competency based curriculum advanced …atimumbai.gov.in/parent/pdfs/syllabus of...

Advanced Diploma

DRAFT

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

Advanced

Sector –Production & Manufacturing

Diploma (Vocational) in Manufacturing Technology

GOVERNMENT OF INDIA


DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

Advanced Diploma (Vocational)

Production & Manufacturing

Manufacturing Technology


(Vocational)

Production & Manufacturing

Advanced Diploma (Vocational) in Manufacturing Technology

Advanced Diploma (Vocational)

(Designed in 2017)

NSQF LEVEL – 6

Developed By

Ministry of Skill Development and Entrepreneurship Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City,

Kolkata – 700 091


The Directorate General of Training (DGT) sincerely acknowledges contributions of the

Industries, Trade Experts, Domain Experts, academia and all others who contributed in preparation &

vetting the curriculum. Special acknowledgement is expended by DGT to the following expert

members who had contributed immensely in this curriculum.

Date of Expert Committee Meeting: 25.04.2017 at ATI, Hyderabad.

Sl.

No.

Name & Designation

S/Shri

Organization Remarks

1. Dinesh Nijhawan

Director,

DGT, MSDE, New Delhi Chairman

2. T V L N Rao

Director i/c

ATI, Hyderabad Member

3. Mihir Pariyal, Joint Director DGT, MSDE, New Delhi Member &

Coordinator

4. S Suryanarayana, Joint Director ATI, Hyderabad Member

5. Dr. G Madhusudhan Reddy

Outstanding scientist, Sc. H

DMRL, DRDO, Hyderabad Member

6. Prof. A Krishnaiah,

Vice-principal

College of Engineering,

Osmania University

Member

7. M Ashok Kumar

Deputy general Manager

BHEL, Hyderabad Member

8. M Satyanarayana

Divisional Manager

HMT Ltd, Hyderabad Member

9. P S N Murthy, AGM (mfg) HMT Ltd, Hyderabad Member

10. G Durga Prasad, Manager Siemens India ltd, Hyderabad Member

11. A Naveen Kumar, Sr. Engineer Siemens India ltd, Hyderabad Member

12. P Rajeswara Reddy

G M, Production

Pennar Industries Ltd,

Hyderabad

Member

13. Srinivas V S W, DGM Pennar Industries Ltd,

Hyderabad

Member

14. O V S S G K Murthy

Sr. Manager

VEM Technologies pvt. Ltd,

Hyderabad

Member

15. K Chandra Sekhar Reddy

AGM

Vasantha tool Krafts Ltd.

Hyderabad

Member

16. M Dorayya Reddy, AGM Vasantha tool Krafts Ltd.,

Hyderabad

Member

17. M Srinivasa Rao

Deputy manager - MFG

Vasantha tool Krafts Ltd.

Hyderabad

Member

18. M Uday kumar

Sr. engineer

CITD, Hyderabad Member

ACKNOWLEDGMENT


19. S Subbanna, AGM J K Fennar, Hyderabad Member

20. Vidyanand, Deputy Director A T I, Hyderabad Member

21. Ch Subba Rao, Deputy Director A T I, Hyderabad Member

22. D Srinivasa Rao, Deputy Director A T I, Hyderabad Member

23. K Naga Srinivas, Deputy Director A T I, Hyderabad Member

24. G Venkatesh, Asst Director A T I, Hyderabad Member

25. K M A Siddiqui, Asst. Director A T I, Hyderabad Member

26. Sandeep Kosaraju, Young

Professional

MSDE Member


S No. Topics Page No.

1 Course Information 1-4

2 Training System 5-9

3 Job Role 10-13

4 General Information 14

5 NSQF Level Compliance 15

6. Learning/ Assessable Outcome 16-18

7. Learning Outcome with Assessment Criteria 19-39

8. Syllabus – Professional Skill, Professional Knowledge 40-76

9. Syllabus – Employability Skill 79-83

Annexure I - List of Trade Tools & Equipment 84-88

Annexure II - Format for Internal Assessment 89

CONTENTS

1


Machining of metals is a process that most of the manufacturing industries depend upon and Capital

Goods industries such as automobile, aerospace, defence production and infrastructure industries

need the requirement of machining technician and the related technology in their manufacturing. The

Capital Goods Industries are having steady market growth as the process of manufacturing is inevitable

in the world. When we consider the old technology of machining, it has many disadvantages and it is

due to the lack in consistency and repeatability of quality output. Later, the technology developed and

many new computer aided manufacturing processes and non–conventional machining methods have

been introduced.

The syllabus matches the changing trends in new technologies adapted by manufacturing Industries.

Creates Quality manpower by blending training with Industry production environment as On-Job

training of 800 hrs contributing to 25% of total diploma course, thereby, Bridging the gap between

Industry & Institution and ensuring career growth for ITI certificate holders working in the Industry.

This course is totally Skill Oriented [70 % practical and 30 % Theory] and the programme is offered for

aspirants who have completed ITI in Mechanical Trades (Fitter, Turner and Machinist).

In this Diploma in Manufacturing Technology, the trainee is trained on Five Core modules each

of 320 hours duration in first year. Each Core module contains professional skill & professional

knowledge. In addition to this, the trainee is entrusted with the project work and extracurricular

activities to build up confidence. In second year there are elective modules, from where the trainee

has to select any of two elective modules, each module containing 320 hours duration with total

duration of 640 hours. The trainee will be trained in Industry for 800 hours (as a part of On-Job

training). There will be a common subject for all Diploma courses on Employability Skills which will be

for 160 hours in second year. The module-wise course coverage is categorized as below:-

1. COURSE INFORMATION

2


Core Module 1 WORKSHOP TECHNOLOGY

This subject deals with Engineering materials – ferrous and non-ferrous, mechanical properties and

their applications. Cutting tools – Types, Mechanics of cutting and chip formation, materials and

nomenclature. Lathe machine – function, types, parts, accessories and attachments, tools and

operations. Drilling machines – types, work holding and tool holding devices, tools and operations.

Boring machines – types, mechanism, tool mounting, tools and operations. Milling machine – types,

principal parts, mechanism, cutters, operations and gear cutting processes. Gear Hobbing machine,

Broaching machine- principal parts, mechanism and operations. Grinding machines – constructional

features, types, grinding wheel structure and operations. Cutting speed, feed, depth cut and machining

time calculations. Principles of Jigs & Fixtures and their application.

Core Module 2 METROLOGY AND QUALITY ENGINEERING

The Subject deals with Concept of metrology, units of measurements, need of inspection,

selection of measuring instruments, system of limits and fits, linear measurements, angular

measurements, Gauges, Optical measuring instruments, Surface measurements, Comparators, Screw

thread measurements, Machine tool alignment, Gear measurement, CNC-CMM, Measurements using

measuring machines, Calibration, Statistical Quality Control, SPC, TQM, TPM, JIT, ISO, 5S, Kaizen,

Kanban, Lean manufacturing and six sigma.

Core Module 3 CNC TECHNOLOGY

This Subject deals with computer numerical control machining. Various machine elements of

CNC turning machine & CNC Milling machines/Machining centres and their constructional features.

Differentiate between conventional and CNC machines. Illustrate the working principle and operation

of CNC machine. Structure of CNC part programme and preparation of part programme for various

machining operations such as milling, drilling and turning and their simulation with software. Usage of

different programming cycles. CNC Grinding machine construction and its elements, CNC Part

programming on Grinding machine. Coordinate Systems used in CNC Grinding. Execute part

programme on CNC machines (Machining centre’s and Turning centre’s, Grinding machines etc.).

Preventive and periodical maintenance of CNC machines and Safety measures to be followed.

3


Core Module 4: CAD/CAM

This Subject deals with Basics of Engineering Drawing, Orthographic projections, Isometric Projections.

Introduction to AutoCAD, Co-ordinate system, 2D Drafting, 3D Modeling., Design need and

requirements, Importance of Parametric constraints, Types of CAD software and their features,

Necessity of CAD-CAM integration. Creating and Editing features, Sheet metal components, Surface

modeling, Designing. Developing parametric modeling , Behavioral modeling, Mechanism simulation.

Core Module 5: ADVANCED MANUFACTURING PROCESSES

The Subject deals with Advanced Manufacturing process viz. computer numerical control 5 axis

machining, EDM. Various machine elements of CNC 5 Axis machining, CNC EDM Wire cut machining

and CNC EDM Die sinker machining. Constructional features of these machines and differentiate

between conventional and CNC machines. Illustrate the working principle and operation of these CNC

machine. Structure of CNC part programme and preparation of part programme for various machining

operations. Usage of different programming cycles. Coordinate Systems used in CNC 5 axis machine.

Execute part programme on CNC machines (Machining centre’s and EDM’s etc.). Preventive and

periodical maintenance of CNC machines and Safety measures to be followed.

Elective Module 1: CONTROL SYSTEMS AND AUTOMATION

The Subject deals with control systems using hydraulics, pneumatics and mechatronics. This subject

covers following topics: Various components of pneumatic and hydraulic systems, ISO symbols of

hydraulic and pneumatic components, interpretation of hydraulic and pneumatic circuit drawings for

various industrial applications, properties of fluids, grades of hydraulic oils, oil viscosity, operation and

control of hydraulic systems, components used in hydraulics, hydraulics for machine tools, hydraulic

pumps, motors and actuators, hydraulic valves and hydraulic system accessories, construction of

hydraulic circuits. Working principle and operation of compressors, pneumatic system components like

FRL unit, actuators, control valves like directional control valve, PCV, Time Delay, Quick exhaust, Twin

Pressure, shuttle valves. Construction of pneumatic circuits for various industrial applications.

4


Applications of Mechatronics. Electronics for Mechanical Engineers, mechatronics for automation,

industrial automation using hydraulic, pneumatic controls and mechatronics.

Elective Module 7: WELDING PROCESSES AND POWER SOURSES

On completion of this module, trainees should be able to work efficiently and perform different

welding methods such as Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW). Gas

Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW) etc. During this course students will be

taught on working principles, equipment, welding techniques, defects of various welding processes.

Also knowledge about the welding power sources, construction features and maintenance aspects will

be taught to the participants.

On the Job Training: In this module the trainees will be working/training in the Industry for 800 hours.

They work as apprentices/Personnel.

Employability Skills: This module is common for all Diploma courses and the total period is 160 hours.

In this module the trainees will improve

• English literacy such as Pronunciation, functional grammar, reading, writing, speaking and

spoken English

• Learn communication skills, listening skills, motivational training, Facing interviews and

behavioural skills.

• Understand concepts of Entrepreneurship, Project preparation and marketing analysis,

Institutions support and Investment Procurement.

• Understand on productivity, its benefits, affecting factors, comparison with developed

countries, personal finance management.

• Understand Safety, Health and Environment Education - Safety & Health, Occupational Hazards,

Accident & safety, First Aid, Basic Provisions, Ecosystem, Pollution, Energy Conservation, Global

warming, Ground Water, Environment.

• Understand benefits guaranteed under various acts- Factories Act, Apprenticeship Act,

Employees State Insurance Act (ESI), Payment of Wages Act, Employees Provident Fund Act,

The Workmen's compensation Act.

5


• Understand Quality Tools: Quality Consciousness, Quality Circles, Quality Management System

and Housekeeping.

6


2.1 GENERAL

Directorate General of Training (DGT) under Ministry of Skill Development & Entrepreneurship offers a

range of Vocational Training courses catering to the need of different sectors of economy/ Labour

market. The Vocational Training Programmes are delivered under aegis of National Council of

Vocational Training (NCVT). Craftsman Training Scheme (CTS) and Apprenticeship Training Scheme

(ATS) are two pioneer programmes of NCVT for propagating vocational training. Recently DGT has

started Technical Diplomas for different streams and primarily implemented at DGT field institutes

such as NSTIs, FTIs and AHI and planned to expand to State Directorates in future.

