ITI's which provides courses for Mechanic Mechatronics

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

History of Institute – necessary information, guidance to the new corner to get familiarize with the working institute, rules, procedures etc. Recreational, Medical & other facilities available in the institute. Familiarization with institute & work place. Scope & Importance of the Trade Training, Types of the work done by the Trainee & role of “MECHANIC MECHATRONICS” in an industry. Rules & regulations of the institute. Allocation of workplace. Issue of tool box & essential tools. Importance of Cleanliness & orderliness at the workplace.

2

General Safety Rules. Introduction to First Aid practices Method of Maintaining First Aid Box. Fire Fighting equipment & their uses. (Shop talk & demonstration).

Importance of safety, accidents & Causes of Accidents. General Safety, Precautions & personal safety to be observed while working in the institute/ sections.

3

Preparation for filing.  Gripping the job suitably in the Vice jaws for filing. Taking correct standing posture with respect to bench vice for filing.

Introduction to measuring & checking instruments. Non-precision linear measurement by using steel rule, depth rule, hook rule & zigzag rule, bit rule, tape etc.

4

Balancing of file using rough file to be continued on channel. Filing flanges of a channel for practicing of filing. Filing flat surface & flanges of a channel maintaining parallelism between them using outside calipers within ± 0.5mm

Work bench, bench vice-on structional details, different types of vices, their uses, care and maintenance of vices. Files:- File parts & material classification of files based on grade, cut, shape, length etc.

5

Exercise on filing the adjoining outside faces of flanges of channel square to flat surface of channel as reference surface.

Introduction to layout marking, making media & marking tools-construction, use, care and maintenance.

6

Marking of profiles combination of straight lines, circles, arcs & angles.

Types of Chisels-material, specification & application. Hot Chisels & Cold Chisels

7

Hammering practice on vertically held round job. Blind hammering practice. Stamping Letters & Numbers on M.S. plates.

Types of Drills - Flat & Twist Drills, straight fluted & special types of drills, parallel & taper shank drills construction/material & use.

8

Introduction to Drills. Preparations for drilling. Marking out the position of holes & Dot punching. Deepening the points with center punch. Checking for center distance.

Introduction to drilling machine –Portable & Hand Drilling Machine. Bench and Pillar Upright type drilling machine. Study of drill holding devices. Drill chuck, chuck key, drill drift, sockets & sleeves construction, material & use.

9

Drilling practice on varying thickness & different materials such as Mild Steel, cast Iron, Stainless Steel, Copper, Brass, Nylon. Epoxy etc.

Introduction to reamers, types of reamers, pitch of flute, precautions to be observed while reaming.

10

Exercise on filing - Radius & Angular filing using templates & gauges. Filing Templates & gauges for checking. Lathe tool angles. Filing to an accuracy of + or - 0.1mm., checking with Vernier Caliper.

Elements of interchangeable system. Definition of Limit, Tolerance & Allowance Basic dimensions or sizes. How Limit & Tolerance is denoted? Application of tolerance. Tolerance of Form & Position.

11

Use of Combination & Round Nose Pliers to make different shapes/profiles by bending wire to match the blue print to develop manipulative skills, hand control & eye judgment Using hand tools such as screw driver, single end/double end spanners, single end/double end ring spanners, box nut spanners, ratchet spanners, circlip pliers, wrenches, pullers, extractors, drift. Correct method to be used & care to be taken in using these tools.

Types of spanners-their material & uses Box, Socket, Tubular, hook spanner etc. Wrenches – material & use of T Socket, Monkey, Ratchet, Pipe wrenches etc. Types of screw drivers- materials & uses.

12

Project work: making parallel clamp “C” clamp or micro meter stand by using acquired skills.

Scrapping- importance of scraping- advantages – different methods of scraping- scraping procedure for producing flat surfaces. Checking of scraped surfaces- use of spirit level.

13

Scraping on flat surface. Taking impression for high spots using Persian blue. Sharpening of scrapers using diamond wheel & lapping stone.

Properties & uses of Ferrous and Nonferrous metals and their alloys such as Cast Iron, Wrought Iron, Mild Steel, Carbon Steel, Tool Steel, High speed steel. Aluminium, Copper, Tin, Lead, Zinc, Brass, Bronze, White metal , Rubber and Plastic

14

Filing & fitting practice within + or 0.06 mm thick plates.

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15

Application and use of dial indicators slip gauges and height gauge/height master.

Study of slip gauges height gauges

16

Application of Advanced Bench Working Skills

Familiarization with plastic deformation of material, Cold & Hot bending of strips. Commonly used pipes sizes, material and specification.

17

Filing flats on cylindrical parts. Filing square at the end & in the middle of cylindrical rod within + or -0.04 mm.

Micro-meters- special types- important features & applications, e.g. Thread checking micrometer, flange Micrometer, Depth Micrometer etc Sine bar, slip gauges.

