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Govt.Tool Room & Training Centre -Bangalore-10 III-SEMESTER SYLLABUS DTDM COURSE Page No: 1

GOVT.TOOL ROOM & TRAINING CENTRE

SEMESTER: THIRD

Course: DIPLOMA IN TOOL & DIE MAKING

Syllabus -Theory and practical Subjects

SL. CODE SUBJECTS

Contact

Hours/Week

Contact

Hours/Semester NO

1 TDM301 Production Technology – III (Milling) 3 60 0 940 260 140 1960 1080

2 TDM302 E M & SOM 3 60

3 TDM303 Engineering Drawing –III(Assembly) 4 80

4 TDM304 Engineering Metrology 2 40

5 TDM305 Press Tool Theory-I 2 40

6 TDM306 Jigs & Fixtures (Theory) 2 40

Practical

7 TDM307 Work Shop – III 28.5 570

8 TDM308 CAD Lab – I (Solid Works) 3 60

Scheme of Examination

Course: DIPLOMA IN TOOL & DIE MAKING

SI.

No

Sub.

Code

Subjects Contact

Hours

per

Week

Exam

Duration

Scheme of Examination Total

Marks

Min

marks

for

passing

Exam Internal

Assessment

Theory Max Min Max Min

Marks Marks Marks Marks

1 TDM301 Production Technology – III (Milling)

3 3 100 50 20 10 120 60

2 TDM302 E M & SOM 3 3 100 50 20 10 120 60

3 TDM303 Engineering Drawing –III(Assembly)

4 4 100 50 20 10 120 60

4 TDM304 Engineering Metrology 2 3 100 50 20 10 120 60

5 TDM305 Press Tool Theory-I 2 3 100 50 20 10 120 60

6 TDM306 Jigs & Fixtures

(Theory) 2 3 100 50 20 10 120 60

Practical

7 TDM307 Work Shop – III 28.5 10 900 540 100 60 1000 600

8 TDM308 CAD Lab – I

(Solid Works) 3 3 100 50 20 10 120 60

Total 47.5

1600 890 240 130 1840 1020


PRODUCTION TECHNOLOGY-III (MILLING)

SUBJECT CODE: TDM 301

Learning goals for Production Technology-

On completion of this subject, the trainees will be able to:

Define milling and various types of milling machines and their parts description

Explain the specification of milling and work holding devices and their applications

Identify various types of milling cutters and classifications & explain cutter

geometry

Explain about tool holding devices

Define various types of milling operations and their working procedure and boring

Explain about Dividing Head and Rotary table

Define Indexing and Explain methods of Indexing with their examples

Explain about milling attachments and their usage

Define speed, feed, and depth of cut and calculations on machining time

Explain the necessity of coolant and mixing ratio

Explain the safety precautions of milling



Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. General safety

- Safety precautions

2. Classifications of Milling

- Definition

- Types and parts description

3. Specification and Work Holding devices

- Specification and example

- Work Holding Devices

- T- bolts and clamps

- Angle plates

- V-blocks

- Vices

- Special fixtures

4. Milling cutters

- Definition

- Types of cutters

- Cutters geometry

- Nomenclature of plain milling cutter

- Nomenclature of side milling cutter

5. Tool holding device

- Arber

- collets

- Adaptor

- Spring collets

- Bolted cutters

6. Milling operations

- Plain milling and Face milling

- Side milling and Straddle milling

- Angular milling and Gang milling

- Form milling and Profile milling

- End milling and Saw milling

- Milling key ways , grooves and slots

- Gear cutting and Helical milling

- Cam milling and Thread milling



7. Dividing Head and Rotary table

- Definition

- Working process and applications of dividing head

- Definition of rotary table

- Working process and applications of rotary table

8. Indexing and methods of indexing

- Definition

- Direct or rapid indexing

- Plane or simple indexing

- Compound indexing

- Differential indexing

- Angular indexing

9. Milling attachment

- Vertical milling attachment

- Universal milling attachment

- High speed milling attachment

- Slotting attachment

- Universal spiral milling attachment

- Rack milling attachment

- Circular milling attachment

- Dividing head milling attachment

10. Problems and Machining time calculations

- Definition of speed, feed and Depth of cut

- Machining time calculations

11. Coolant

- Necessity of coolant

- Mixing ratio

12. Safety

- Safety precautions


WEEKLY PLAN FOR PRODUCTION TECHNOLOGY-III (MILLING )