Manufacturing Technology course is very much essential in the current scenario due to a lot of demand

in manufacturing industries due to the rise of Make in India campaign by Government of India and the

aim to increase the share of manufacturing sector in gross domestic product (GDP) upto 25

per cent from 16 per cent by 2022, and to create 100 million new jobs by 2022. The course is for two

years duration. In the first year there are five core modules each module is credit base and

employable. Each module is of 320 hours and is very much independent. In second year the trainee will

be taking two elective modules out of three electives each of 320 hours and will be doing On-Job

training in Industry for 800 hours. In addition the trainees will undergo employability skills for 160

hours. After passing out the training programme, the trainee will be awarded Technical Diploma by

NCVT which has worldwide recognition.

Candidates need broadly to demonstrate that they are able to:

• Read and interpret technical parameters/ documents, plan and organize work processes,

identify necessary materials and tools;

• Perform task with due consideration to safety rules, accident prevention regulations and

environmental protection stipulations;

• Apply professional skill, knowledge & employability skills while performing jobs.

• Document the technical parameters related to the task undertaken.

2. TRAINING SYSTEM

7


2.2 CAREER PROGRESSION PATHWAYS

• Can pursue higher technical education like BE/B. Tech.

• Can start own manufacturing units.

• Can apply for jobs in Industry as Shop Floor Supervisor.

2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements during a period of

two years: -

S No. Module Course Element Notional Training

Hours

1

For five Core Modules

Professional Skill (Trade Practical) 1000

Professional Knowledge (Trade

Theory) 600

2 For two Elective Module

Professional Skill (Trade Practical)

400

Professional Knowledge (Trade

Theory) 240

3 Employability Skills 160

4 On the job training

800

Total 3200

5

Project Work for each Module (40 Hours x 7 Modules)

Note : For Elective modules in second year work included in the

Instructional hours.

280

6 Revision (80 Hours x 7 Modules) 560

7 Theory & Practical Examination of 7 Modules + Employability

Skills + On -Job Training 120

Grand Total 4160

8


2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of this course in each

module and at the end of the training programme as notified by Govt of India from time to time.

a) The Internal assessment during the period of training will be done by Formative assessment

method by testing for assessment criteria listed against learning outcomes. The training

institute have to maintain individual trainee portfolio as detailed in assessment guideline. The

marks of internal assessment will be as per the template (Annexure – I).

b) The final assessment will be in the form of summative assessment method. The All India Trade

Test for awarding Technical Diploma will be conducted by NCVT as per guideline of Govt of

India. The pattern and marking structure is being notified by Govt of India from time to time.

The learning outcome and assessment criteria will be basis for setting question papers for

final assessment. The examiner during final examination will also check individual trainee’s

profile as detailed in assessment guideline before giving marks for practical examination.

2.4.1 PASS REGULATION

The minimum pass percent for Practical is 60% & minimum pass percent for Theory subjects 40%.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial barriers to

assessment. The nature of special needs should be taken into account while undertaking assessment.

Due consideration should be given while assessing for team work, avoidance/reduction of

scrap/wastage and disposal of scarp/wastage as per procedure, behavioral attitude, sensitivity to

environment and regularity in training. The sensitivity towards OSHE and self-learning attitude are to

be considered while assessing competency.

9


Assessment will be evidence based comprising the following:

• Job carried out in labs/workshop

• Record book/ daily diary

• Answer sheet of assessment

• Viva-voce

• Progress chart

• Attendance and punctuality

• Assignment

• Project work

Evidences of internal assessments are to be preserved until forthcoming semester examination for

audit and verification by examination body. The following marking pattern to be adopted while

assessing:

Performance Level Evidence

(a) Weightage in the range of 60 -75% to be allotted during assessment

For performance in this grade, the candidate

with occasional guidance and showing due

regard for safety procedures and practices, has

produced work which demonstrates

attainment of an acceptable standard of

craftsmanship.

• Demonstration of good skill in the use of

hand tools, machine tools and workshop

equipment.

• 60-70% tolerance dimension achieved

while undertaking different work with

those demanded by the component/job.

• A fairly good level of neatness and

consistency in the finish.

• Occasional support in completing the

project/job.

(b) Weightage in the range of above 75% - 90% to be allotted during assessment

For this grade, the candidate, with little

guidance and showing due regard for safety

procedures and practices, has produced work

which demonstrates attainment of a

reasonable standard of craftsmanship.

• Good skill levels in the use of hand tools,

machine tools and workshop equipment.




• A good level of neatness and consistency

in the finish.

• Little support in completing the

project/job.

10


(c) Weightage in the range of above 90% to be allotted during assessment

For performance in this grade, the candidate,

with minimal or no support in organization and

execution and with due regard for safety

procedures and practices, has produced work

which demonstrates attainment of a high

standard of craftsmanship.

• High skill levels in the use of hand tools,

machine tools and workshop equipment.




• A high level of neatness and consistency

in the finish.

• Minimal or no support in completing the

project.

11


Brief description of the Job Role:

Shop Floor Supervisor: Shop Floor Supervisor supervises machining operations in workshop on

different conventional, non-conventional, CNC machine tools and ensures machining of components

as per drawing. Studies component drawings in detail, decides Process planning, selects proper

cutting tools, jigs and fixtures, if required.

Set the machine and cutting tools for machining the component. Machines the component on

different conventional, non-conventional, CNC machine tools and check for the quality requirement as

mentioned in the drawing. Maintains log book of the machine and communicates with shop floor in

charge.

Operate and control of Pneumatic and Hydraulic equipment (air compressor, power pack). Maintain

Pneumatic and hydraulic pressure for various applications as per requirement of CNC and other

machines.

Safety precautions to be taken while working on the machine tools. Quality checks to be followed

while machining and at the end of the component machining. Ensures routine maintenance of

machines and maintains schedules of production and discipline in section. Maintains production and

material records and registers.

Prepares CAD drawings for individual parts, assemblies, parts list etc. Integrates CAD data to required

CNC machines through CAM software like MasterCAM, DelCAM, Creo etc., and generates tool path,

selects suitable cutting tools. Simulates required machining operations as per process plan and

generates NC code. Transfer of NC code to required machine tool, finishes machining as per

component drawing.

Carry out the Fabrication of parts as per drawing by using various welding processes such as Shielded

Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW) and Gas

Tungsten Arc Welding (GTAW).

3. JOB ROLE

12


Reference NCO 2015:

i) 3122.1900 - Supervisor and Foreman, Machine tool operations

ii) 7223.0501-Machine Shop Master Technician/Setter

iii) 7223.0502-Machine Shop Supervisor

iv) 7223.0601-Turner/Conventional Turning

v) 7223.1201-Miller/Operator-conventional Milling

vi) 7223.5002 –CNC Operator - Machining Technician

vii) 7223.5003 –CNC Operator – Machinist

viii) 7223.5004 –CNC Operator – Vertical Machining centre

ix) 7223.5005 –CNC setter cum operator – Vertical Machining centre

x) 7223.6001 –CNC Setter cum Operator – Turning

xi) 7223.6002 –CNC Operator – Turning

xii) 7223.6003 –CNC Programmer

xiii) 7233.0100 –Fitter, General

xvi) 7233.0101 –Machinist

xv) 7212.0200-Welder, Electric

xvi) 7212.0105-Tungsten Inert Gas Welder

xvii) 7212.0303 -Gas Metal Arc Welder (MIG/MAG/GMAW)

13


Name of the Course Diploma in Manufacturing Technology

NCO – 2015

3122.1900 - Supervisor and Foreman, Machine tool operations

7223.0501 - Machine Shop Master Technician/Setter

7223.0502 - Machine Shop Supervisor

7223.0601 - Turner/Conventional Turning

7223.1201 - Miller/Operator-conventional Milling

7223.5002 – CNC Operator - Machining Technician

7223.5003 – CNC Operator – Machinist

7223.5004 – CNC Operator – Vertical Machining centre

7223.5005 – CNC setter cum operator – Vertical Machining centre

7223.6001 – CNC Setter cum Operator – Turning

7223.6002 – CNC Operator – Turning

7223.6003 – CNC Programmer

7233.0100 – Fitter, General

7233.0101 – Machinist

7212.0200 - Welder, Electric

7212.0105 - Tungsten Inert Gas Welder

7212.0303 - Gas Metal Arc Welder (MIG/MAG/GMAW)

NSQF Level Level 6

Duration of Training

2 Years (5 Core Modules of 320 hours each, Two Elective Modules of 320

hours each, On-the-job training of 800 hours and Employability Skills of

160 hours).

Entry Qualification

10th

passed alongwith national trade certificate (NTC)/ national

apprenticeship certificate (NAC) passed out in any of these trades

machinist, machinist grinder, operator advanced machine tools, tool & die

maker, turner, mechanic machine tool maintenance and fitter.

Unit Strength (No. Of

Student) 20

Space Norms

Power Norms

Instructors Qualification for

Manufacturing

Technology

Degree in Mechanical / Production Engineering/ Mechatronics with two

year post qualification industrial experience in Machining.

OR

Diploma in Mechanical/ Production/ Mechatronics with three years post

qualification industrial experience in Machining.

OR

4. GENERAL INFORMATION

14


10th class pass + NTC/NAC in any of these trades “Machinist, Machinist

Grinder, Operator Advanced Machine Tools, Tool & Die Maker and

Turner” with four years’ post qualification experience in machining.

Employability Skill MBA with one year post qualification experience in relevant field

OR

BBA with three years’ post qualification experience in relevant field

OR

Graduate in Sociology/ Social Welfare/ Economics with three years’ post

qualification experience in relevant field.

15


NSQF level for Diploma in Manufacturing Technology: Level 6

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill Qualification

Framework total 10 (Ten) Levels are defined.

Each level of the NSQF is associated with a set of descriptors made up of five outcome

statements, which describe in general terms, the minimum knowledge, skills and attributes that a

learner needs to acquire in order to be certified for that level.

Each level of the NSQF is described by a statement of learning outcomes in five domains,

known as level descriptors. These five domains are:

a. Process

b. Professional Knowledge

c. Professional Skill

d. Core Skill

e. Responsibility

The Broad Learning outcome of Diploma in Manufacturing Technology mostly matches with

the Level descriptor at Level- 6.

The NSQF level-6 descriptor is given below:

Level Process

Required

Professional

Knowledge

Professional

Skill

Core

Skill Responsibility

Level 6 Demands wide

range of

specialized

technical skill,

clarity of

knowledge and

practice in broad

range of activity

involving standard

non standard

practices.

Factual and

theoretical

knowledge in

broad contexts

within a field of

work or study.

A range of

cognitive and

practical skills

required to

generate

solutions to

specific problems

in a field of work

or study.

Reasonably good

in mathematical

calculation,

understanding of

social, political

and reasonably

good in data

collecting

organizing

information and

logical

communication.

Responsibility

for own work

and learning

and full

responsibility

for other`s

works and

learning.

5. NSQF LEVEL COMPLIANCE

16


Learning outcomes are a reflection of total competencies of a trainee and assessment will be carried

out as per the assessment criteria.

6.1 GENERIC LEARNING OUTCOME

1. Recognize & comply with safe working practices, environment regulation and housekeeping.

2. Explain the concept in productivity, quality tools and labour welfare legislation and apply such

in day-to-day work to improve productivity & quality.