18

Bending of solid sections by using bending fixtures, bending dies etc. Cold & Hot bending of pipes of different diameters of ferrous metal i.e. hydraulic pipes Non-ferrous metal i.e. copper tubes for lubrication system.

Types of gauges- Plug, Ring, Snap, Taper, feeler, screw Pitch, Radius & sheet metal gauges. Dial indicators- construction & use. Various types.

19

Using hand tools such as screw driver, single end/double end spanners, single end/double end ring spanners, ratchet spanners, circlip pliers, wrenches, pullers, extractors, drift.

Definition of lapping & its necessity. Constructional features of lapping. Design of laps-Cast Iron, Copper, Lead, Mild steel etc.

20

Familiarization and use of different types of ropes such as hemp, manila, nylon, wire etc. Practicing different types of knots and its applications.

Specification and use of different types of ropes such as hemp, manila, nylon, wire etc. Practicing different types of knot sand its applications.

21

Basics and use of different types lifting tackles both mechanical and hydraulic such as – screw jacks, chain pulley block, crabs and winches, rollers and bars, levers, lashing and packing.

Different types of appliances and tackles for shifting, loading and unloading of machine and equipment. Screw jacks- their use and working principles. Chain pulley blocks- their use and working principles.

Project Work

Sem. II

Trade Practical

Trade Theory

1

Machine tool technology Constructional features and working principles of Lathe machine. Functional relationship of various parts of the machine. Study of the gear box and drives used on the machine.

Introduction to metal cutting process Metal cutting and cutting tools. Mechanism of metal cutting- orthogonal and oblique cutting, chip formation, types of chips and chip breakers.

2

Constructional features and working principles of shaping machine. Functional relationship of various parts of the machine.

Constructional features, function and use of shaping machine, working principle, use of Quick Return Mechanism

3

Practice on Milling Machines Constructional features and working principles of Milling Machine. Functional relationship of various parts of the machines.

Introduction to Milling Machines Constructional features and working principles, types, functions, use of milling machines, attachment and accessories.

4

Practice on Grinding Machine Constructional features and working principles of surface and cylindrical grinding machines. Functional relationship of various parts of the machine.

Introduction to Grinding Machines Constructional features, types, functions and use of grinding machines.

5

Practice in drawing simple geometric shapes on sheet metal using marking tools. Practice in cutting sheet metal in these shapes and cutting sheets to various angles using hand shear, snip and chisel.

Material Science & Process Commonly used sheet metals-rolled sheets such as tin, galvanized iron, copper, brass, aluminium sheets-their physical properties and uses.

6

Practice & Application of Meterolgical Instrument & Inspection techniques.

Introduction Meterology & Inspection Techniques: Inspection, quality control, quality assurance, total quality management concepts and quality awareness.

7

Practice on welding Process Working principles of Arc, gas and spot welding machines. Connecting and setting of machine for operation.

Introduction to Welding: Gas and electric welding – tools and equipment. Principle of fusion welding.

8

Joining of flexible cables by soldering. Staggered joints in case of twin wires or multi- core cables. Familiarization with different types of plugs, sockets, switches, fuses and fuse holders, cut outs etc. with their specifications and applications.

Introduction to general Electrical & Electronics Modern theory of atomic structure in general –nucleus, orbits and free electron, orbital electron, valance electron – free electron.

9

Practical on basic Electronics Scope of industrial electronics with reference to its applications in machine tool operation. Identification of basic components such as registers, capacitor, inductors etc. From their outlook.

Basic Electronics Semi-conductor theory. Intrinsic and extrinsic semi -conductors. P and N type semiconductors and P-N junction – Semi-conductor diode – two layer and two terminal device.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Industrial hydraulics – principles, advantages, disadvantages and safety. Study of block diagram of hydraulic system in general. Construction features, principles of operation, Function and uses of various hydraulic components such as pumps, valves, actuates and power pack.

Industrial hydraulics – principles, advantages, disadvantages and safety. Study of block diagram of hydraulic system in general. Construction features, principles of operation, function and uses of various hydraulic components such as pumps, valves, actuators and power pack.

2

Construction features, principles of operations and uses of pneumatic components such as valves and their actuators. Identification of components from their outlook and their specifications.

Construction features, principles of operations and uses of pneumatic components such as valves and their actuators

3

Introduction to levelling of machines. Practice on levelling – use of sprit level, camel back, straight edge, bridge, parallel blocks etc.

Methods employed for installation and erection of precision and heavy duty machines. Location and excavation of foundation

4

Study of various spindle drive mechanism used on bench grinder, drilling, milling, lathe and grinding machines. Checking for spindle run out – axial and radial play.

Machine alignment – different types- procedure. Equipment for aligning machine – use of test mandrel, master cylinder, straight edge, centricities, slip gauges, dial indicators etc.

