

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.

8

Program generation & Simulation (Turning, Milling and Machining of punch & dies) with CAD/CAM software. Inspection of machined punch and dies with measuring instruments.

Basic concept of CNC Machine and its different code for programming. Practice of simple programming. CAD (Theory)/ CAM Basic concepts of inspection of 3D surfaces (Finishing of punch and Die).

Project Work