3. Explain energy conservation, global warming, pollution and contribute in day-to-day work by

optimally using available resources.

4. Explain personnel finance, entrepreneurship and manage/ organize related task in day-to-day

work for personal & societal growth.

5. Plan and organize the work related to the occupation.

6. Problem solving skills and supervise team.

6.2 SPECIFIC LEARNING OUTCOME

CORE MODULE 1: WORKSHOP TECHNOLOGY

7. Produce components involving different operations on lathe observing standard procedure and

check for accuracy. [Different Operations – facing, plain turning, step turning, parting,

chamfering, shoulder turn, grooving, knurling, boring, taper turning, threading (external ‘V’

only)]. Carry out routine maintenance of lathe.

8. Produce components on Milling machines involving different operations such as Face milling,

End milling, Rack cutting, Gear cutting, Angle cutting etc.

9. Produce Gear components on a Gear Hobbing machine.

10. Produce components on a Drilling machine involving different hole machining operations such as

drilling, reaming, counter boring, counter sinking, tapping etc.

11. Produce the component on Grinding machines involving different operations such as cylindrical

grinding (OD&ID), shoulder grinding, surface grinding and perform cutting tool resharpening on

tool and cutter grinder.

6. LEARNING/ ASSESSABLE OUTCOME

17


Core Module 2 : Metrology and Quality Engineering – to be finalized by Shri S. Reddy

12. Recognize & comply safe in Metrology Lab, working practices of measuring instruments: Non-precision and Indirect measuring instruments.

13. Measure the linear and angular measurement of work pieces with different Vernier Calipers, Micrometers, Protractors, Clinometer, Sine bars/centres.

14. Measure thread & gear profiles, use of gauges and Alignment tests for Lathe and Milling machines.

15. Measure Geometrical measurements using different equipment.

16. Measure different jobs using optical measuring instruments and other measuring machines. 17. Calibrate different instruments and use of different comparators & related Management tools.

18. Measure the surface roughness using different instruments. 19. Test the Hardness of metal using various hardness testing machines.

20. Test the Compressive and Tensile strength using Universal Testing Machine. 21. Test the metal using Non-Destructing Testing machines.

CORE MODULE 3: CNC TECHNOLOGY

22. Plan and organize the work in predictable/routine environment for limited range of

machining operations on CNC Turning machine by applying appropriate cutting

parameters, measuring instruments and check for work result.


machining operations on CNC Milling machine/Machining centre by applying

appropriate cutting parameters, measuring instruments and check for work result.


machining operations on CNC Grinding machine by applying appropriate cutting

parameters, measuring instruments and check for work result.

CORE MODULE 4: CAD/ CAM to be finalized by Sri G. Venkat

25. Develop the Orthographic and Isometric drawings by using AutoCAD.

26. Draw given sketches in AUTOCAD and enhance the sketches with additional features in

AutoCAD.

27. Build new part model and generate surfaces with Creo.

28. Perform assembly modelling with sequencing and simulate part mechanism

dynamically.

18


29. Design and Develop independent functional and stable assembly models.

30. Convert the given sketch to part programme using Mastercam.

CORE MODULE 5: ADVANCED MANUFACTURING PROCESSES


machining operations on CNC 5 axis Vertical machining centre by applying appropriate

cutting parameters.

32. Produce components on CNC 5 axis machining centre.


machining operations on CNC EDM Wire cut machine by applying appropriate cutting

parameters.

34. Produce components on EDM Wire cut machine.

35. Plan, organize and produce the work in predictable/routine environment for limited

range of machining operations on CNC EDM Die Sinking machine by applying

appropriate cutting parameters, measuring instruments and check for work result.

36. Produce components on EDM Die Sinking machine.

ELECTIVE MODULE 1: CONTROL SYSTEMS & AUTOMATION to be finalised by Shri D S Rao

37. Perform operation and control of pneumatic equipment in the industry.

38. Operate and control of air compressors. 39. Regulate air pressure for pneumatic applications. 40. Construct Pneumatic circuits for various industrial applications. 41. Visualise how the Pneumatic Circuit will work to accomplish the given task.

42. Trouble shoot Pneumatics. 43. Construct electro –pneumatic Circuits for various industrial applications.

44. Visualise how the electro-pneumatic Circuit will work to accomplish the given application. 45. Trouble shoot electro-pneumatics. 46. Perform operation and control of hydraulic equipment.

47. Operate pressure relief valve (PRV) for regulation of hydraulic pressure. 48. Construct and maintain hydraulic circuits for a given application.

49. Visualise how the hydraulic Circuits will work to accomplish the given application. 50. Trouble shoot hydraulics.

51. Construct electro- hydraulic circuit for a given application. 52. Visualise how the electro-hydraulic circuit will work to accomplish the given application. 53. Trouble shoot electro-hydraulics.

54. Construct circuits using hydraulic, pneumatic and mechatronic components for various industrial applications.

19


ELECTIVE MODULE 2: WELDING PROCESSES AND POWER SOURCES

55. Demonstrate welding of Mild steel in 1G/1F, 2G/2F, 3G/3F and 4G/4F positions by

Shielded Metal Arc Welding process. (SMAW).

56. Plan and perform welding of Mild steel Plate and sheets by Gas Metal Arc Welding

process. (GMAW).

57. Demonstrate welding of Mild steel Plate by FCAW process. (FCAW).

58. Plan and perform welding on of Mild steel Stainless steel & Aluminium sheets & pipes by

Gas Tungsten Arc Welding.(GTAW).

20


GENERIC LEARNIG OUTCOME

Outcomes to be assessed/ NOSs

to be assessed Assessment criteria for the outcome

1. Recognize & comply with

safe working practices,

environment regulation and

housekeeping.

1.1 Follow and maintain procedures to achieve a safe working

environment in line with occupational health and safety

regulations and requirements.

1.2 Recognize and report all unsafe situations according to site

policy.

1.3 Identify and take necessary precautions on fire and safety

hazards and report according to site policy and procedures.

1.4 Identify, handle and store/ dispose of

dangerous/unsalvageable goods and substances according

to site policy and procedures following safety regulations

and requirements.

1.5 Identify and observe site policies and procedures in regard to

illness or accident.

1.6 Identify safety alarms accurately.

1.7 Report competent of authority in the event of accident or

sickness of any staff and record accident details correctly

according to accident/injury procedures.

1.8 Identify basic first aid and use them under different

circumstances.

1.9 Identify different fire extinguisher and use the same as per

requirement.

1.10 Identify environmental pollution & contribute to avoidance

of same.

1.11 Take opportunities to use energy and materials in an

environmentally friendly manner.

1.12 Avoid waste and dispose waste as per procedure.

1.13 Recognize different components of 5S and apply the same in

the working environment.

2. Explain the concept in

productivity, quality tools

and labour welfare

legislation and apply such in

day-to-day work to improve

productivity & quality.

2.1 Explain the concept of productivity and quality tools and

apply during execution of job.

2.2 Understand the basic concept of labour welfare legislation

and adhere to responsibilities and remain sensitive towards

such laws.

2.3 Knows benefits guaranteed under various acts.

7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

21


3. Explain energy conservation,

global warming, pollution

and contribute in day-to-day

work by optimally using

available resources.

3.1 Explain the concept of energy conservation, global warming,

pollution and utilize the available resources optimally &

remain sensitive to avoid environment pollution.

3.2 Dispose waste following standard procedure.

4. Explain personnel finance,

entrepreneurship and

manage/ organize related

task in day-to-day work for

personal & societal growth.

4.1 Explain personnel finance and entrepreneurship.

4.2 Explain role of various schemes and institutes for self-

employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for

financing/ non-financing support agencies to familiarize with

the policies/ programmes, procedure & the available

scheme.

4.3 Prepare Project report to become an entrepreneur for

submission to financial institutions.

5. Plan and organize the work

related to the occupation.

5.1 Communicate effectively with others and plan project tasks.

5.2 Assign roles and responsibilities of the co-trainees for

execution of the task effectively and monitor the same.

6. Problem solving skills and

supervise team.

6. 1. Ability to understand a problem by breaking it down into

smaller parts.

6. 2. Identify the key issues, implications and identifying solutions.

6. 3. Apply knowledge from many different areas to solving a task.

6. 4. Motivate and supervise team for achieving the required goal.

22


SPECIFIC LEARNING OUTCOME

CORE MODULE 1: WORKSHOP TECHNOLOGY

Sl. No. Learning Assessable Outcome Assessment Criteria

1. Produce components

involving different operations

on lathe observing standard

procedure and check for

accuracy. [Different

Operations – facing, plain

turning, step turning, parting,

chamfering, shoulder turn,

grooving, knurling, boring,

taper turning, threading

(external ‘V’ only)]. Carry out

routine maintenance of lathe.

1.1 Ascertain basic working principles and safety practices

on lathe machine.

1.2 Demonstrate types, functions and operations of lathe,

cutting tools, accessories and attachments.

1.3 Mount the work and tool holding devices with

required alignment and check for its functional usage

to perform lathe operations.

1.4 Demonstrate operations of facing, plain turning, step

turning, parting, chamfering, shoulder turn, grooving,

knurling, boring, taper turning, threading and profile

turning observing safety procedures.

1.5 Produce components by observing standard

operating procedure.

1.6 Check for accuracy/ correctness of job using

appropriate measuring equipment/gauges.

1.7 Maintain proper housekeeping and practice

environment friendly procedures.

2. Produce components on

Milling machines involving

different operations such as

Face milling, End milling, Rack

cutting, Gear cutting, Angle

cutting etc.

2. 1 Ascertain basic working principles and safety

practices on milling machine.

2. 2 Demonstrate functional application of different

levers, stoppers, adjustment etc.

2. 3 Demonstrate Milling, mounting and dismounting of

Milling cutters and attachments.

2. 4 Demonstrate Milling a right angled block with surface

finish.

2. 5 Illustrate slot and angular milling.

2. 6 Demonstrate Male and Female Dovetail cutting, T-

slot cutting, concave & convex milling, Cam milling,

Gear cutting and make a base of Machine vice.

2. 7 Maintain proper housekeeping and practice


3. Produce Gear components on

a Gear Hobbing machine.

3.1 Illustrate cutting of Spur gear, Helical gear and Bevel

gear.

3.2 Illustrate cutting of Worm wheel and shaft.

3.3 Check the dimensions of the produced components

to ensure dimensions as per the drawing.

23


4. Produce components on a

Drilling machine involving

different hole machining

operations such as drilling,

reaming, counter boring,

counter sinking, tapping etc.

4. 1. Ascertain and select tools and materials for the job

and ensure their availability for use in timely

manner.

4. 2. Plan work in compliance with standard safety norms.

4. 3. Demonstrate machining operations such as drilling,

reaming, counter boring, counter sinking, tapping

etc, by observing standard operating procedure.

4. 4. Check the dimensions of the produced components

to ensure dimensions are within the prescribed limits.

4. 5. Maintain proper housekeeping and practice


5. Produce the component on

Grinding machines involving

different operations such as

cylindrical grinding (OD&ID),

shoulder grinding, surface

grinding and perform cutting

tool resharpening on tool and

cutter grinder.

5.1 Ascertain and select tools and materials for the job

and ensure their availability for use in timely

manner.

5.2 Demonstrate balancing of the Grinding wheel.

5.3 Mount and align/truing Wheel on to the machine

and dress the Wheel by using dressers.

5.4 Demonstrate Surface grinding and slot grinding.

5.5 Illustrate Cylindrical grinding for Internal and

external grinding.