WEEK

NO CHAPTER TITLE CONTENTS OF TOPICS

1

2

General safety Safety precautions

2 Classifications of Milling

Definition

Types and parts description

3-4

Specification and Work

Holding devices

Specification and example

Work Holding Devices

T- bolts and clamps

Angle plates

V-blocks

Vices

Special fixtures

5-6

Milling cutters

Definition

Types of cutters

Cutters geometry

Nomenclature of plain milling cutter

Nomenclature of side milling cutter

7

Tool holding device

Arber

collets

Adaptor

Spring collets

Bolted cutters

8-10

Milling operations

Plain milling and Face milling

Side milling and Straddle milling

Angular milling and Gang milling

Form milling and Profile milling

End milling and Saw milling

Milling key ways , grooves and slots

Gear cutting and Helical milling

Cam milling and Thread milling

11

Dividing Head and Rotary

table

Definition

Working process and applications of dividing head

Definition of rotary table

Working process and applications of rotary table

12-14

Indexing and methods of

indexing

Definition Direct or rapid indexing

Plane or simple indexing

Compound indexing

Differential indexing

Angular indexing


WEEKLY PLAN FOR PRODUCTION TECHNOLOGY-III (MILLING)

15-16

Milling attachment

Vertical milling attachment

Universal milling attachment

High speed milling attachment

Slotting attachment

Universal spiral milling attachment

Rack milling attachment

Circular milling attachment

Dividing head milling attachment

17

Problems and Machining

time calculations

Definition of speed, feed and Depth of cut

Machining time calculations

18

Coolant

Necessity of coolant

Mixing ratio

20 Safety

Safety precautions


ENGINEERING MECHANICS & STRENGTH OF MATERIALS



Learning goals for EM&SOM -

On completion of the course the students should be able to…

Understand the Basics of Engineering Mechanics & SOM

Understand the force analysis and moment of a force.

Understand the concept of centre of gravity

Understand the concept of simple stresses & strains.

Understand strain energy & impact loading.

Understand the concept of thick & thin cylinders.

Understand the concept of Torsion and its applications.





1. INTRODUCTION TO ENGINEERING MECHANICS AND STRENGTH OF

MATERIALS

1.1 Introduction to Engineering Mechanics & SOM

1.2 Scalar & Vector quantities.

2. FORCE ANALYSIS

2.1 Composition & Resolution of forces – Force, examples of force, effect, characteristics

of a force, system of forces, Resultant force, methods for the resultant force and

simple problems.

2.2 Parallelogram law of forces and simple problems.

2.3 Triangle law of forces

2.4 Polygon law of forces2.5 Equilibrium of forces – Introduction, principles of

equilibrium, lami’s theorem, (with proof) Types of equilibrium.

3. CENTRE OF GRAVITY

3.1 Centre of gravity, methods of finding centre of gravity and axis of reference.

3.2 Centre of gravity of symmetrical unsymmetrical plane figures & cut out hole sections.

3.3 Simple problems.

4. SIMPLE STRESSES & STRAINS

4.1 Elasticity, stress, types of stress, strain.

4.2 Elastic limit, Hooke’s law, modulus of elasticity, factor of safety, working stress &

ultimate stress. With stress-strain Diagram.

4.3 Deformation of a body due to force acting on it.


4.5 Volumetric strain of a rectangular body subjected to an axial force and 3 mutually

perpendicular forces.

