ITI's which provides courses for Mechanic Machine Tool Maintenance

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

Usage of First aid box and practice of Cardiopulmonary Resuscitation (CPR)

Accidents, major types and causes of accidents, accident prevention. Near-Miss, hazard identification. Unsafe acts and unsafe conditions.

3

Marking practice: Marking - straight, parallel and curved lines with odd leg calipers, steel rule, dividers, Scriber. Cut metal pieces of different profiles & sections by hack sawing to accuracy of 0.5 mm.

Basic Fitting Skill: Classification, constructional and functional details of different type of vices (bench & machine), Care of vices, hacksaw, its classification, saw setting, selection of hacksaw blades.

4

Marking of flat job as per drawing and parallel filing practice within the accuracy of 0.5mm.

Classification, construction, material and functional details of Files. Specification of files & Filing technique.

5

Filing- flat, square and steps surfaces to an accuracy of 0.4mm. (Measurement by caliper and steel rule).

Linear measurements & its units Classification, construction, materials and functional detail of following basic measuring and marking tools

6

Checking and setting of Vernier calipers, vernier height gauge & vernier bevel protractor.

Vernier calipers, vernier height gauge & vernier bevel protractor - principle, construction, calculation of least count and its use and care.

7

Checking and setting of micrometer. Filing flat, square and steps to an accuracy of 0.3mm (Measurement by Precision Instrument).

Precision Measuring Instruments: Concept of precision & accuracy Micrometer (outside, inside and depth) –working principle, construction, use & care, calculation of least count

8

Transfer of dimensions from drawing to work pieces. Finding center of a round bar with the help of ‘V’ block and marking block.

Classification, construction and functional detail of following marking devices Surface plate, angle plate, marking block and V-Block.

9

Fixing of hammer handle. Chipping practice on flat surface, slots & oil grooves, and chamfer at different angle on MS plate.

Classification, construction, materials and functional detail of Chisels & Hammers. Chipping technique. Related hazards, risk and precautions while working

10

Truing of Pedestal grinding wheels. Grinding/Repair and maintenance of ordinary fitter’s hand tools such as chisel, Screw driver, Scriber, Centre punches, dividers, trammel, scrapers and Hammer.

Pedestal grinder – Introduction, care & use. Procedure of wheel mounting & wheel dressing. Related hazards, risk and precautions.

11

Grinding practice of Drill. Use of drilling machine for drilling through & blind holes, counter boring and counter sinking on mild steel (MS) flat. Drilling on cylindrical surface.

Drilling machines: Introduction to Drilling machines. Types of drilling machines like bench, pillar & radial drilling machines and their constructional details. Types of drilling operations, calculation of cutting speed, feed & drilling time.

12

Filing & fitting mating components by filing within an accuracy of ± 0.15 mm & angular 30 minutes.

Tolerances & interchangeability - Definition and its necessity, basic size, actual size, limits, deviation, Tolerance, allowance, clearance, interference, Fitsdefinition, types, description with sketches. Method of expressing Tolerance as per BIS, Hole and Shaft basis (BIS standard).

13

Practice on dovetail fitting mating components by filing and scrapping within an accuracy of ± 0.10 mm & angular within 30 minutes for cylindrical surfaces.

Fasteners: Introduction to fasteners, screw threads, related terminology and specification. Keys- types & use, (parallel, sunk, tangential, gib head, woodruff, key ways.) Related hazards, risk and precautions, while working.

14

Preparation of flat surfaces and scraping practice on flat surface taking impression on face high spots using prussian blue sharpening by diamond dresser & wheel and lapping stone.

Types of nuts, bolts, studs, locking devices for nut, wrench and spanner, pliers, screw drivers, Circlip, split pin, washers, spring washer.

Sem. II

Trade Practical

Trade Theory

1

Identification and study of various components of mechanical power transmission assembly System. Dismantling & assembly of Shafts, couplings, keys, gears, bearings, belts, chain pulley, rope pulley. Related hazards, risk and precautions while working

Maintenance Practice and Mechanical Assembly &  Transmission of Power

2

Identification of various types of clutches, clutch arrangements in power transmission system (machine tools), maintenance of clutch mechanism in machine tool. Dismantling & assembly of mechanical & electromagnetic assembly. Related hazards, risk and precautions while working.