5.6 Demonstrate Tool and various types of Cutters in

cylindrical taper& eccentric grinding.

5.7 Check the dimensions of the produced

components to ensure dimensions are within the

prescribed limits.

5.8 Maintain proper housekeeping and practice


CORE MODULE 2: METROLOGY AND QUALITY CONTROL to be finalized by S Reddy

1. Measure the linear and

angular measurement of

workpieces with different

Vernier Calipers,

Micrometers, Protractors,

Clinometer, Sine bars/

centres.

1. 1 Identify non-precision measuring instruments viz.

Calipers, Dividers, Steel Rules, Different types of

tapes, Ordinary protractors.

1. 2 Identify indirect measuring instruments viz.

Telescopic gauges, Hole test gauges.

1. 3 Demonstrate Linear and Angular measurements

using vernier calipers, height gauges,

micrometers, protractors etc.

1. 4 Demonstrate miscellaneous measurements using

precision balls and rollers.

2. Measure jobs using thread &

gear measurements,

2. 1 Demonstrate thread, gear and machine tool

metrology by using Ring and Plug gauge, snap

24


Geometrical measurements,

optical measuring instruments

and Measuring machines.

gauges and Alignment test for Lathe machine &

Milling machine.

2. 2 Demonstrate Geometrical measurements using

Bore and limit gauges.

2. 3 Use measuring machines like Optical profile

projector,

optical dividing head, autocollimator etc.

2. 4 Demonstrate calibration using vernier callipers,

micrometers, dial test indicators and slip gauge

calibration.

2. 5 Operate mechanical comparators, electrical and

electronic comparators, Pneumatic and Optical

comparators.

3. Apply quality control

management tools like

statistical process control

with SPC software.

3. 1 Demonstrate Statistical Process Control with SPC

software.

3. 2 Illustrate quality charts.

3. 3 Solve Case studies of Management Techniques.

4.

Measure jobs using

Destructive and Non-

Destructing Testing.

4. 1 Perform Surface roughness inspection by Touch,

Visual Scratch, microscopic & surface photographs

and Surf test .

4. 2 Perform Hardness testing with Brinell, Rockwell

and

Vickers hardness tester.

4. 3 Perform Non-Destructive testing with Liquid

penetration Test, magnetic particle testing etc.

4. 4 Perform Tensile and Compressive strength testing

using UTM.

CORE MODULE 3: CNC Technology

1. Plan , organize and produce

the work in predictable/

routine environment for

limited range of machining

operations on CNC Turning

machine/Turn Mill Centre by

applying appropriate cutting

parameters, measuring

instruments and check for

work result.

1. 1 Demonstrate Safety measures for Personal and CNC

Turning machine.

1. 2 Demonstrate features of CNC Turning machine in

different modes of operation (JOG, MPG, Edit, MDI

and AUTO).

1. 3 Appraise Simulation software, File management,

menu management, Geometry creation, Setup, Tool

management, Work plan, part programme creation

and Simulation.

1. 4 Demonstrate Absolute and incremental

25


programming assignments and simulations.

1. 5 Demonstrate Jaw removal from chuck, Tool removal

from Turret, Tail stock Centre removal and mount

them on CNC Lathe as per requirement of work

piece.

1. 6 Demonstrate Work and tool setting, Work off set

measurement, Tool off set measurement and entry

into CNC Control.

1. 7 Demonstrate Soft jaw boring.

1. 8 Demonstrate Part program, Simulation, Program

checking in dry run, single block mode & Automatic

Mode execution for the exercise on Facing, Plain

turning and Step turning.

1. 9 Demonstrate linear interpolation, and Circular

interpolation assignments and simulations on soft

ware & Automatic Mode execution for the exercise

on Turning with Radius / chamfer with TNRC.

1. 10 Adopt Tool Wear Correction for desired

Geometrical requirements as per drawing and wear

offset correction.

1. 11 Illustrate dimensions of the finished components

with appropriate measuring instruments for the

components produced from Stock removal cycle on

OD, Drilling, Reaming and Tapping cycles etc.

2.

Plan, organize and produce

the work in predictable

/routine environment for


operations on CNC Milling

machine/Machining centre by

applying appropriate cutting



work result.

2. 1 Demonstrate Safety measures for Personal and

CNC Milling machine/ Machining centres.

2. 2 Demonstrate features of CNC Milling machine/

Machining centres, CNC console etc.

2. 3 Demonstrate Simulation software, File

management, menu management, Geometry

creation etc.

2. 4 Demonstrate system assignments and simulations,

perform Absolute and incremental programming

assignments and simulations.

2. 5 Demonstrate Vice alignment with the Table, Mount

the tools on ATC as per requirement of work piece.

2. 6 Demonstrate Work and tool setting, work off set

measurement, Tool off set measurement and entry

in CNC Control.

2. 7 Demonstrate Part program preparation,

Simulation, Program checking in dry run, single

block mode & Automatic Mode Execution for the

26


exercise on Simple edge milling& Facing.

2. 8 Demonstrate linear interpolation, and Circular

interpolation assignments and simulation on soft

ware.

2. 9 Demonstrate Program, Simulation & Automatic

Mode Execution for the exercise on Milling with

Radius / chamfer with CRC.

2. 10 Adopt Tool Wear Correction for desired

Geometrical requirements as per drawing and wear

offset correction.

2. 11 Demonstrate part program, Simulation &

Automatic Mode Execution of CNC Milling Machine

for the following exercises on Milling like End

milling with polar coordinates, contour milling

internal with CRC etc.

3. Plan, organize and produce

the work in predictable

/routine environment for


operations on CNC Grinding

machine by applying

appropriate cutting



work result.

3. 1 Demonstrate Safety measures for Personal and CNC

Grinding machine.

3. 2 Validate dimensions of several machined parts as

per drawing with suitable measuring instruments

such as vernier calipers, Micro meters, Depth

gauges for ascertaining grinding allowance.

3. 3 Demonstrate CNC Grinding machine, CNC console,

Machine starting & operating in Reference Point,

JOG, MPG, Incremental, MDI and AUTO Modes.

3. 4 Demonstrate balancing a grinding wheel, mounting

a grinding wheel, Truing of a grinding wheel.

3. 5 Demonstrate Part program & Automatic Mode

Execution of CNC Grinding Machine for Plunge and

traverse grinding a parallel diameter, Grinding of

slow and fast taper surfaces etc.

CORE MODULE 4 : CAD/ CAM to be finalized by G Venkat

1. Develop the Orthographic and Isometric drawings by using AutoCAD

1. 1 Demonstrate orthographic views of object containing

lines, circles and arc geometry.

1. 2 Interpret given orthographic views and show the

actual shape of the component.

1. 3 Demonstrate with AutoCAD for Constructing Isometric

drawing.

1. 4 Demonstrate isometric view from orthographic

views of object/s containing lines, circles and arcs.

1. 5 Demonstrate with AutoCAD, changing different

workspaces, open new drawing sheet and set limits,

use of templates and units.

27


1. 6 Illustrate attributes of Absolute, relative, Absolute

polar and relative polar co-ordinate system in Auto

CAD.

2. Draw given sketches in

AUTOCAD and enhance the

sketches with additional

features in AutoCAD

2. 1 Demonstrate draw bar, modify bar features by

using drawing.

2. 2 Demonstrate Mirroring and Arraying commands,

Modify commands, create parametric dimension

Delete & Add Dimension.

2. 3 Illustrate the features such as single & multiple

texts in a drawing, construct tables, changing the

properties of object and managing drafting aids.

2. 4 Demonstrate features such as make a block, write

it & then insert it in any file.

2. 5 Demonstrate Geometric constraints and

Dimensional constraints.

3. Build new part model and

generate surfaces with Creo

3. 1 Demonstrate Interface, Sketcher, constraining, and

modifying sketches in CREO.

3. 2 Demonstrate editing Geometry, base Feature,

datum and Secondary features in CREO.

3. 3 Demonstrate Part modelling, Surface modelling,

Assembly modelling with constraints, top-down

assemblies and Bottom-up assemblies in CREO.

3. 4 Demonstrate simulation of components on

assembly.

4.

Perform assembly modeling

with sequencing and simulate

part mechanism dynamically.

4.1 Demonstrate Assembly model with constraints.

4.2 Distinguish between top-down and Bottom-up

assemblies

4.3 Verify the modifications in components which are

done in assembly.

4.5 Demonstrate dynamics of parts by Simulation.

5. Convert the given sketch to part programme using Mastercam.

5.1 Demonstrate virtual machining in Milling by creating

NC code.

5.2 Demonstrate virtual machining in Turning by creating

NC code.

28


CORE MODULE 5 : ADVANCED MANUFACTURING PROCESSES

1. Plan and organize the work in predictable/routine environment for limited range of machining operations on CNC 5 axis Vertical machining centre by applying appropriate cutting parameters.

1. 1 Demonstrate features of CNC 5 axis Vertical

machining centre, CNC console, machine starting

&

operating in reference point, JOG, MPG,

Incremental,

MDI and AUTO Modes.

1. 2 Demonstrate Simulation on the machine, File

management, File editor, Program transfer (CAM)

to

machine etc.

1. 3 Demonstrate Co-ordinate system and working

with

planes and rotary planes and usage of measuring

probe.

2.

Produce components on CNC 5 axis machining centre.

2.1 Demonstrate work alignment with the Table and other multiple axis, Work off set measurement, Tool off set measurement and Verify the zero offsets and tool offsets in MDI mode.

2.2 Demonstrate tool path generation with UG cam, generate NC code and transfer to the machine.

2.3 Demonstrate the program execution for Ruled surface & Splined surfaces and Check the finish sizes with measuring probe systems.

2.4 Demonstrate the program execution for Splined surfaces with rotation and Check the finish sizes with measuring probe systems.

2.5 Demonstrate the program execution for Solid aluminium structural parts of Aerospace industry and Check the finish sizes with measuring probe systems.

2.6 Demonstrate the program execution for Impeller machining and Check the finish sizes with measuring probe systems.

2.7 Demonstrate the program execution for Turbine blade machining and Check the finish sizes with measuring probe systems.

3. Plan and organize the work in predictable/routine environment for limited range of machining operations on CNC EDM Wire cut machine by applying appropriate cutting parameters.

3.1 Demonstrate wire loading, wire feeding, work offset measurements, setting up of Power supply system and initiation of fluid tank system.

3.2 Demonstrate features of CNC EDM Wire cut machine.

29


4. Produce components on EDM Wire cut machine.

4.1 Demonstrate the production of external and internal profiles with simple configuration. 4.2 Demonstrate the production of external and internal profiles with complex contour configuration. 4.3Demonstrate the production of external and internal profiles with tapering configuration.

5. Plan and organize the work in predictable/routine environment for limited range of machining operations on CNC EDM Die Sinking machine by applying appropriate cutting parameters.

5.1 Demonstrate features of CNC EDM Die sinking machine, loading and unloading of electrode, align the tool electrode and work piece on EDM machine and initiation of Power supply system.

6. Produce components on EDM Die Sinking machine.

6.1 Demonstrate the production of external and internal profiles (plain cavities) with simple configuration.

6.2 Demonstrate the production of external and internal profiles (angular cavities) with simple configuration.

6.3 Demonstrate the production of complex contours having plain, angular and radius profiles.

6.4 Demonstrate the production of concave contours.

6.5 Demonstrate the production of tapering configurations-frustum.

ELECTIVE MODULE 1 : CONTROL SYSTEMS & AUTOMATION to be finalised by D S Rao

1. Perform simulation

mechanism dynamically,

design and develop

independent functional and

stable assembly models.