4.6 Elastic constants, linear strain, lateral strain, volumetric strain & Poisson’s ratio.

4.7 Bulk modulus, relation between bulk modulus & young’s modulus (with proof).

4.8 Shear stress, shear strain & modulus of rigidity.

4.9 Relation between modulus of elasticity & modulus of rigidity (with proof).


4.11 Stresses in Bars of varying Cross sections & Simple Problems.



5. STRAIN ENERGY & IMPACT LOADING

5.1 Introduction, resilience, proof resilience and modulus of resilience.

5.2 Types of loading.

5.3 Equation for strain energy stored in a body when the load is gradually applied.


5.5 Equation for strain energy stored in a body when the load is suddenly applied.


6. THICK AND THIN CYLINDERS

6.1 Introduction to thin cylinders, stresses in thin cylindrical shells.

6.2 Expression for circumferential stress & longitudinal stresses (without proof).


6.4 Design of thin cylinders with simple problems.


7. TORSION:

7.1 Torsion stress and strain 7.2 Theory of pure torsion

7.3 Angle of twist and shear strain – formulas 7.4 Equation for the strength of a shaft 7.5 Polar moment of inertia 7.6 Power transmitted by a shaft

7.7 Simple problems REFERENCE BOOKS

1. Engineering mechanics by R.S.Khurmi. 2. Strength of materials by R.S.Khurmi.

3. Applied Mechanics by S.S.Bhavikatti.

4. Strength of Materials by S.S.Bhavikatti.

5. Applied Mechanics & Strength of Materials by S.Ramamrutham.

6. Applied Mechanics & Strength of Materials by I.B.Prasad.


WEEKLY PLAN FOR EM&SOM

WEEK NO CHAPTER TITLE CONTENTS OF TOPICS

1

INTRODUCTION TO

ENGINEERING

MECHANICS AND

STRENGTH OF

MATERIALS

Introduction to Engineering Mechanics & SOM

Scalar & Vector quantities.

2-5

FORCE ANALYSIS

Composition & Resolution of forces – Force,

examples of force, effect, characteristics of a force,

system of forces,

Resultant force, methods for the resultant force and

simple problems.

Parallelogram law of forces and simple problems.

Triangle law of forces

Polygon law of forces

Equilibrium of forces – Introduction, principles of

equilibrium, lami’s theorem,(with proof)

Types of equilibrium

6-7 CENTRE OF

GRAVITY

Centre of gravity, methods of finding centre of

gravity and axis of reference.

Centre of gravity of symmetrical unsymmetrical

plane figures & cut out hole sections.

Simple problems.

8-10

SIMPLE STRESSES &

STRAINS

Elasticity, stress, types of stress, strain.

Elastic limit, Hooke’s law, modulus of elasticity,

factor of safety, working stress & ultimate stress.

With stress-strain diagram.

Deformation of a body due to force acting on it.

Simple problems.

11-14

Volumetric strain of a rectangular body subjected to

an axial force and 3 mutually perpendicular forces.

Elastic constants, linear strain, lateral strain,

volumetric strain & Poisson’s ratio.

Bulk modulus, relation between bulk modulus &

young’s modulus (with proof).

Shear stress, shear strain & modulus of rigidity.

Relation between modulus of elasticity & modulus of

rigidity (with proof).

Simple problems.

Stresses in Bars of varying Cross sections & Simple

Problems.


WEEKLY PLAN FOR EM&SOM

WEEK NO CHAPTER TITLE CONTENTS OF TOPICS

15-17

STRAIN ENERGY &

IMPACT LOADING

Introduction, resilience, proof resilience and modulus

of resilience.

Types of loading.

Equation for strain energy stored in a body when the

load is gradually applied.

Simple problems.

Equation for strain energy stored in a body when the

load is suddenly applied.

Simple problems.

WEEKLY PLAN FOR

EM&SOM

18

THICK AND THIN

CYLINDERS

Introduction to thin cylinders, stresses in thin

cylindrical shells.

