ITI's which provides courses for Machinist

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)

Hand tools and its importance

3

Chipping flat surfaces and grinding various angles to chisels, filing flat surface. Grooving with Hammer and chisel.

Classification and types of chisels, files & uses, vices - its constructions and uses. Hammers and its types. Related safety.

4

Filing Flat surfaces, Uses of marking tools, Punch, Try square & basic measuring tools, caliper, steel rule.

Marking block, Steel rule, and callipers different types and uses. Combination set its components and uses.

5

Filing flat surfaces, checking with steel rule and Try square. Hack sawing.

Hacksaw blade, Hacksaw frame and its types. Drill bits- parts, Types & uses.

6

Marking and Drilling holes on flat pieces. Tapping as per simple drawing.

Introduction to Hand Taps & Dies and their types, applications, care and maintenance.

7

Filing Tee shape job.

Forging tools, its importance and types such as tongs, swage block, anvil etc

8

Filing flat type polygon.

Heat treatment process Annealing, Normalising, Tempering, Hardening, case hardening and its importance.

9

Fitting male and female square piece to close limit.

Outside micrometer, its types and construction, parts, reading use, care and maintenance.

10

Fitting male and female square piece to close limit

Study about Depth gauge, micrometers and dial test indicator - their parts and construction.

11

Introduction to Shaping machine and its construction. Setting of strokes, tools, job on table machining of Rectangular block, steps, with the use of Basic tools.

Introduction of shaper, types classification, General principles of power transmission on shaping mechanism.

12

Shaping Hexagonal, Rectangular block as per sketch checking with caliper & steel rule, angle protractor.

Various tools of shaping machine and their angles and importance of angles.

13

Shaping “V” blocks with slides, measurement of ‘V’ groove with vernier bevel protractor, measurement of slots by vernier caliper with 0.02 mm accuracy.

Various methods of holding jobs, use of clamps, nuts & bolts V- blocks, angle plates shaping operations, their importance.

14

Shaping Tee slots, shaping angular surfaces.

Tool head - its parts and application, function of each part of tool head.

15

Cutting of external keyway on shaper.

Shaping tools and types. Speed, feed, depth of cut.

16

Shaping concave & convex surface with use of tee slot tools, form tools.

Surface finish as per ISI system.

17

General introduction to slotting. Safety points to be observed while working on a slotter.

Slotter-principle, construction, details, driving mechanism, quick return motion and speed ratio.

18

Slotting a rectangular job checking and measuring with gauges & precision measuring instruments.

Job holding devices-vice, clamps, V-block, parallel block etc

19

Slotting square and hexagon internal and external. Slotting a double ended spanner.

Slotting tools with different shapes

20

Practice on slotting key ways on pulley Internal and external slotting irregular shaped jobs having curved surfaces.

Use of tools with holder for internal operation

21

Slotting internal operations.

Introduction to coolant & lubricant difference between them, types and uses of each.

Sem. II

Trade Practical

Trade Theory

1

Introduction of planning machines, Adjustment of stroke, setting of tool, vice on planer table machining of rectangular block on planer

Introduction to Planning M/c. parts, types, constructions, details of Driving mechanism of planer, quick return motion etc.

2

Planning angular, Horizontal, vertical operations, planning Dovetail.

Tool head of planer its construction and various function of each part v- block, clamps, bolts, step block and other holding devices.

3

Planning of various key ways (open & blind).

Cutting tools for Planer – their material and types.

4

Planning V Block machining of planer gauge.

Hydraulic mechanism of planer their advantages, disadvantages.

5

Planning male & female dovetail, grinding of tools, checking with Vernier bevel protractor & roller methods.

Dovetail measurement external and internal by vernier bevel protractor.

6

Introduction to lathe. Holding of round job in an independent chuck and truing it.

Introduction to lathe. Its types, engine lathe construction, detail function of parts size and specification.

7

Parallel turning between centers, parting off, chamfering using roughing, finishing and parting off tools

Lathe tools their angles & uses.

8

Holding the job in jaw chuck truing, centering facing.

Chucks-different types of job holding devices on lathe and advantages of each type.

9

Taper turning by offset method checking of the taper with precision instruments.

Taper introduction, types and uses. Calculations of tapers.

10

Cutting V thread external and internal in a lathe.

Different thread forms their related dimensions and calculations screw cutting in a lathe.

11

Introduction to milling machine, demonstration on working principle, setting of job, setting of cutter in arbor, setting of vice on table.

Milling machine importance of milling machine, types and specification of milling machine, driving and feed mechanism of milling machine.

12

Sequence of milling six faces of a solid block

Classification & different types of milling cutters & their use.

13

Step milling using side and face cutter checking with micrometer.

Vernier height gauge construction, graduations vernier setting & reading, vernier bevel protractor, construction graduation setting and reading.

14

Straddle and gang milling operations including up-milling and down milling

Different milling operations plain-face, angular, form, slot, gang and straddle milling etc.

15

Introduction to indexing head types, setting and aligning of indexing head with reference to job on milling machine. 

Indexing-introduction & types. Indexing head constructional details, function of indexing plates and the sector arms.

16

Milling square and hexagonal job by simple indexing method.

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17

Milling dovetail and ‘T’slots both male and female matching each other.

Gear introduction, use and type. Elements of a spur gear.

18

Milling of spur gear having even and odd number of teeth.

Gear cutter type, form & various methods

19

Introduction to grinding machine surface grinder, cylindrical grinder.

Grinding machine introduction types, specification, their parts and functions & uses.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Checking of alignment of lathe centers and their adjustments. Center drilling, step turning between centers recessing and chamfering & measurement with vernier caliper.