1. 1 Operate, maintain and control of air compressors.

1. 2 Identify pneumatic components: pressure gauge,

FRL

unit i.e. Filter-Regulator-Lubricator, Manifold, T-

connectors, plastic tubing and different types of

valves

and actuators.

1. 3 Perform Dismantling, repair and assembling of FRL

unit.

2. Perform operation and control

of pneumatic equipment in

the industry.

2. 1 Plan and identify tools, instruments and

equipment for the work and make it available

timely.

2. 2 Set up workplace/ assembly location with due

consideration to operational stipulation.

2. 3 Plan work in compliance with standard safety

30


norms and collecting desired information.

2. 4 Construct pneumatic control system as per

design/ application requirement.

2. 5 Measure various parameters as per the set up.

2. 6 Record data as per standard format/ designed

chart.

3. Construct Pneumatic and

Electro–pneumatic circuits for

various industrial applications,

check and troubleshoot.



timely.



3. 3 Plan work in compliance with standard safety

norms

and collecting desired information.

3. 4 Construct electro-pneumatic circuit as per design/

application requirement.

3. 5 Check the functioning of processes as per desired

requirement.

3. 6 Check the functioning of system as per desired

requirement.

3. 7 Trouble shoot the faults during functioning.

4. Perform operation and control

of hydraulic equipment in the

industry, pressure relief valve

(PRV).



timely.



4. 3 Identify Hydraulic components – hydraulic power

pack, Pumps, Oil Reservoir, different grades of

hydraulic oils, Pressure relief valve (PRV), Filters,

different types of valves, actuators, accumulator,

and hoses.

4. 4 Dismantling and assembling of different types of

Directional Control Valves.

4. 5 Install accessories in hydraulic system as per

design/ application requirement.

4. 6 Check the functioning of system as per desired

requirement.

31


4. 7 Trouble shoot the faults during functioning.

5. Construct and maintain

hydraulic, electro- hydraulic

circuits for a given application,

check and troubleshoot.

5.1 Plan and identify tools, instruments and


timely.

5.2 Set up workplace/ assembly location with due


5.3 Construct a circuit for the control of a hydraulic

Cylinder using a 3/2-way valve, 4/2 & 4/3 way

valves.

5.4 Construct a hydraulic circuit for operation and

control.

5.5 Install accessories in hydraulic system as per

design/

application requirement.

5.6 Check the functioning of system as per desired

requirement.

5.7 Trouble shoot the faults during functioning.

6. Construct circuits using

hydraulic, pneumatic and

mechatronic components for

industrial applications.

6. 1 Develop electronic circuit as per desired

application.

6. 2 Assemble and test Electronic Circuit on simulation

6. 3 Software.

6. 4 Detect fault observing diagnostic procedure and

rectify using simulation software.

6. 5 Rectify by resetting errors using simulation

software.

6. 6 Manufacture and assemble Mechanical sub

system.

6. 7 Prepare Pneumatic circuit and interface.

6. 8 Prepare Electrical/Electronic circuit and interface.

6. 9 Develop and download PLC program.

6. 10 Integrate, Test and Repair for functionality.

ELECTIVE MODULE 2: WELDING PROCESS & POWER SOURCE

1 Demonstrate welding of Mild

steel in 1G/1F, 2G/2F, 3G/3F

and 4G/4F positions by

Shielded Metal Arc Welding

process. (SMAW)

1.1 Plan and select the type & diameter of electrode,

welding

Current type and polarity.

1.2 Prepare weld metal edges as per drawing

requirement

32


1.3 Check and set Shielded metal arc welding power

source and tack the pieces as per drawing

requirement.

1.4 Set up the tacked pieces in specific position.

1.5 Deposit the weld maintaining appropriate arc length,

electrode angle, welding speed, weaving technique

and maintain safety aspects.

1.6 Carryout cleaning the welded joint thoroughly.

1.7 Inspect visually for soundness of the weld joint &

check dimensions using weld gauges.

2 Plan and perform welding of

Mild steel Plate and sheets by

Gas Metal Arc Welding

process. (GMAW)

2.1 Plan and select the type & diameter of electrode

wire, contact tip, nozzle, and liner .

2.2 Ensure proper functioning of wire feeder and set

wire feed speed.

2.3 Adjust shielding gas pressure according to the nozzle

size


requirement

2.5 Check and set welding power source and tack the

pieces as per drawing requirement.

2.6 Set up the tacked pieces in specific position.



and maintain safety precautions.


2.9 Inspect the weld joint using visual and Dye

penetration Technique & check dimensions using

weld gauges.

3 Demonstrate welding of Mild

steel Plate by FCAW process.

(FCAW)

3.1 Plan and select the FCAW diameter of electrode

wire, contact tip and nozzle.

3.2 Ensure proper functioning of wire feeder and set

wire feed speed

3.3 Adjust shielding gas pressure according to the

nozzle size.


requirement.


pieces as per drawing requirement.



and maintain safety precautions.


33


3.8 Inspect the weld joint using visual and dye

penetration technique & check dimensions using

weld gauges.

4 Plan and perform welding on

of Mild steel Stainless steel &

Aluminium sheets & pipes by

Gas Tungsten Arc

Welding.(GTAW)

4.1 Plan and select the type & diameter of tungsten

electrode, and proper nozzle size.

4.2 Adjust shielding gas pressure according to the nozzle

size.

4.3 Prepare weld metal as per drawing requirement


pieces as per requirement.


Torch angle, welding speed, and maintain safety

precautions.

4.6 Inspect the weld joint using visually for the

soundness of the weld.

34


Syllabus for Diploma in “Manufacturing Technology”

Core Module 1 : Workshop Technology : 320 Hrs

Hour

No. Learning outcome Professional Skills – 224Hrs.

Professional Knowledge = 96Hrs.

(with indicative Hours)

1-20 Produce

components

involving different

operations on

lathe observing

standard

procedure and

check for

accuracy.

[Different

Operations –

facing, plain

turning, step

turning, parting,

chamfering,

shoulder turn,

grooving, knurling,

boring, taper

turning, threading

(external ‘V’

only)]. Carry out

routine

maintenance of

lathe.

Introduction to workshop and

Metals (14 Hrs.)

• Plan and organize work

schedule, work area, tools,

equipment and materials in

the Workshop to improve

productivity. (3 Hrs.)

• Demonstrate Safety

procedures related to machine

shop. (3 Hrs.)

• Demonstrate First aid (Basic

life support) and Fire

extinguishers. (2 Hrs.)

• Operate electrical mains for

machinery and other allied

installations (3Hrs.)

• Maintenance of machinery,

tools and equipment for

regular operation. (3 Hrs.)

Related theory (06 Hrs.)

• General machine shop

awareness.

• Material properties and their

application.

• Tool Geometry/ nomenclature.

• Tool designation as per ISO.

• Precautions and Checklist before

using tools, equipment and

machinery.

• Commercially available work

and tool materials in the

market.

• Introduction to Shaping, Slotting

and Planning machines, types,

parts and specifications

• Different mechanisms of

Shaping, Slotting and Planning

machines.

• Work and tool holding devices

for Shaping, Slotting and

Planning machines.

• Calculations related to Cutting

speed, depth of cut, feed and

cycle time calculations.

• Calculation of material removal

rate (MRR).

21-

100

Lathe machine (51 Hrs.)

• Demonstration of Lathe and

lathe tools. (1 Hrs.)

• Perform Plain turning. (1 Hrs.)

• Perform Step turning with

corner radius and fillet. (4

Hrs.)


• Introduction to Lathe, functions

and types.

• Introduction to Tool materials

and tool selection.

• Different tool nomenclatures.

• Feed and thread cutting

8. SYLLABUS

35


• Perform Knurling operation on

different materials. (2 Hrs.)

• Demonstrate taper turning-

External and Internal. ( 3 Hrs.)

• Perform boring and counter

boring (3 Hrs.)

• Perform blind Hole boring (3

Hrs.)

• Perform profile turning (3

Hrs.)

• Perform simple Eccentric

turning (3 Hrs.)

• Perform Simple eccentric

boring (3 Hrs.)

• Practice Acme thread cutting

(3 Hrs.)

• Machining Multi-start thread.

(3 Hrs.)

• Machining Square thread.

(3 Hrs.)

• Generating Double start

square thread cutting.(3 Hrs.)

• Perform V- groove on shaft.

(2 Hrs.)

• Perform Threading on pipe

end. (3 Hrs.)

• Demonstrate production of

components. (5 Hrs.)

• Maintenance of machinery,

tools and equipment for

regular operation. (3 Hrs.)

mechanisms.

• Lathe accessories and

attachments.

• Lathe operations.

• Cutting tool signature.

• Calculations related to cutting

speed, feed, taper turning and

thread cutting.

• Material specific coolant

selection.

101-

170

Produce

components on

Milling machines

involving different

operations such as

Face milling, End

milling, Rack

cutting, Gear

cutting, Angle

cutting etc.

Milling (52 Hrs.)

• Demonstration of Milling

machines, Milling cutters,

attachments and accessories.

(2 Hrs.)

• Milling of a right angled block

with good surface finish. (4

Hrs.)

• Milling a slot and angular

milling. (4 Hrs.)

• Perform Male and Female

Dovetail cutting.(6 Hrs.)

• Perform Male and Female T-


• Introduction to Milling

machines, types and

mechanisms.

• Types of cutters.

• Importance of coolant and its

preparation.

• Accessories and attachments

used.

• Cutter holding devices.

• Milling process

• Milling operations

• Calculations related to spindle

36


slot cutting. (6 Hrs.)

• Demonstrate concave and

convex milling. (6 Hrs.)

• Perform Cam milling (7 Hrs.)

• Make a base of Machine vice.

(6 Hrs.)

• Cutting of Gear Rack (3hrs.)

• Demonstrate Gear cutting (8

Hrs.)

speed, feed, depth of cut and

machining time.

• Indexing and dividing heads.

• Indexing methods

171-

215

Produce Gear

components on a

Gear Hobbing

machine.

Gear cutting (33 Hrs.)

• Generating Spur gear (5 Hrs.)

• Generating Helical gear (7

Hrs.)

• Generating Bevel gear (6 Hrs.)

• Generating Worm wheel (7

Hrs.)

• Generating Worm shaft (8

Hrs.)


• Gear Cutting Theory

• Gear Nomenclature &

standards

• Gear cutting methods

• Gear generating methods &

processes

• Gear Hobbing

• Broaching.

216-

245

Produce

components on a

Drilling machine

involving different

hole machining

operations such as

drilling, reaming,

counter boring,

counter sinking,

tapping etc.

Drilling and Reaming (14 Hrs.)

• Demonstration of Different

Drilling machines (1 Hr.)

• Demonstration of Different

drilling practices (2 Hrs.)

• Demonstration on use of

drilling jigs, clamping and

unclamping methods. (1 Hr.)

• Perform Drilling on Pillar and

Radial and Drilling machine. (2

Hrs.)

• Perform Reaming (1 Hr.)

• Practice Counter boring,

Counter sinking, Spot facing

(2 Hrs.)

• Perform Trepanning (1 Hr.)

• Perform Machine tapping (1

Hrs.)

• Marking with a template and

scrabrer on surface plate. (3

Hrs. )


• Introduction function of drilling

machine.

• Types of drilling machines and

parts.

• Work holding devices.

• Tool holding devices.

• Different drilling operations.

• Jigs and Fixtures.

• Principles of jigs and fixture

design.

• Speed, Feed, Depth of cut and

time.

246-

320

Produce the

component on

Grinding machines

involving different

Grinding (60 Hrs.)