Expression for circumferential stress & longitudinal

stresses (without proof).

Simple problems.

Design of thin cylinders with simple problems.

Simple problems.

TORSION Torsion stress and strain

19-20

Theory of pure torsion

Angle of twist and shear strain – formulas

Equation for the strength of a shaft

Polar moment of inertia

Power transmitted by a shaft Simple problems


ENGINEERING DRAWING (ASSEMBLY)



Learning goals of Engineering Drawing (Assembly):

Draw the sectional views and interpret them correctly.

Prepare the assembly drawing with the help of the given detail drawings.

Prepare the assembly drawing with the help of given details for blanking tool

and progressive tool with all the parts.

Prepare the bill of materials.

Decide dimensions for all mating parts.

Interpret special views.

Interpret the symbols for surface finish.

Interpret tolerances and fits correctly.


ENGINEERING DRAWING (ASSEMBLY)


1. ASSEMBLY AND DETAIL DRAWINGS

- Review previously done assemblies. - Concept of assembly drawings from the given part drawings. - Indication and interpretation of surface roughness symbols as per IS

696:1972. - Indication of fits and tolerances in assembly drawings.

2. Preparation of assembly drawings and parts list for the following:

Leaf Drill Jig

Universal Coupling

Tool Head of shaping Machine

Lathe slide rest

Tail Stock

Machine Swivel Vice

Machine Vice

Swivel Bearing

Knuckle Joint

2 Stage Progressive Tool

Blanking Tool


WEEKLY PLAN FOR ENGINEERING DRAWING (ASSEMBLY)

Week No. Topics

1 DETAIL DWG - PARTS OF LEAF JIG 2 LEAF JIG ASSEMBLY

3 & 4 UNIVERSAL COUPLING - Part & Assembly

5 & 6 KNUCKLE JOINT - Part & Assembly 7 TOOL HEAD OF SHAPING MACHINE 8 LATHE SLIDE REST 9 TAIL STOCK 10 I - INTERNALS 11 MINI VICE ASSEMBLY 12 MACHINE SWIVEL VICE 13 SWIVEL BEARING 14 PLUMMER BLOCK 15 & 16 BLANKING TOOL - Part & Assembly

17 & 18 PRESS TOOL (3rd YEAR PRACTICAL) - Part & Assembly

19

HAND INJECTION MOULD - Part & Assembly

20 II - INTERNALS

INSTRUCTIONS TO THE FACULTY 1. The above assemblies are framed for III Semester. 2. The assemblies have to be explained in detail before drawing.

3. Explain each part for material, quantity, manufacturing, fits, tolerance, functionality & purpose. 4. Explain about selection of cutting plane, sectioning, number of views, part list & title block.

5. Standard sizes for relief holes, counter bore, counter sink, chamfers, importance of reamed holes, Hole & shaft basis system, conventions.

6. Selection criteria of standard parts. 7. Script & Line standards, Dimensioning standards - zero line, chain line & Ordinate dimensioning.

8.Dimensioning standards - aligned & unidirectional methods, zero & chain line, Ordinate dimensioning

Reference books – Machine Drawing by KRG & N D Bhatt, Engineering Drawing by KRG & N D Bhatt. Engineering drawing with problems & solutions by K R Hart, Engineering drawing

for mechanical trades by K L Narayana, P Kannaiah, K Venkata Reddy. Fundamentals of Engineering drawing by Warren J Luzadder, Jon M Duff