Clutches Function of Clutches, its types and use in power transmission system. Function of mechanical & Electro-magnetic system in clutch mechanism. Couplings: Concept of coupling and its type  viz. Rigid coupling- Muff coupling, Flange coupling, Flexible coupling, Pin-bush coupling, Chain coupling, Gear coupling, Spider coupling, Tyre coupling, Grid coupling, Oldham-coupling, Fluid coupling, Universal coupling and their specific applications.

3

Installing drive belts, Measuring and adjusting the belt tension. Related hazards, risk and precautions while working.

BeltsBelt types (Flat and V) and specifications. Pulleys used for belt drive. Installation, Alignment of belts. Problems related to belts (Creep and slip) Belt maintenance.

4

Identification of various types of Gears & Gear boxes. Inspection of various aspects of Gears & Gear boxes such as PCD checking by Cylindrical Pin, Checking of gear tooth thickness, clearance, concentricity & wear etc.

Gear: Type, description and function of gearsSpur, Helical, Spiral, Bevel, Straight and Spiral bevel, Worm gears, Rack and pinion. Gear Terminology. Gear train- simple, compound, reverted and epicyclic.

5

Practice on oil removing & filling from gear box. Inspection of the drained oil for contaminants & wear debris with focus on visual inspection.

Lubrication and its importance, lubricating systems Concept of lubrication Types and properties of Oil and Grease. Methods of oil lubrication Once through and centralized lubrication system. Methods of grease lubrication system- grease guns, centralized lubrication system.

6

Preparation of coolants. Identification of various parts of cooling systems. Preventive & breakdown maintenance of coolant systems

Cutting Fluids and Coolants. Essential parts of a basic cooling system used in the cutting of metals. Various types of coolants, its properties and uses, cooling system type-soluble oils- soaps, sudsparaffin, soda water etc

7

Demonstration for location & excavation for foundation bolts, method employed for installation & erection of precision & heavy duty machines.

Machine Foundation: Purpose & methods employed for installation & erection of precision & heavy duty machines.

8

Leveling of a machine – Practice on models

Leveling Definition and importance of leveling. Types of levels- Spirit level, Water level, Dumpy level, Method of leveling. Preparation of packing and shim

9

Shaft alignment, Pre-check: coupling fit, eccentricity, perpendicularity, with feeler, dial gauge and corrections methods.

Alignment: Definition and importance of alignment, Types of misalignment, Planes of misalignment, Shaft vs coupling alignment, Actions to be taken before alignment, Concept of axial float, Concept of Indicator sag, Dial Test Indicator, Methods of alignment - Rim and Face readings on Stationary Machine, Rim and Face reading on machine to be seamed.

 10

Safety precautions in dismantling & assembly of Drilling machines. Dismantling and assembly of various parts such as Motors, Spindle & Spindle head, Gear box and Arm.

Maintenance and Repairs of Various types of drilling machines.

12

Practice of Lathe tool grinding, tool setting. Lathe operations – plain turning, facing, step turning, undercut, chamfering, grooving, drilling, boring, counter boring, fillet radius within the accuracy of ±0.1mm and its checking of square ness, diameter, length, chamfer, fillets radius using micrometer, vernier caliper and gauges.

Machine Tool Operation & Maintenance Lathe Machine Introduction to lathe machines parts, constructional details and Different simple lathe operations - parallel/straight turning, step turning, grooving, radius forming, drilling and boring, counter boring.

13

Dismantling & Assembly of various parts & sub assemblies of lathe such as head stock, apron, saddle, tool post, tail stock etc. Checking & accuracy of lathe after assembly.

Breakdown maintenance and preventive maintenance of a lathe.

14

Holding the job on shaping machine vice, setting of length of ram stroke. Making square block and “V” block. Dismantling & assembly of parts of a shaper machine, Inspection & accuracy of shaper after assembly Simple preventive and breakdown maintenance of Shaping m/c.

Shaper: Introduction to Shaper machine parts & constructional details, its function and operations. Quick return mechanism of shaper. Calculation of cutting Speed, feed & depth of cut.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Arc Welding Setting up of an arc welding machine before start welding considering material thickness, diameter of electrode etc. Edge preparation for arc welding. Practice for straight horizontal and vertical position – Lap, Butt & Tee joint. Practice on pipe joint.

Welding & Gas Cutting Arc Welding Introduction to arc welding process viz Fusion, Non-fusion & Pressure, its classifications, accessories and its safety.