• Balancing of the Grinding

wheel (1 Hr.)

• Mount and align/truing


• Introduction to Grinding, Types

and Mechanisms.

• Importance of Grinding and

37


operations such as

cylindrical grinding

(OD&ID), shoulder

grinding, surface

grinding and

perform cutting

tool resharpening

on tool and cutter

grinder.

Wheel on to the machine. (2

Hrs.)

• Dress the Wheel by using

dressers. (2 Hrs.)

• Practice on Surface grinders.

(8 Hrs.)

• Perform slot grinding. (3 Hrs.)

• Demonstrate Cylindrical

grinder machine for Internal

and external grinding. (12

Hrs.)

• Perform cylindrical taper

grinding. (6 Hrs.)

• Perform eccentric grinding. (8

Hrs.)

• Perform resharpening of

cutting tools on Tool and

Cutter grinder.(18 Hrs.)

surface finish parameters.

• Applications of Grinding.

• Work holding devices and

attachments.

• Types of Grinding wheels and

their usages.

• Selection of Grinding wheel

and abrasives.

• Concept of Glazzed and Loaded

wheels.

• Calculations on speed, feed,

depth of cut and machining

time.

Project work/ Industrial Visit

Revision

Examination

38



Core Module 2 : Metrology And Quality Control : 320 Hrs.

Hour No. Learning outcome Professional Skills 224 Hrs Professional Knowledge 96 Hrs.


1-40 Plan, organise and measure the linear, angular, Thread and gear profile measurement of work pieces with various measuring instruments viz. Vernier Calipers, Micrometers, Protractors, Clinometer, Sine bars/centres, gauges etc.

Linear and Angular measurements

(56 Hrs.)

• Introduction and familiarization

of Metrology Lab.(4 Hrs.)

• Measure dimensions using

Vernier Calipers, Height gauges,

Micrometers. (12 Hrs.)

• Measure angular dimensions

using Protractors. (2 Hrs.)

• Measure cylindrical taper using

Sine center. (4Hrs.)

• Measure different angle

measurement using Sine bar. (6

Hrs.)

• Measure angle measurement

using Clinometer and Angle slip

gauges. (4 Hrs.)

• Obtain dimensions by using indirect instruments viz. Telescopic gauges, Bore gauges, etc. (6 Hrs.)

• Ensure acceptability of dimensions by using Radius gauges, Feeler gauges, Angle gauges, Thread pitch gauges, Standard Wire Gauge etc. (8 Hrs.)

• Measure coating/plating thickness by using thickness gauge. (2 Hrs.)

• Measure non standard dimensions by using precision balls and rollers.(8 Hrs.)

Related Theory (24 Hrs.)

• Introduction to the Metrology and

Engineering Inspection.

• Rules for measuring.

• Care and maintenance of measuring instruments.

• Units of measurements and their standards.

• Use and application of Surface plate (Cast Iron, Granite, Glass), V-block and clamps.

• Identifying the characteristics of precision measuring instruments.

• Errors likely to creep in precision measurements and their care.

• Gauges viz. plug, ring and snap gauges.

• Dial gauges, Slip gauges use, Angle slip gauges and applications.

• Vernier calipers

• Micrometers

• Protractors

• Clinometer

• Spirit level

81-120 Thread, Gear and Machine Tool

Metrology (28 Hrs.)

• Check dimensions using Ring

and Plug gauge. (2 Hrs.)

• Check dimensions using Snap

gauges. (2 Hr.)

• Measure all parameters of

Thread. (12 Hrs.)

• Measure all parameters of Gear

measurements. (12 Hrs.)


• Limits and Fits terminology as

per BIS and ISO and its

calculations.

• Taylor’s principle.

• Screw threads terminology.

• Effect of pitch errors.

• Terminology of gear tooth.

• Machine alignment.

39


121-160 Geometrical measurements (34

Hrs.)

• Check perpendicularity and

parallelism using square master. (6Hrs.)

• Check Flatness, Straightness. (6 Hrs.)

• Check Circularity, Concentricity, Cylindricity, Eccentricity, Run-out and Total run-out using Talleyrand. (10 Hrs.)

• Measure dimensions of holes using Bore gauges. (6 Hrs.)

• Measure dimensions of components by using profilometer/Profile measuring machine. (6 Hrs.)


• All geometrical measurements

definition and descriptions.

• Description of different profiles.

• Bore gauges.

• Limit gauges

• Light wave interference.

• Interference of two rays.

161-215 Measure different jobs using optical measuring instruments and determine surface features.

Measuring machines (36 Hrs.)

• Check dimensions using Optical

Profile projector. (3 Hrs.)

• Check cam profile by using Optical Dividing Head. (4 Hrs.)

• Check linear measurements using Tool Maker’s Microscope. (3 Hrs.)

• Check angular measurements using Tool Maker’s Microscope. (2 Hrs.)

• Check various dimensions using Universal measuring machine. (3 Hrs.)

• Perform Surface roughness inspection by microscopic and surface photographs. (3 Hrs.)

• Perform Surface roughness testing using surftest. (2 Hrs.)

• Check surface features using Monochromatic light source with Optical flat. (1 Hrs.)

• Check surface level using Autocollimator. (3 Hrs.)

• Check various dimensions Vision measuring machine (system). (2 Hrs.)

• Measure all dimensions of components using CNC-CMM. (7


• Light source for interferometry.

• Interferometers.

• Laser interferometers.

• Care and maintenance of

Optical measuring machines.

• Profile projector.

• Dividing Head.

• Tool Maker’s Microscope.

• Autocollimator.

• Measuring machines.

• Scanning electronic Microscope

40


Hrs.)

• Practice of SEM (3 Hrs.)

Calibrate different instruments and use of different comparators & related Management tools.

Calibration (18 Hrs.)

• Perform and practice of Vernier

Calipers calibration. (2 Hrs.)

• Perform and practice of

Micrometers calibration.(2 Hrs.)

• Perform and practice of Dial

Test Indicators Calibration. (2

Hrs.)

• Perform and practice of Slip

gauge calibration. (3 Hrs.)


mechanical comparators. (3

Hrs.)


Electrical and Electronic

comparators. (3 Hrs.)


Pneumatic and Optical

comparators. (3 Hrs.)


• Calibration of

- Vernier Calipers

- Micrometers

- Dial Test Indicators

- Slip gauges

• Use and Types of Comparators.

- Mechanical

- Electrical

- Electronics

- Pneumatic

- Optical

241-280 III) Quality Control and

Management Tools (28 Hrs.)

• Perform and Practice of

Statistical Process Control with

SPC software. (5 Hrs.)

• Perform and Practice of quality

charts. (8 Hrs.)

• Perform and Practice of Case

studies of Management

Techniques (15 Hrs.)

Related Theory (12Hrs.)

• Quality Control.

• Fundamentals of statistics.

• Statistical Quality Control.

• Control charts.

• Applications of control charts.

• Sampling inspection.

• Q. C. Tools

• Quality management and TQM

• Total Productive Maintenance.

• 5’S

• Just in Time manufacturing

(JIT).

• Implementation of Kaizen.

• Kanban

• Lean manufacturing and Six

Sigma.

281-320 Test the mechanical properties of metals viz. Hardness, Compressive and

Destructive and Non-Destructive

Testing (24 Hrs.)

• Perform Surface inspection by


• Surface roughness.

• Hardness testing machines

41


Tensile strength using hardness testing machines and Universal Testing Machine. Analyse the defects of components by using Non-Destructing Testing machines.

Touch, Visual and Scratch. (2 Hrs.)

• Measure Hardness with Brinell hardness tester. (2 Hrs.)

• Measure Hardness with Rockwell hardness tester. (2 Hrs.)

• Measure Hardness with Vickers hardness tester. (2 Hrs.)

• Perform Non-Destructive testing with Liquid penetration test. (3 Hrs.)

• Perform Tensile and Compressive strength testing using UTM. (4 Hrs.)

• Perform NDT with magnetic particle testing. (3 Hrs.)

• Perform NDT with ultrasonic testing. (2 Hrs.)

• Perform NDT with radiographic testing and film observation. (4 Hrs.)

- Brinel

- Rockwell

- Vickers

• Strength testing methods and

UTM

• NDT methods

- Liquid penetration testing

- Magnetic particle testing

- Ultrasonic testing

- Radiographic testing

• Revision and Internal test.

Projects

Revision

Examination

42



Core Module 3 : CNC TECHNOLOGY: 320 Hrs

Hour

No. Learning outcome

Professional Skills 224 Hrs. Professional Knowledge 224 Hrs.


1-90 Plan , organize and

produce the work

in predictable/

routine

environment for

limited range of

machining

operations on CNC

Turning machine/

Turn Mill Centre by

applying

appropriate cutting

parameters,

measuring

instruments and

check for work

result.

CNC Turning machine: (60

hours)

• Demonstrate Personal and

CNC Turning machine Safety.

Select, use, clean and store

personal protective

equipment.(1hr.)

• Demonstrate CNC Turning

machine/CNC Turn Mill

centre, CNC console.

Machine over travel limits

and emergency stop.

Machine starting &

operating in Reference

Point, JOG, MPG,

Incremental, MDI and AUTO

Modes. (2hrs.)

• Demonstrate Simulation

software, File management,

menu management,

Geometry creation, Setup,

Tool management, Work

plan, part programme

creation and

Simulation.(3hrs).

• Prepare Co-ordinate system

assignments and simulations

(2hrs).

• Prepare Absolute and

incremental programming


(2hrs).

Related CNC Turning Theory:(30 hours) Safety Precautions to be followed in CNC Turning operations. Safe handling of tools, equipment & CNC machines.

Explain working principle of CNC Turning Machine/CNC Turn Mill centre. Types of CNC Turning machines and their applications, advantages & limitations of CNC Turning machine. Describe CNC interpolation, open and close loop control systems. CNC Machine Control Unit (Keys & Menus)

Describe the screen management,

Navigation of software, saving of

part programmes and work plans.

Tool path simulation. ISO/DIN G

and M codes for CNC Turning

machine/CNC Turn Mill centre. Importance of feedback devices for CNC control.

Co-ordinate systems and Points.

Describe the method of arriving

Work Zero off sets and tool off sets

in Turning machine. Function of Hydraulic power pack, Direction control valves, accumulator, characteristics of hydraulic oil and precautions to be taken while holding different shapes of materials.

43


• Perform Jaw removal from

chuck, Tool removal from

Turret, Tail stock Centre

removal and mount them on

CNC Lathe as per

requirement of work piece.

Practice of hydraulic

pressure setting for work

clamping to different types

of work Pieces such as

ferrous, non ferrous, solid

and hollow (4hrs).

• Perform Work and tool

setting. Work off set

measurement, Tool off set

measurement and entry into

CNC Control. Tool nose

radius and tool orientation

entry into CNC control.

Checking of work zero

offsets and tool offsets

(3hrs).

• Carry out Soft jaw boring

(1hrs).

• Prepare Part program,

Simulation, Program

checking in dry run, single

block mode & Automatic

Mode execution for the

exercise on Simple turning &

Facing (step turning). Check

the finish size. (2hours).

• Perform linear interpolation,

and Circular interpolation


on soft ware. Part program

preparation, Simulation &

Automatic Mode execution

for the exercise on Turning

with Radius / chamfer with

TNRC (2hours).

• Prepare Part program,

Simulation & Automatic

Mode Execution of CNC

Cutting tool materials for CNC Turning and its applications ISO nomenclature for tool holders used on CNC Turning machine and for indexable inserts. Tool holders and inserts for radial grooving, face grooving, threading, drilling. Cutting parameters- cutting speed CSS, feed rate, depth of cut, tool wear, tool life, relative effect of each cutting parameter on tool life. Cutting parameters selection from a tool manufacturer’s catalog for various operations. Describe the tooling systems for CNC Turning Centers.