ENGINEERING METROLOGY



Learning goals for Engineering Metrology

Explain the various standards of measurement

Define different types of tolerances

Explain & use tolerances disposition chart

Define various types of gauges & state the applications

Define comparators & explain the working principles

Explain the different options for angle measurement

Define surface roughness & explain inspection methods

Explain the function & application measuring machines

Explain the basics of statistical quality control




1. STANDARDS OF MEASUREMENT

1.1 Definition of Metrology

1.2 Objectives of Metrology

1.3 Definition of a standard

1.4 Need for standards

1.5 Imperial standard Yard

1.6 Airy points

1.7 International Prototype Meter

1.8 Types of Standards-Line, End and Wavelength standards

1.9 Subdivision of standards

1.10 Standardization and standardizing organizations

2. LIMITS,FITS AND TOLERANCES

2.1 Concept of tolerances 2.2 Need for tolerances 2.3 Types of tolerances- Unilateral and Bilateral 2.4 Analysis of tolerances- Addition & Subtraction of tolerances 2.5 Accuracy & Precision 2.6 Interchangeability & Selective assembly 2.7 ISO representation of holes & shafts & basic terminology 2.8 Classes & grades of tolerances 2.9 Fits and types of fits 2.10 Hole basis and Shaft basis system 2.11 Gauges- plug & snap/ring gauges, Go & NOGO gauges 2.12 Maximum & Minimum metal condition 2.13 Taylors principle, Wear allowance and limitation of gauges

Design problems 2.14 Brief description of form & positional tolerances

3. COMPARATORS

3.1 Definition

3.2 Difference between comparators & measuring instruments

3.3 Mechanical comparators – Dial indicators & its advantages & disadvantages

3.4 General working principle of pneumatic comparators, advantages &

disadvantages

3.5 Optical ,Electrical & Electronic comparators



4. ANGULAR MEASUREMENTS

4.1 Concept of Sine bars 4.2 Applications & limitations of sine bars 4.3 Sine table 4.4 Sine centre 4.5 Angle gauges 4.6 Problems on sine bar & Angle gauges

5. SURFACE ROUGHNESS

5.1 Surface irregularities 5.2 Profile geometry 5.3 Terminology of a surface – Real surface, nominal surface, roughness, waviness, sampling length, lay, central line of profile, Ra value, RMS value 5.4 Indication of surface roughness 5.5 Measurement of surface finish by Tomlinson surface tester

5.6 Indirect inspection methods – Touch inspection, Visual inspection, Scratch inspection, Surface photographs, Microscopic inspection

6. MEASURING MACHINES

6.1 Working principle of

6.2 Tool makers Microscope

6.3 Coordinate Measuring machines(CMM)

REFERENCE BOOKS:

1. Engineering Metrology – R.K.Jain

2. A text book of Metrology – M.Mahajan

3. Engineering metrology –K.J. Hume

4. Engineering Metrology & Instrumentation –R.K.Rajput

5. Metrology & Quality control – P.G.Deshpande

6. Mechanical measurements – BeckwithMarangoni & Lienhard,Pearson

Education,6th

Ed,2006

7. Engineering Metrology – I.C. Gupta, Dhanpat Rai Publications,Delhi

8. Measurements Systems Application & Design – Ernest O, Doblin, Mc Graw

hill book Co.


