ITI's which provides courses for Operator Advanced Machine Tool

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

Basic Fitting: Preparation of filing. Standing posture with respect to bench vice for filing. Marking lines on the job surface for filing to the marked lines. Gripping the job suitably in the vice jaws for filing. Balancing of file, using rough file. Measurement by using inside/outside calipers and scale.

Basic Fitting: Vice – purpose, types, description, size, construction method to use and maintenance. File –purpose, types, description, sizeand method to use. Use of file card, printing of file, convexit y of file and proper filing technique.

3

Use of simple measuring instruments such as steel rule, Vernier caliper, Inside/Outside Micrometer. Care and precaution to be observed in handling these instruments. Exercises on measurement of various geometrical shapes.

Divider – purpose, types, description and method to use. Scriber – purpose, types, description and method to use. Marking Block – purpose, types, description and method to use. Punch – purpose, types, description and method to use.

4

Exercises on filing to develop control and Field layout the dimensional features of the work piece using vernier height gauge, engineering square, angle plate and surface plate. Exercise on filing the adjoining sides Squareness with respect to one reference surface.

Vernier height gauge – purpose, types, Construction, method to use and read, care and maintenance. Engineer’s square – purpose, description and method to use. Surface Plate – purpose, description, method to use, care and maintenance. Angle P late – purpose, description and method to use.

5

Marking of profiles – combination of straight lines, circles, arcs and angles using scale, divider height gauge, protractor, combination set etc. Marking geometrical profiles on sheet metal and filing to mark lines. Sharpening of marking tools, use of bench grinder for sharpening of scriber, centre punch, dot punch, divider etc.

Combination set – purpose, description and method to use. Vernier bevel protractor – purpose, description, calculation of vernier constant, method to read and use, care and maintenance. Bench Grinder – purpose, description, procedure and precautions to be observed during grinding of marking tools, chisels and drill bits. Hack saw – purpose, types, description, method to use and precautions to be taken during hack sawing.

6

Hammering practice on vertical hold round job. Blind hammering practice. Stamping letters and numbers on M.S. plates. Exercise on stamping to develop judgment, control on hand and feel.

Hammer – purpose, types, description, method to use and precautions to be observed. Bending of solid selections using fixtures. Letters and Numbers – purpose, description, method to use and precautions to be observed. Hollow Punch – purpose, description, method to use for preparations of gaskets and other packing materials.

7

Preparation for drilling, marking out the position of holes and dot punching. Deepening the points with centre punch. Checking for centre distance. Drilling practice on sensitive drilling machine using different types of drills and drill holding devices. Safety to be observed while working on drilling machine.

Drills – purpose, types, description, drill holding devices, method to use a drill with or without drill chuck (or collect) and precaution to be observed. Reamer –purpose, types, description, method to use, reaming allowance, coolant used and precautions to be observed during reaming.

8

Measurement of shaft and hole diameters using outside and inside micrometer. Filing round out of square bar within ±0.1mm. Filing to an accuracy of ±0.1mm., checking with an outside micrometer.

Defining and explanation of the elements of interchangeable system basis size, limits, tolerance, allowances.

9

Filing of various angle & clearances of lathe tool on square blanks. Checking with templates & gauge already prepared. 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.

Gauges & Template-purpose, types, description and method to use dial test indicator. Limit gauges - purpose, types, construction and method to use limit gauges.

10

Cutting of sheet metal with chisel. Marking parallel clamp, ‘C’ clamp or micrometer stand using acquired skills. Simple project work.

Sheet metal work-purpose, types, description and method to use snip & stake. Description and method to use hand shear. Rivets & riveting-types & description of rivets.

11

Basic Maintenance Skills: Using hand tools such as screw driver, single end/double end spanners, box nut spanners, ratchet spanners, circlip, pliers, wrenches, pullers, extractors, drift. Correct method to be used and care to be taken in using those tools.

Basic Maintenance Skills: Screw drivers – purpose, types, description and method to use screw drivers. Spanners – purpose, types, description and method to use box, socket, tubular, hook spanner etc. Wrenches – purpose, types, description and method to use T-socket, monkey, ratchet, pipe wrenches etc.

12

Basic turning: Safety precautions to be observed while handling machines. Demonstration of change gear in the Gear box. Practice of holding work piece and tool using different devices. Exercises on plain, stepped, taper and form turning, knurling etc.

Turning: Types, construction features working principles, functions, use accessories and attachments of lathe machine. Driving mechanism – cone pulley, all geared headstock, quick-change gearbox and apron mechanism.

13

Basic Milling: Safety precautions in handling machine. Demonstration of various parts of the milling machines. Practice on different work and tool holding devices.