2

Gas Welding Setting up of a gas welding set. Setting of different types of flames with gas welding & adjustment of flame.

Gas Welding Introduction to gas welding process, its classifications, accessories and its safety. Principle of gas cutting. Systems of Oxy-cetylene Welding- Flashback & backfire Types of Oxy-Acetylene flames: Gases used in welding & Gas flame combination.

3

Identification and familiarisation of various types of hydraulic elements such as pumps, valves, actuators and oil filters. Overhauling of valves

Hydraulics & Pneumatics Basic principles of Hydraulics - Advantages & limitation of hydraulic system, hydrostatic transmission, Pascal’s law, Brahma’s press, pressure Temperature & flow, speed of an actuator.

4

Overhauling of - Hydraulic pumps, Hydraulic actuators. 

Function and construction of gear pump, vane pump and piston pump, cylinder & hydraulic motor.

5

Simulation of hydraulic circuits - Simple hydraulic circuits. Hydraulic circuit reading practice & constructing hydraulic circuits for single & double acting cylinders, meter in, meter out circuit, pressure control circuits & regenerating circuit.

Auxiliary & fluid conditioner: Reservoir, filter, strainer, pressure gauge, pipe & pipe fitting, accumulator, seals & packing Simple hydraulic circuits.

6

Practice on constructing hydraulic circuits.

Electro hydraulic circuit, Electrical components

7

Identification of various types of pneumatic elements such as: control valves, actuators, filter, pressure regulator and lubricator.

Basic principle of pneumatic system. Advantages & limitation. Air preparation. Constructional & functional details of pneumatic cylinder, motor, control valves and FRL unit.

8

Overhauling of pneumatic cylinders. Practice on construction of Pneumatic circuit. Practice on construction of two-hand safety pneumatic circuit.

Introduction to Pneumatic actuators Pneumatic Symbols Pneumatic circuit Electrical control components

9

Cutting & Threading of pipe. Fitting of pipes as per sketch.

Pipe Fitting and Valves, Types of pipe, tubes and different fittings. Tools used in pipe work.

10

Bending of pipes as per drawing. Making pipe joint (flaring and ferrule).

Pipe bending and jointing methods. Different types of expansions joints and their applications.

11

Use of different type of valve like: Gate, Globe, butterfly, Diaphragm. Direction control valve, pressure relief valve, non return valve, flow control valve. Assembly and disassembly of valves. Making and replacement of gaskets.

Pipe colour code. Safety precautions to be observed while working at pipeline. Constructional detail of different type of valve & their uses like: Gate, Globe, butterfly, Diaphragm.

12

Setting of milling cutters, machine vice (job holding device), cutting speed, feed, setting of table movement. Preparation of rectangular block by milling with in an accuracy of ± 0.2 mm.

Milling: Introduction to milling machine, parts & constructional details, types. Safety precaution followed during milling operation. Milling machine attachments.

 13

Angular milling (external) & Dovetail milling & calculating roller reading. Concave and convex radius milling.

Milling cutter holding devices, work holding devices, Milling machine operations, Up milling and Down milling.

14

Dismantling & Assembly of various parts & sub assemblies of milling machine such as head stock, gear box, lead screw, table, etc. Checking & accuracy of milling machine after assembly.

Breakdown maintenance and preventive maintenance of a lathe.

15

Procedure for holding of job, setting of machine – stroke length. Practice of wheel balancing. Grinding of parallel and perpendicular surfaces with in the accuracy of ±0.02mm, using magnetic chucks and C-clamp.

Grinding: Grinding machine – introduction, parts & constructional details, types – surface grinding and cylindrical grinding machines. Safety precaution followed while working on grinding machines. Grinding wheels – abrasives, bond and bonding process, grit, grade, and structure of grinding wheels and its marking system.

16

Dismantling & Assembly of various parts & sub assemblies of grinding machine such as grinding head, ,lead screw, table, hydraulic cylinder etc. Checking & accuracy of grinding machine after assembly. Practice of preventive maintenance on grinding machines and Demo with case studies on breakdown maintenance & Trouble shooting.

Preventive and breakdown maintenance of grinding machine.

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Electrical: Safety precautions to be observed while working in electrical shop. Identification of electrical accessories. Making simple wiring circuits and measurement of current and voltage.