WEKLY PLAN FOR


Week

No Chapter Topics to be covered

1-4 STANDARDS OF

MEASUREMENT

Definition of Metrology

Objectives of Metrology

Definition of a standard

Need for standards

Imperial standard Yard

Airy points

International Prototype Meter

Types of Standards-Line, End and Wavelength

standards

Subdivision of standards

Standardization and standardizing organizations

5-10

LIMITS,FITS AND

TOLERANCES

Concept of tolerances

Need for tolerances

Types of tolerances- Unilateral and Bilateral

Analysis of tolerances- Addition & Subtraction of

tolerances

Accuracy & Precision

Interchange ability & Selective assembly

ISO representation of holes & shafts & basic

terminology

Classes & grades of tolerances

Fits and types of fits

Hole basis and Shaft basis system


WEKLY PLAN FOR

ENGINEERING METROLOGY Week

No Chapter Topics to be covered

11-14 COMPARATORS

Definition

Difference between comparators & measuring

instruments

Mechanical comparators – Dial indicators & its

advantages & disadvantages

General working principle of pneumatic

comparators, advantages & disadvantages

Optical ,Electrical & Electronic comparators

15-17 ANGULAR MEASUREMENTS

Concept of Sine bars

Applications & limitations of sine bars

Sine table

Sine centre

Angle gauges

Problems on sine bar & Angle gauges

18-19 SURFACE ROUGHNESS

Surface irregularities

Profile geometry

Terminology of a surface – Real surface ,nominal

surface, roughness, waviness, sampling length,

lay, central line of profile, Ra value, RMS value

Indication of surface roughness

Measurement of surface finish by Tomlinson

surface tester

Indirect inspection methods – Touch inspection,

Visual inspection, Scratch inspection, Surface

photographs, Microscopic inspection

20 MEASURING MACHINES Tool makers Microscope

Coordinate Measuring machines(CMM)


PRESS TOOL THEORY – I



Learning goals Press Tool Theory- I:

At the end of the subject, the trainee will be able to know:

Explain the different types of press tool operations

Explain shearing theory and action

Describe and calculate cutting clearance between punch and die

Calculate cutting and stripping force and methods to reduce them

Explain the principles of fine blanking

Design and draw an optimum strip lay out for the given component drawing

Explain the materials, calculations and specifications of various elements of a press

tool and their functions

Explain the mounting methods of punches

Describe different types of strippers, stoppers and pilots

Calculate centre of pressure

Explain progressive, compound, fine blanking, combination, shaving, lancing and

trimming tools and their applications





1. INTROCUTION TO TOOLING.

- Introduction

- Purpose, applications and advantages

- Types

2. TYPES OF PRESS TOOLS.

- Basic description of different types of press tools, their applications

3. ELEMENTS OF A PRESS TOOL.

- Different parts of a press tool

- Materials, functions and their importance

4. THEORY OF SHEARING.

- Shearing action on metal

- Plastic deformation

- Penetration

- Fracture

5. CUTTING CLEARANCE.

- Necessity of clearance

- Calculation of clearance

- Effects of insufficient, sufficient and optimum clearance

- Misalignment between punch and die

- Land and angular clearance

- Problems

6. CUTTING FORCE.

- Calculation of cutting force

- Methods of reducing the cutting force

7. STRIP LAYOUT.

- Unit stock and stock strip

- Types of strip layout

- Economic strip layout

- Problems



8. PUNCH AND DIE.

- Introduction

- Basic requirement of a die

- Types of dies - solid and split type

- Types of punches

- Classification of punches

- Mounting of punches

- Materials for punches and dies

- Heat treatment methods

- Methods of manufacture of punch and die

9. STRIPPER.

- Functions

- Types and applications

10. STOPPER.

- Functions


11. PILOT.

- Functions


12. CENTRE OF PRESSURE.

- Meaning

- Importance in design

- Calculation of COP by analytical and graphical methods

13. DIE SETS.

- Elements of a die set

- Types of die sets

- Accuracy and manufacture

- Applications of different types



14. PROGRESSIVE DIES.

- Introduction

- Pitch and pitch punch

- Advantages and disadvantages

- Classification

- Design considerations

15. COMPOUND DIES.

- Introduction

- Applications

- Construction

- Comparison with a progressive die

REFERANCE BOOKS:

1. Tool and die maker by Mahajan

2. Design fundamentals by Pacquin

3. Tool design by Donaldson

4. Basic die design by Osterguard

5. Advanced die design by Osterguard

6. Fundamentals of Tool Design By SME

7. Press Tools and Press Work By Waller


WEEKLY PLAN FOR PRESS TOOL THEORY – I

Week

No

Chapter Topics to be covered Remarks

1

INT

RO

DU

CT

ION

Introduction

Purpose of Tooling

Application of Tooling

Advantages of Tooling

Types of tooling (press tools, moulds,

die casting dies, jigs and fixtures)

Explanation and

demonstrate

different tools

2

Types

of

Pre

ss T

ools

Basic description of different types of a

press tool – blanking tool, piercing tool

and progressive tool

Compound Tool

Combination tool Brief explanation

and demonstrate the

products from each

tool

3

Coining tool

Bending tool

Embossing tool

Drawing tool

Flaring tool

Curling tool

Bulging tool

Swaging tool

4

Ele

men

ts o

f a

pre

ss t

ool

Different parts of a press tool and their

functions and importance

Top plate

Bottom plate Guide plate

Punch holder

Explain the

function, material,

requirements and

importance of each

element in detail.