Application of soft jaws, Materials

used for soft jaws, precautions to

be taken while boring soft jaws.

Tool path study of machining operations. Setting of Graphic screen parameters for simulation. Geometric development, work plan, tool selection for roughing and finishing operations.

Importance of Tool Nose Radius Compensation (TNRC). Study of Blue print and defining of co ordinate points.

Requirement of tool wear offset corrections for achieving dimensions as per drawing during mass production.

44


Turning Machine for the

exercise on Blue print

programming of contours

with TNRC (2 hrs).

• Perform Tool Wear

Correction for desired

Geometrical requirements

as per drawing and wear

offset correction (2hrs).

• Carryout dimensional

measurement and check

quality as per the drawing

with appropriate measuring

instruments for all the

following Exercises :

- Prepare Part program,



Machine for the exercises

on turning.

- Perform Stock removal cycle on OD (3 Exercises-06 hrs)

- Perform Drilling, Reaming and Tapping cycles

- (2 Exercises-04 hrs) - Perform Grooving and

thread cutting on OD (2 Exercises-6 hrs)

- Perform Grooving and thread cutting on ID

- (2 Exercises-6 hrs) - Perform Turn Mill

operations on OD and ID. - (3 Exercises-06 hrs) - Perform Sub programming

with repetition in the Main Program. (2 Exercises-6 hrs)

Describe the stock removal cycle in CNC turning for OD / ID operation. Drilling, Tapping cycles in CNC Turning. Grooving, Threading. C-axis programming with polar interpolation. Trouble shooting in CNC lathe machine. Preventive and periodical maintenance of CNC machines Identify Factors affecting turned part quality/ productivity.

91-

230

Plan, organize and

produce the work in

predictable/

routine

environment for

limited range of

machining

operations on CNC

Milling machine/

CNC Milling machine: (104

hours)

• Demo. of Personal and CNC

Milling machine/ Machining

centres Safety. Select, use,

clean and store personal

protective equipment.(1hr.)

Related CNC Milling Theory:(36

hours)

Safety Precautions to be followed

in CNC milling operations. State

the Safe handling of tools,

equipment & CNC machines.

Describe CNC system working.

Types of CNC Milling Machines and

45


Machining centre

by applying

appropriate

Simulation &

Automatic Mode

Execution and

check for work

result.

• Demo. of CNC Milling

machine/ Machining

centres, CNC console.


and emergency stop.

Machine starting &


Point, JOG, MPG,

Incremental, MDI and

AUTO Modes.(3hrs.)

• Demonstrate Simulation of

software, File management,

menu management,

Geometry creation, Setup,

Tool management, Work

plan, part programme

creation and

Simulation.(3hrs).

• Prepare Co-ordinate system

assignments and

simulations (2hrs).

• Perform Absolute and

incremental programming

assignments and

simulations (2hrs).

• Carryout Vice alignment

with the Table, Mount the

tools on ATC as per


(2hrs).

• Perform Work and tool

setting. Work off set

measurement, Tool off set

measurement and entry in

CNC Control. Check the zero

offsets and tool offsets

(5hrs).


measurement and check



instruments for all the

following Exercises -

Machine axes

Conventional & CNC machining.

Explain the working principle of CNC Milling Machine.

Describe Machine tool elements,

Feed Drives and spindle drive.

Describe the screen management,

Navigation of software, saving of

part programmes and work plans.

Tool path simulation. ISO/DIN G

and M codes for CNC milling.

Co-ordinate systems and Points.

Describe the method of Zero off

sets and tool off sets in Milling.

Use of ISO codes for carbide

indexable inserts and tool holders

for Milling.

Describe the tooling systems for

CNC Machining Centres.

Work locating principles and

locating devices for CNC milling.

Identify cutting tool materials for

CNC Milling and its applications.

Cutting parameters- cutting speed,

feed rate, depth of cut, tool wear,

tool life, relative effect of each

cutting parameter on tool life.

Cutting parameters selection and

process planning.

Tools layout and process sheet

preparation.

Calculation of approach and

escape distance in tangential entry

and circular entry.

Bi-directional and Unidirectional

cuts and calculation of overlap

distance during cutting. Single and

multiple passes of cutting.

Carry out tool path simulation on

machine.

46



Simulation, Program

checking in dry run, single

block mode & Automatic

Mode Execution for the

exercise on Simple edge

milling& Facing. Check the

finish size (3 hours).

- Perform linear interpolation,

and Circular interpolation

assignments and simulation

on soft ware (3 hours).



Mode Execution for the

exercise on Milling with

Radius / chamfer with CRC (3

hours).

- Perform Tool Wear

Correction for desired

Geometrical requirements as

per drawing and wear offset

correction (1hrs).




Milling Machine for the

following exercises on

Milling Perform End milling

with polar coordinates

(3hrs).

- Perform Slot milling with

CRC (3hrs).

- Perform hole machining

operations with Hole

patterns using Canned

cycles: Simple drilling-G 81,

Chamfer and counter-sink

drilling-G82, Deep hole

drilling - G 83. Tapping G 84

and G74, Boring cycles G 85 -

G 89. (4 Exercises-10 hours).

- Perform Contour milling

external with CRC and

Contour milling internal with

Purpose of Cutter Radius

Compensation (CRC).

Describe the shifting of Work-piece

zero points.

Indicate Machining parameters for milling for face milling and end milling. Requirement of tool wear offset corrections for achieving dimensions as per drawing during mass production.

Describe the Drilling /Boring cycles in CNC Milling.

Programming for Grooving/

Threading on external and internal

in CNC Milling.

Importance of Helical Interpolation

and Thread Milling, advantages

and limitations in CNC Milling.

Machining of rectangular/ circular pockets on CNC milling. Drilling, slot milling patterns on CNC milling. Datum shift and Transformation functions-scaling, mirror image, rotation and translation.

Using Sub Programs & Cycles in the

Main Program.

Trouble shooting in CNC Milling

machine. Preventive and periodical

maintenance of CNC machines.

47


CRC. (4 Exercises-12 hours).

- Perform Rectangular pocket

and Circular pocket milling.

(3 Exercises-8hours).

- Milling of Slot patterns. (2

Exercises-8 hours).

- Perform Thread Milling.(2

Exercises-8 hours)

- Mill patterns by using Mirror

image, Scaling, Rotation and

translate functions. (3

Exercises-10hours).

- Practice Sub programming

with repetition in the Main

Program. (3 Exercises-10

hrs)

231-

30

Plan, organize and

produce the work

in predictable/

routine

environment for

limited range of

machining

operations on CNC

Grinding machine

by applying

appropriate

cutting

parameters to

control

dimensional

accuracies with

specific surface

finish and check

for work result

using measuring

instruments.

CNC Universal Cylindrical

Grinding machine (60 hours)

• Demonstrate Personal and

CNC Grinding machine Safety.

Select, use, clean and store

personal protective

equipment.(3hr.)

• Measure dimensions of

several machined parts as

per drawing with suitable

measuring instruments such

as vernier calipers, Micro

meters, Depth gauges for

ascertaining grinding

allowance. (2hrs)

• Demonstrate CNC Grinding

machine, CNC console.


and emergency stop.

Machine starting &


Point, JOG, MPG,


Modes (3hrs.).

• Perform balancing of

grinding wheel, mounting of

grinding wheel, Truing of

grinding wheel.(4hrs)

Related CNC Grinding Theory:(30 hours)

Safety Precautions to be followed

while working on CNC Grinding

machine. State the Safe handling

of tools, equipment.

Importance of surface roughness

and measuring methods.

Importance of demagnetization of

jobs.

Purpose of cylindrical grinding,

types of Grinding, function and

operation of each element of the

machine.

Types of grinding wheels for Cast

Iron, Steel, stainless Steel and

Carbide.

Specifications of grinding wheels.

Grinding wheel markings.

Importance of inspection of

wheels.

Selection criteria of grinding

wheels.

Standard grinding wheel shapes.

Handling and storage of grinding

48


• Prepare Part program &

Automatic Mode Execution

of CNC Grinding Machine for

all following exercises and

Carryout dimensional

measurement and check for



instruments:

- Perform Plunge grinding a

parallel diameter to a

dimensional accuracy of ±

0.05 mm.(3 exercises-

10hrs)

- Perform traverse grinding a

parallel diameter to a

dimensional accuracy of ±

0.05 mm.(3 exercises-

10hrs)

- Grinding of slow taper

surfaces with in a accuracy

of 5minutes(4hrs)

- Grinding fast taper surfaces

with in a accuracy of 5

minutes(4hrs)

- Perform Grinding on a

tapered bore(4hrs)

- Mount spindle for ID

grinding (1hrs)

- Grind cylindrical plain

internal surfaces on a

cylindrical grinder to an

accuracy of ± 0.05

mm(3hrs)

- Measure the taper with

sine bar and slip

gauge(2hrs)

- Measure internal

dimensions with bore dial

gauge with 0.01 to 0.001

accuracy(1hr)

- Carry out dressing of

grinding wheel with dresser

attachment for radius

grinding and

wheel.

Procedure of Balancing, mounting

and Truing of a grinding wheel.

Work holding devices- 4- jaw

Independent chuck, 3 - jaw chuck,

faceplate and carriers.

Type of grinding fluids and

purposes.

Methods of producing external

and internal cylindrical surfaces of

plain taper and stepped surfaces.

Describe the main factor of

grinding parameters wheel speed,

work speed, depth, and work

traverse speed, depth in feed.

Describe the method of Inspection

of cylindrical surfaces.

Concept of Centre less Grinding &

Surface Grinding.

Cylindrical grinding defects, causes

and remedy.

Trouble shooting in CNC Grinding

machine. Preventive and periodical

maintenance of CNC machines.

49


measure.(2hrs)

- Perform Profile (contour)

grinding. (4 exercises- 17

hrs)

Project work / Industrial visit

Revision

Examination

50



Core Module 4 : CAD/ CAM: 320 Hrs

HOUR

No.

Learning outcome Professional Skills (224 HRS) Professional Knowledge (96

HRS)


1-23 Develop the

Orthographic and

Isometric drawings

by using AutoCAD.

Review of Drawings – 20 hrs

• Open AutoCAD and Changing

different workspaces.[1 hr]

• Open new drawing sheet and set

limits, use of templates and units.[1

hrs]

• Develop drawing using Absolute co-

ordinate system. [1 hr]

• Develop drawing using relative co-

ordinate system. [1 hr]

• Develop drawing using Absolute

polar co-ordinate system. [1 hr]

• Develop drawing using relative polar

co-ordinate system. [1 hr]

• Draw the orthographic views of

object containing lines, circles and arc

geometry. [1 hrs]

• Interpret given orthographic views

and to imagine the actual shape of

the component. [2 hrs]

• Setup AutoCAD for Constructing

Isometric drawing and start simple

Isometric Drawing[1 hrs]

• Practice on the making Isometric

Drawing [1 hrs]

• Draw the isometric view from

orthographic views of object/s

containing lines, circles and arcs.

[4hrs]

Related Theory [08 hours]

Types of projections-

orthographic, perspective,

isometric and oblique: concept

and applications.

Conversion of simple pictorial

views into Orthographic views.

Isometric scales. Isometric view

and isometric drawing.

Difference between isometric

projection and isometric

drawing. Geometric

measurements & Tolerances.