Basic Electricals Safety in electrical shop Measurement of current, voltage, resistance and power. Use of multimeters. Basic principles of DC generators and motors, Alternators and AC motors and transformers. Various types of switches, circuit breakers, fuses, lamps, proximity switches, relays and contactor in electrical circuits.

2

Testing of power supply (AC & DC) Demonstration of use of test lamp and megger. Connections of DC/AC motors and its speed control – demonstration only. 

Passive circuit elements – resistors, capacitors and inductors. Its identification and testing. Colour code. Ohm’s law and its applications. Energy sources. Series and parallel connections.

3

Identification of passive and active electronic components. Observation of waveforms in a power supply using oscilloscope. Verification of logic gate operations.

Introduction to electronics and its industrial applications. Introduction to digital electronics – numbers system and logic gates.

4

Scope of industrial electronics with reference to its application in machine tools operation. Identification of basic components - such as Resistor capacitors Inductors etc, from their outlook.

Study of electronic circuit – macro level with block diagram.

5

Study of rectifiers available in different package –lead identification & testing by multimeter. Study of rectifier circuits –half wave full wave & brige rectifiers.

Study of PLC - macro level

6

Instrumentation Demonstration on various measuring devices Demonstration of PLC Trouble shooting of mechanical elements with case studies.

Introduction to industrial process control system and equipment - sensors, transmitters and final control elements.  Measurement of displacement, pressure, temperature, flow, level and speed. Application of encoders.

7

Safety precautions in use & maintenance of hydraulic presses. Dis-assembly of hydraulic power pack from press unit.

Study & working of a hydraulic press along with its components. Breakdown & preventive maintenance of a hydraulic press. Safety in use of and maintenance of hydraulic presses.

8

Practical Demo on CNC lathe / machining centre operation, its essential parts. Functioning of each part. Multi-media demo.

Introduction to CNC lathe and machining center, constructional details, Mechanical, electrical and Electronic elements of CNC machine, CNC Part program.

9

Identification of various types of centrifugal pumps, their parts. Overhauling of pump. Priming of pump, Fitting gland packing. Starting and stopping of pumps.

Centrifugal Pump, Fan, Blower and Compressor: Pump Function of pump. Types and working principle of centrifugal pump.

10

Identification of various types of fans, Blowers, their parts. Dismantling, cleaning and assembly of parts. Identification of various types of compressors, their parts.

Fan & Blowers: Types and working principle Constructional detail of Fans & Blowers. Starting and stopping of Fans and Blowers Different parts of Fans & Blowers Concept of surge. Preventive & scheduled maintenance. 

11

Practice of different type of knots & hitches used in material handling Raving sets of pulley block. Splicing of manila rope. Inspection of wire rope/steel rope/belts. 

Rigging Knowledge of different tools & tackles used in rigging. Construction and capacity of wire rope/steel rope/belts.

12

Use of mechanical & hydraulic jack, rope puller, chain puller, chain block, Winch. Inspection of tools and tackles Loading, unloading and shifting of common and uncommon shapes of material.

Different type of jacks, chain block and pull lift. Knowledge of different types of scaffolding. Material movement by using different rigging tools and techniques.

13

Demonstration on Belt conveyor system, Vibratory screen & feeder. Demonstration & practice on flat belt jointing

Bulk Material Handling (Conveyor belt, Vibratory screen, Feeders) Principle & mode of material handling. Various components used in belt conveyor system & their functions

14

Revision of Dismantle, inspect and do minor repairs and assemble machine tools such as drill, shaper, lathe and power saw machines.

Breakdown Maintenance, Preventive Maintenance, Predictive Maintenance & Concepts of TPM, OEE.

15

Practice on accuracy testing of machine tools. Logging checklist for machine tools.

Accuracy testing of machine tools. Various maintenance practices. Concepts & Measurement of machine performance: MTBF, MTTR.

16

Preparing inspection check-list, taking measurement with the help of industrial thermometer and temperature gun. Use of vibration meter to take measurement. Fault finding practice & attending breakdowns of equipment available in workshop.

Inspection & Condition Monitoring. Maintenance strategy – Reactive, Preventive, Predictive and proactive Importance of inspection. Type / methods of equipment inspection. Shutdown inspection, Inspection of running equipment and inspection of spare parts. Commonly used gadgets for inspection. Concept of inspection check-list. Importance of condition monitoring. Various techniques used for condition monitoring. (vibration, temperature, sound and lubricant condition).

Project Work