Demonstrate all the

elements 5

Punch back plate

Stripper

Die plate

Pillars and bushes

Shank



Week

No


6

Shea

ring t

heo

ry

Principle of shearing action between punch

and die

3 stages of shearing

Edge radius

Cut band

Fracture

Blank

Burrs

Explain with the

help of pressed

components

7

Cutt

ing c

lear

ance

Importance of cutting clearance between

punch and die

Effect of insufficient and excessive

clearance

Optimum clearance

Misalignment between punch and die

Explain with the

help of components

with insufficient,

excessive and

optimum clearance.

8

Calculation of cutting clearance

Factors on which the cutting clearance

depends

Relation between piece part and punch size

Problems

Both the

mathematical

formula and thumb

rule to be

explained.

9 Land and angular clearance

Purpose Explain in detail

10 Determination of the sizes of punch and die

by applying clearances on punch and die

properly

Solve problems

11

Cutt

ing f

orc

e

Calculation of cutting force

Problems

Methods of reducing the cutting force

Selection of press

and its relation

with cutting force



Week

No


12

Str

ip l

ayout

Unit stock and stock strip

Direction of material grain

Strip layout and its types

Problems for

determining the

economic strip

layout

Economic utilization of strip

Strip width and its importance

Blank positioning

13

Punch

and D

ie

Types of dies

Basic design requirement of a die

Solid dies

Split dies

Factors influencing the selection of die sets

14

Introduction

Cutting, non-cutting and hybrid punches

Segregated and integrated punches

Types of punches – Plain, pedestal, bossed

and flanged Mounting of punches peening,

by screws, cross pins, araldite

15

Advantages and disadvantages of each

Materials for punches

Materials for dies

Effects of important alloys

Heat treatment methods



Week

No


16

Manufacture of punch and die – Filing,

Conventional machining, CNC machining,

EDM and WEDM.

Application of

each method to

be explained

Str

ipper

Function

Types

Solid stripper

Floating stripper

Rubber stripper

17

S

topper

Function

Stop position and registry position

Position types

Primary and secondary stoppers Finger stop

End stopper

Button stopper

Nest gauges and its types

Auto stopper (trigger)

18

Pil

ots

Function

Types and construction

Direct and indirect pilots

Bullet nose pilot

Flat arrows

Spring loaded pilots



Week

No


19

Cen

tre

of

pre

ssure

Shank positioning and its importance

Meaning of COP

Calculation of COP – approximate moments

method, centre of gravity method and

graphical method

Problems on calculating COP

Die

set

s

Introduction

Day light and shut height

Elements of a die set

Die set standards

Die set material

Explanation and

demonstrate Die

sets

Types of die set

Applications of different types of die sets

Accuracy of die sets and factors affecting the

accuracy

Manufacture of die sets

21

Pro

gre

ssiv

e to

ols

Introduction

Selection criteria

Construction and applications

Pitch and pitch punch

Advantages and disadvantages of progressive

dies

Explanation and

demonstrate tools

Classification of a progressive die -

Progressive blank die, progressive cut off and

form die, progressive draw die, progressive

cut and carry die

Design considerations in a progressive die

Explanation and

demonstrate tools


WEEKLY PLAN FOR PRESS TOOL

THEORY – I

22

Com

pound T

ools

Definition

Selection criteria

Application

Construction Difference between progressive

and compound die

Advantages and disadvantages


JIGS & FIXTURES (THEORY)


Learning goals Jigs & Fixtures

Students demonstrate their knowledge in various Jigs and Fixtures,

its design, clamping methods and design and drawing of jigs and

fixtures.