Turning of taper by taper turning attachment advantages and dis-advantages taper calculations.

2

Cutting square threads (left & right hand) on a lathe-checking with thread gauge-grinding of tool and setting in correct position

Screw cutting on a lathe. Terms relating screw thread major/minor diameter pitch and lead of the screw, depth of thread simple gear train and compound gear train change gears for fractional pitches.

3

Cutting multi-start V thread on lathe. Cutting key way broaches.

Difference between single and multi-start threads-their uses merits and demerits.

4

Cutting ACME threads (Male and female) on a lathe. Lead screw.

Square thread its form and calculation of depth, core dia, pitch dia.

5

Cutting acme threads on lathe (Male and female).

Square threads-its forms and calculations of depth, core dia, pitch dia, Acme threads-its forms, use and calculations.

6

Turning of irregular jobs using face plate. Balancing the face plate.

Face plate- its construction safety precaution in holding jobs on face plate.

7

Exercise on use of pillar drill in drilling, counter sinking, counter boring.

Pillar drill machine constructional details, functions of parts. Application of pillar drill. Radial drills function parts etc.

8

‘T’ slots cutting in shaping machine.

Various material for single point cutting tools, tipped tools, their brazing and grinding process.

9

Cross Dovetail cutting on shaper

Cutting speed, feed, depth of cut for slotting, shaping and time calculation.

10

Shaping cross dovetails mating jobs male and female

Checking of dovetail grooves with vernier caliper and roller.

11

Shaping of casting jobs, using angle plate, jack and clamps.

Properties of metals general idea of physical, mechanical properties of metals, colour, weight, hardness toughness, malleability, ductility their effect on machine ability.

12

Grinding of form tools and shaping of convex and concave surfaces.

Use of radius gauges and template. Introduction to jigs and fixtures

13

Machining of profiles on a slotting machine.

Interchangeability – Limit, Fit, Tolerances and allowances.

14

Machining of internal spline and external spline on slotter uses to match each other

Introduction and their indexing process on a slotter by its rotary table graduations.

15

Cutting external and internal sprocket teeth on slotting machine, use of rotary table

Form tool for slotting machines. Calculation for spur gear in relation to graduation of circular table.

16

Slotting regular & irregular job and contours and sprockets.

Calculation for cutting sprocket.

17

Planing long jobs having ‘T’ slots and dovetail grooves.

Tool setting for dovetail use of relevant tool and their grinding process.

18

Setting and planing multiple jobs at a time.

Hydraulic transmission in machine tool- its advantages and application hydraulic system of a planer.

19

Boring a cast block on a vertical milling machine, measurement of bore size

Vertical milling machine its parts, construction, method of boring in a vertical milling.

20

Milling hexagonal hole on a plate by attachment.

Elements of milling cutter Rake angle, primary, secondary and clearance angles, lead etc.

21

Demonstration of marking system of Grinding wheels. Different Tool and Cutter grinding practices on Tool & Cutter grinding m/c. Milling tongue and groove on a mating job. Checking with precision instruments and gauges.

Selection procedure of grinding wheels. Abrasives its types Bonds, Grade Grit, structure, different shape of wheels and their uses. Inside micrometer, Principle, construction graduation reading both in English and metric system gauge types and uses.

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Demo of parts of CNC machining center – control switches, console buttons and machines specifications (spindle power, axes traverse, etc.)

CNC technology basics: Difference between CNC and conventional lathes. Advantages and disadvantages of CNC machines over conventional machines.

2

CNC part programming with simple exercises and various programming codes. Practice on CNC machine simulator.

Programming – sequence, formats, different codes, canned cycles. Absolute and incremental programming. Tool nose radius compensation (G41/42).

3

CNC machining center operation in various modes: jog, single block, auto, MDI, edit, etc.

Program execution in different modes like single block, manual and auto. Tool and work offsets setting

4

Program and cut parts on CNC machining center with face milling, contour milling with tool radius compensation, pocket milling, drilling, peck drilling, countersinking, tapping operations using canned cycles for hole operations.

Surface finish. Surface roughness related BIS symbols

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 card

6

Milling cylindrical cutter.

Spiral introduction, type and elements. Difference between helix & spiral.

7

Milling end mill/drum cam.

Spiral-lead, helix angle and calculation. Cam Introduction development and use.

8

Cutting face cam.

Use of proper cutting speed and feed for various metals.

9

Cutting a plate cam with angular setting

Cam-lobe, lead setting of dividing head, Calculation

10

Milling gears by differential indexing, Measuring the teeth with a vernier gear tooth caliper.

Vernier gear tooth caliper, its construction and application in checking gear tooth.

11

Milling spline (external) Milling straight fluted Reamer.

Introduction to broaching methods of milling splines.

12

Milling a helical groove in a vertical milling machine.

Spiral milling lead, pitch, helix angle R.H. and L.H. swiveling the table in relation to the helix angle, selection of cutter for spiral milling

13

Milling a drum cam. Milling a plate cam.

Cam-types, application in modern m/c. tools, its special advantages, manufacturing process, calculation for milling a drum cam.

14

Milling helical gears. Cutting bevel gears on a milling machine by using bevel gear cutter.

Helical gear introduction elements and calculation. Introduction geometry and uses of bevel gears.

15

Milling a rack. Milling face cam.

Introduction to rack, its use & application. Rack cutting attachment, calculation for linear pitch, circular pitch, Gear ratio, Indexing movement, etc.

16

Cutting worm and worm wheel on a milling machine, gashing and finishing

Introduction, geometry and use of worm and worm wheel.

17

Cutting graduations on a steel rule on milling machine. Use of tolly cutter.

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Project Work