Milling: Construction features, working principles, types, functions. Use of accessories and attachment of milling machine. Types of milling cutters. Different method of holding work piece and cutters.

Project Work

Sem. II

Trade Practical

Trade Theory

1

Grinding: Safety precautions t o be observed while using machine Demonstration of various parts of the grinding machines. Use of drive – both mechanical and hydraulic.

Types of machines- Constructional features, working principle, types, functions and use of surface and cylindrical grinding machine. Grinding wheels and their specifications – grit, grain, size, structure, bond, grades etc. Procedure to use grinding wheels for balancing and truing.

2

Other machining processes:
i) Shaping
ii) Planning
iii) Slotting
iv) Hobbing
v) Broaching
vi) Finish machining process

3

Advanced Machining Skills Turning

Advanced Machining Skills Turning

4

Milling

Milling

5

Inspection

Inspection

6

Geometrical accuracy test of machine as per test chart. 

Defects and remedies of turning, milling and grinding. Defects such as: Taper, Chattering, Poor Surface finish, Parallelism.

Project work

Sem. III

Trade Practical

Trade Theory

1

CNC Fundamentals: Familiarization of computer as CNC works station. Communication between CNC and computer i.e. series, parallel port.

CNC Fundamentals: Background application, block diagram, input devices, output devices, CPU. Memory, Use of computer as CNC workstation. Communication between CNC and computer.

2

Demo/Identification of different elements of CNC machine Construction & functions, Axis designation

Familiarization with co-ordinate system. Types of co-ordinate system and their applications. Different types/functions of G codes & M codes used in CNC part programming. Different types of interpolation & its applications.

3

Practice on exercises with different coordinate systems with linear & circular interpolation

Cutter Radius comp, Tool wear comp Tool nose radius comp, Tool nomenclature, tool change, command, work & tool offset.

4

Writing the part program for both turning & milling manually and practice on simulation software. Selection of tools Practice of work & tool offset on simulator.

Introduction to part programming for both turning & milling using geometrical information & technological information (G & M codes) such as feed, speed, depth of cut.

5

CNC Turning: Operating the CNC machine in different modes such as JOG, MPG, MDI/MDA. Procedure for reaching reference point. Practice on Work & Tool offset measurement. Program loading and machine setting. Executing the program in auto Single Block and auto continuous mode.

CNC Turning: Modes of operation such as JOG, MPG, REF, MDI/MDA. Program execution in different modes like auto SBL and auto cont. mode. Knowledge on CNC cutting tools-Geometry, material, cutting speed, feed, and depth of cut. Techniques of tool off-setting and tool setting. Prepare various programs as per drawing.

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Practice of contour program for different profiles on CNC simulation software

Concept of contour programming for different profiles.

2

Practice on CNC lathe.  Turning - parallel, taper, step, radius, groove and threads of different pitches

Program for different cycles such as stock removal, Grooving, Threading, Undercut & canned/ fixed cycles Tool type chart, TNRC (G41 and G42). Surface finish-Primary and Secondary. Surface roughness related BIS symbols.

3

CNC Milling: Operating the CNC machine in different modes such as JOG, MPG, MDI/MDA. Procedure for reaching reference point. Practice on Work & Tool offset measurement. Program loading and machine setting. Executing the program in auto SBL and auto cont. mode.

CNC Milling: Modes of operation such as JOG, MPG, REF, MDI/MDA. Program execution in different modes like auto SBL and auto cont. mode. Knowledge on CNC cutting tools-Geometry, material, cutting speed, feed, and depth of cut. Techniques of tool off-setting and tool setting. Prepare various programs as per drawing.

4

Practice on CNC Milling such as Face milling, Edge milling, slot milling (Radial & circumferential), Pocket milling (square & circular), Application of Canned/Fixed cycles

Programming for different operation such as Face milling, Edge milling, Slot milling (radial & circumferential) Tool type chart, Application and effect of Cutter radius compensation (G41 and G42). Surface finish-Primary and Secondary. Surface roughness related BIS symbols Programming for Pocket milling (square & circular) & Canned / Fixed cycles for whole machining.

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

Practice of contour program for different profiles on CNC simulation software

Concept of contour programming for different profiles.

7

Practice on routine maintenance, Periodic checking for lubrication, Hydraulic oil level, Hydraulic system pressure, chuck Pressure adjustment for different material. Cleaning & adjusting the Pneumatic Filter, Pressure regulator & Lubricator.

Preventive Maintenance, Predictive Maintenance & Concepts of TPM. Difference between breakdown and preventive maintenance – Its importance in productivity, types. Normal procedure followed for maintenance of machine tool in the shop floor. Importance of centralized lubrication system, Hydraulics & pneumatics.

Project Work