Subject aims at making the students learn jigs and fixtures, Locating

methods, clamping methods and guiding elements etc.





1. INTRODUCTION

- Definition of jigs and fixtures and their importance in industry

- Interchangeability

- Difference between jigs and fixtures

- Design considerations for jigs and fixtures

- Elements of jigs & fixture

- Materials

- Advantages and disadvantages

- Applications

2. LOCATION

- Definition and choice of location

- Degrees of freedom, 3-2-1 principle

- Types of locators

Locating methods and chip removal

Locating by Flat surface , support pads & pins

Conical locators (Fixed & Adjustable)

Diamond locators

V Locators ( Fixed& Adjustable )

- Redundant location

Errors caused in locating

- Fool proofing

3. CLAMPING

- Definition and need

- Requirements of a good clamping system

- Types of clamping

Plate or strap clamp, Solid clamp with heel pin,

Sliding clamps, slotted clamp, pivoted clamps, latch

clamps, swing clamps, Quick action clamps, multiple

clamps & Power clamps.


4. GUIDING ELEMENTS

- Introduction

- Classification of drill bushes

- Types of bushes

Fixed bush, Liner bush, Slip bush, Threaded bush

- Special bushes

Headed & Headless bushes, shaped bush, extended

bushes.

- Materials and hardness requirements

5. TYPES OF JIGS

- Introduction

- Constructional features

- Elements of a jigs

- Types of jigs

Solid jig

Post jig

Pot jig

Turn over jig

Latch jig

Box jig

- Indexing Device – Liner & Rotary indexing


- Jigs design for some simple components

6. TYPES OF FIXTURES

- Introduction


- Elements of a fixtures

- Setting blocks and tenons

- Types of fixtures

Milling fixtures – Indexing fixtures

Turning fixtures

* Grinding fixtures


- Fixture design for some simple components

REFERENCE BOOKS:

1. Jigs & Fixtures by P.H. Joshi

2. An introduction to jig & Tool Design by M.H.A. Kempster.


WEKLY PLAN FOR


Week No

Chapter Topics to be covered

1-4

INTRODUCTION


- Interchangeability

- Difference between jigs and

fixtures

- Elements of jigs & fixture

- Materials

- Advantages and

disadvantages

- Applications

5-9 LOCATION


- Degrees of freedom, 3-2-1

principle

- Types of locators

- Locating by Flat surface ,

support pads & pins

- Conical locators (Fixed &

Adjustable)

- Diamond locators

- V Locators ( Fixed&

Adjustable )

- Redundant location

- Errors caused in locating

- Fool proofing


Week No


10-12 CLAMPING


- Requirements of a good

clamping system

- Types of clamping

13

Plate or strap clamp, Solid clamp with heel

pin, Sliding clamps, slotted clamp, pivoted

clamps, latch clamps, swing clamps, Quick

action clamps, Multiple clamps & Power

clamps.

14-16 DRILL BUSHES

- Introduction

- Classification of drill bushes

- Types of bushes

- Fixed bush, Liner bush, Slip

bush, Threaded bush

- Special bushes

- Headed & Headless bushes,

Shaped bush, Extended

bushes.

17

JIGS

- Introduction


- Elements of a jigs

- Types of jigs

- Solid jig

- Post jig

- Pot jig

- Turn over jig

-


- Latch jig

- Box jig

- Indexing Device – Liner &

Rotary indexing


18 - Jigs design for some simple

components

19-20 FIXTURES

- Introduction


- Elements of a fixtures

- Setting blocks and tenons

- Types of fixtures

- Milling fixtures – Indexing

fixtures

- Turning fixtures

- Grinding fixtures


- Fixture design for some

simple components

WEKLY PLAN FOR JIGS & FIXTURES (THEORY)

Week No


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