5

Study of Belt Pulley, Chain, Gear, Rack & Pinion etc. Used on different Machines. Introduction to various gear transmission mechanisms.

Prime movers. Types of drives Rope & Chain. Variable speed transmission PIV drives and Harmonic drives. Friction drives. Clutches- positive clutches friction clutches.

6

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Types of pulleys solid, split, “V” groove, step, cone, taper, guided and jockey or rider pulleys etc. their functions and uses.

7

Inspection of machine guide ways and slides. Checking for straightness, flatness, scoring/scuffing marks and condition of oil grooves and wear.

The object of belts- Types / sizes / specifications and uses. Materials used for belts-leather, cotton canvas, Indian rubber (Batala).

8

Familiarization with plain/journal bearings, anti-friction bearings used on machine assembly. Specification & selection for appropriate use.

Types of belt drives, velocity ratio of belt drive. Horse Power transmitted by belt. Ratio & driving tension in a belt. Parallel & cross belt drive, open & cross belt drive, angular belt drive

9

Study of Various machine tools such as Lathe, Milling Grinding & shaping machine with special attention to transmission mechanism.

Types-materials and uses of gears. Various manufacturing processes. Study of spur gear elements-tooth profile-pitch circler-diametric pitch velocity ratio of a spur gear.

10

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Method o f reducing friction, Use of is a ring advantages & disadvantages. Bearings-different types of high speed & low speed their application

11

Dismantling simple mechanisms such as machine vice, three jaw chucks, index head, tail stock, slotting attachment, coolant pumps, using various hand tools with specific reference to functional part of their machine elements.

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12

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Introduction to maintenance work. Importance of maintenance. Methods & tools of maintenance, basic concepts of routine & preventive maintenance.

13

Dismantling of simple machines such as Bench grinder, Pedestal Grinder, Sensitive Drilling machines.

Methods of repairing damaged parts.

14

Use of painting /protective coating for rust prevention. Surface operation, use of primers and surfaces.

Methods of various set ups. Reclamation of worn out parts such as slides, gears, shafts, broken parts of cast iron etc. By metal deposition hard chrome plating etc.

15

Familiarization with electrical symbols being used in electrical circuit diagrams. Practice in reading electrical circuit/connection diagrams from the instructional manual.

Planning for scheduled overhauling of machine. Methods of dismantling, precautions to be taken while dismantling

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Introduction to logic gates and their truth tables. Building logic gates such as AND, OR, NOR, INVERTER, NAND, EX-OR using diodes and transistors output lamps indicating conditions in truth table (Analogy of logic gates to series and parallel combination of switches).

Introduction to logic gates e.g. AND, OR, INVERTER, NAND, NOR, EX-OR, etc. Their truth table analogy of logic gates, combination of series and parallel switches.

2

Study of commonly used Transducers such as thermocouples, LDRS, the misters, LVTs, strain gauges, magnetic pick up photo diodes, photo transistors etc.

Introduction to commonly used transducers in industries such as Timers o f different types, counter s, proximity switches (AC and DC), over current relays, DC motor controller, photo electric relays, temperature controller

3

Circuit building practice-regenerative (sequencing) circuit with speed and pressure (clamping) control.

Construction features, working principles and uses of pumps, positive and non positive displacement of pumps, gear pump, vane pump, piston pump, axial position and radial position pumps.

4

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Friction –its effect, methods of reducing friction. Use of lubricants, use of bearings.

5

Circuit building practice-use of shuttle valves for control, circuit for speed regulation of single and double acting cylinder, circuits for indirect control on single and double acting cylinders, time dependent control circuits etc.

Constructional details, specifications, application of power unit, actuating unit, control unit.

6

History o f computer (first generation to fifth generation), classification of computers, characteristics of computer block diagram, representation of characters in computers.

Background application, block diagram, input devices, output devices, CPU.

7

Introduction to CNC technology. Study of special constructional and operational features with reference to driving mechanism, machine tool design, lubrication system. Familiarization with co-ordinate system, use of CNC codes and programming for simple test jobs.

Introduction to CNC machines. Difference between NC, CNC and GPM Importance of CNC machines over other mass production processes.

8

Study and practice of various CNC operating elements on CNC vertical machining cente.

Spindle speed system

9

Introduction to CNC machine maintenance, use of maintenance card, history card & recording the data.

Linear axis feed system

10

Study of Spindle speed system

Study of Coolant and lubrication systems.

11

Study of Linear axis feed system

Hydraulic & Pneumatic power and circuits.

12

Study of Coolant and lubrication systems

Study of Electrical /electronic circuits for a CNC m/c.

13

Hydraulic & Pneumatic power source and circuits.

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14

Study of Electrical /electronic for a CNC m/c; CNC system hardware; Feed and spindle drives; Feedback devices; Programmable logic controller; Machine power supply and Safety interlocks.

CNC tooling and fixtures. Manual part programming