Concept of CAD. Latest Software used on CAD/CAM

Introduction to AutoCAD,

Familiarization of workspace,

Ribbon bar, command window.

Setting of Units & limits.

Understanding co-ordinates.

24-95 Draw given sketches

in AUTOCAD and

enhance the

sketches with

additional features

in AutoCAD.

AUTOCAD-45 hrs

• Construct drawings with lines and

circles [4 hrs]

• Construct standard geometrical

shapes.[4 hrs]

• Explain other draw commands .[4

hrs]

• Enhance drawing with Chamfer &

[25 hrs]

Understanding Draw commands-

Line, Circle, Arc, Ellipse, Polygon,

rectangle, text, hatch and other

draw commands.

Understanding Modify

commands- Erase, Move, Copy,

Offset, Extend, Trim, Break, Join,

51


fillet commands. [1 hr]

• Mirroring and Arraying commands.[2

hrs]

• Develop drawings with other Modify

commands. [2 hr]

• Create parametric dimension Delete

& Add Dimension.[2 hr]

• Putting a single & multiple texts in a

drawing.[1 hr]

• Construction of tables (BOM) in the

drawing. [2 hrs]

• Changing the properties of object. [2

hrs]

• Managing drafting aids. [ 2 hrs]

• Drafting different 2D mechanical

component drawings. [2 hrs]

• 2D Machine/Assembly drawings. [2

hrs]

• Make a block, write it & then insert

it in any file. [2 hr]

• Pick the items from design centre

and insert in to the drawing fit to the

requirement. [2 hr]

• Putting other format file/photos

/information in drawing.[1 hr]

• Managing layers with different

drawings.[2 hrs]

• Use of Geometric constraints.[2 hrs]

• Use of Dimensional constraints.[1

hr]

• Assignment: - Draft the given

Machine drawing [5 hrs](Create,

make Dimensions, in the given

template).

Rotate, Lengthen, Fillet,

Chamfer, Mirror, Array Stretch,

Scale, Explode, Pedit

Understanding & Managing

Dimension.

Object properties and working

with Drafting aids.

Blocks, Design center

External Reference, Layers

Parametric constraints.

96-167

Build new part

model and

generate surfaces

with Creo.

CREO- 55

• Develop Interface. [5 hr]

• Develop Sketcher.[5 hrs]

• Develop constraining sketch [5 hrs]

• Develop modifying sketches.[6 hrs]

• Develop editing Geometry [5hrs]

• Develop base Feature.[5 hrs]

• Develop datum features[5 hrs]

• Develop Secondary feature [5 hs]

• Prepare Part modeling. [8hrs]

Related Theory [16 hrs]

Introduction to parametric

modeling and its difference from

non-parametric with one

example.

Introduction to Creo modelling

and basic concepts, Using the

creo interface, Selecting and

Editing, Sketcher geometry,

52


• Generate Surface modelling. [6hrs]

Planes and Axes, Creating

extrudes, Revolves and Ribs,

Creating sweeps and blends,

Creating holes, shells and drafts,

Creating rounds, chamfers , Copy

and mirror tools, Creating

patterns.

168-215 Perform assembly

modelling with

sequencing and

simulate part

mechanism

dynamically.

[35 Hrs]

• Prepare inspecting models. [2 hrs]

• Prepare Assembly model with

constraints. [6 hrs]

• Prepare top-down assemblies. [3

hrs]

• Prepare Bottom-up assemblies. [3

hrs]

• Modify components on assembly. [3

hrs]

• Organise Drawings from model.

[4hrs]

• Develop dynamics of parts by

Simulation. [4 hrs]

Assignment:- Design a given Mechanical

Assembly [Sketch, Model the parts,

Assemble, Simulate and make Detail

drawing.] [10 hrs]

Related Theory [16 hrs]

Review of Part modelling, Basic

Assembly Creation with

constraints, Exploding

assemblies, Using layers, Adv

Assembly modeling, Detailing

(Drawing), Editing view,

dynamics of Mechanism using

Simulation techniques.

216-320 Convert the given

sketch to part

programme using

Mastercam.

MASTERCAM- 74 hrs

• Practice on Mastercam Interface. [01

hr]

• Creating 2D drawings (using Line,

Arc, Rectangle, Fillet, Chamfer, Point,

Polygon, Rectangle shapes). [04 hrs]

• Practice on 2D toolpath generation.

[01 hr]

Milling Operations [ 25 hrs]

• Selection of Suitable Machine

[Milling].

• Practice on different types of Stock

setup for milling operations.

• Choose suitable Tools and tooling

parameter for milling operations.

• Perform Milling Operations by

[31 hrs]

Introduction on Master CAM.

Concepts on 2D drawing and

Solid design.

Review on Milling / Turning

operation.

Understanding tool path

generation.

Understanding Tool parameter

and job set up parameter.

53


selecting suitable machining

parameters.

Turning Operations [ 27 hrs]

• Selection of Suitable Machine

[Turning].

• Practice on different types of Stock

setup / Chuck selection for Turning

operations.

• Choose suitable Tools and tooling

parameter for Turning operations.

• Formulate suitable machining

parameters for Turning Operations.

• Verify machining operation

(simulation).[1 hr]

• Validate by Backplot verification [1

hr]

• Generate NC code by Post-

processing [1 hr]

• Compile generated NC code. [1 hr]

• Transfer of generated NC code to

CNC Machine and simulate on CNC

machine. [4 hrs]

• Creating 3D models (Solid &

Surface). [2hrs]

[Extrude, Revolve, Fillet, Chamfer,

Sweep, Thicken, Ruled, Boolean

operations]

• Demonstrate virtual 3D machining in

Milling and Turning. [6hrs]

Verification methods - Backplot

Machine definition of different

controls. Post Processor transfer.

Understanding Planes in

Mastercam.

Introduction to 3D Machining

features, Benefits of 3D

Machining Operations,

Application of 3D Machining

operations in industries.

Features of Mastercam in 3D

Machining.

Project work/Industrial visit (optional)

Revision

Examination

54



Core Module 5 : Advanced Manufacturing Processes : 320 Hrs

HOUR


Professional Skills Professional Knowledge

With Indicative Hours

Plan and organize

the work in

predictable

/routine

environment for

limited range of

machining

operations on

CNC 5 axis

Vertical

machining centre

by applying

appropriate

cutting

parameters.

Advanced CNC Milling Lab: (120

hours)

• Demonstrate Personal and CNC 5

axis machine Safety. Select, use,

clean and store personal

protective equipment. (2 hr.)

• Demonstrate features of CNC 5

axis Vertical machining centre,

CNC console. Machine over travel

limits and emergency stop.

Machine starting & operating in

Reference Point, JOG, MPG,


Modes. (10 hrs.).

• Perform Simulation on the

machine, File management, File

editor, menu management,

Geometry creation, Setup, Tool

management, Work plan, part

programme creation and

Simulation. Program transfer

(CAM) to machine (8hrs).

• Organise Co-ordinate systems and

working with planes and rotary

planes and usage of measuring

probe. (4hrs).

Related CNC Milling Theory:(20 hours)

• Safety Precautions in CNC

operation. State the Safe

handling of tools,

equipment & CNC 5 axis

machine.

• Describe CNC system of

CNC 5 axis Vertical

machining centre and

machine elements.

Features of 5 axis machine.

• Graphic parameters

selection for Virtual

simulation, Tool library,

features of machine

graphic simulation.

• Co-ordinate systems and

Points. Describe the

method of Zero off sets

and tool off sets in Milling.

• Describe the tooling

systems for CNC 5 axis

Vertical machining centre.

Work locating principle

and locating devices for

CNC 5 axis Vertical

machining centre, tool

selection.

• Cutting parameters-

cutting speed, feed rate,

depth of cut, tool wear, tool

life, relative effect of each

55


Produce

components on

CNC 5 axis

machining centre.

• Carryout work alignment with the

Table and other multiple axis,

Determining pivot distance, simple

and compound plunges using

world coordinate system, Fixture

placement compensations. Mount

the tools on ATC as per


Perform Work and tool setting.

Work off set measurement, Tool

off set measurement and entry in

CNC Control. Verify the zero

offsets and tool offsets in MDI

model (6 hrs).

• Practice with UG CAM software for

tool path generation and tool

selection. NC code generation and

transfer of programme to the

machine. (4 exercises- 20 hrs).


measurement and check quality as

per the drawing with appropriate

measuring instruments for all the

following Exercises :

- Part program preparation,

Simulation, Program proving in

dry run, single block mode &

Automatic Mode Execution for

the exercise on Ruled surfaces.

Check the finish sizes with

measuring probe systems. (8

hrs).


Simulation, Program checking in



the exercise on Splined surfaces.

Check the finish sizes with

measuring probe systems.

(8hrs).





the exercise on Solid aluminium

cutting parameter on tool

life.

• Cutting parameters

selection and process

planning. Tooling layout

and process sheet

preparation.

• Describe the Work-

piece zero points.

ISO/DIN G and M codes for

CNC 5 axis Vertical

machining centre.

Carry out tool path

simulation.

Cutter Radius

Compensation (CRC) in

multiple planes.

Definition of ruled surfaces

and their characteristics.

Application of ruled

surfaces.

• Definition of splined

surfaces and their

characteristics. Control

polygon. Application of

splined surfaces.

• Using Sub Programs &

Cycles in the Main

Program.

Datum shift and

Transformation functions-

scaling, mirror image,

rotation and translation.

• Configuration of Aerospace components and their geometrical definitions. Transfer of program from system to machine.

• Using of world coordinate

system. Programs with

56


structural parts of Aerospace

industry. Check the finish sizes

with measuring probe systems.

(08hrs).





the exercise on Impeller

machining. Check the finish sizes


(08 hrs).





the exercise on Turbine blade



(12hrs).





the exercise on Die and mould



(18hrs).

continuous loops. Stock

removal methods from a

solid block. Tools used for

complex machining.

Cutting parameters in 5

axis machining.

• Trouble shooting in CNC 5

axis Vertical machining

centre. Preventive and

periodical maintenance of

CNC machines.

1421-

1520

Plan and organize

the work in

predictable/

routine

environment for

limited range of

machining

operations on CNC

EDM Wire cut

machine by

applying

appropriate cutting

parameters.

CNC EDM Wire cut LAB: (80 hours)

• Practice safety measures for

Personal and CNC EDM Wire cut

machine. Select, use, clean and

store personal protective

equipment. (2hrs.)

• Demonstration of CNC EDM Wire

cut machine and its allied

equipment (2hrs.)

• Demonstration of features of CNC

EDM Wire cut machine. (2hrs.)

• Demonstration of Modes of

operation.(4hrs.)

• Practice of modes of operation.

(3hrs.)

• Demonstrate wire loading and

Related CNC Wire cut EDM

Theory:(20 hours)

Safety Precautions in CNC

Wire cut operation. State the

Safe handling of tools,

equipment & CNC EDM

machines.

Introduction to Non-

conventional machining –

Water Jet machine, Abrasive

machine. Classification of

modern machining processes

Difficulties faced for

machining Hard and Heat

resisting materials.

Introduction to Electric

57


wire feeding mechanism. (3hrs.)

• Set up the Job on EDM machine

(work offset measurements).

(2hrs.)

• Set up the Wire on EDM machine

(offset measurements).(1hr.)

• Setting up of Power supply system

and parameters selection. (1hrs.)

• Setup of fluid tank system and

Dielectric fluid selection. (2hrs.)

• Prepare part Programme and

execution of external profiles of

simple configuration. (2 exercises-

6hrs.)


execution of internal profiles of

simple configuration. (2 exercises-

8hrs.)


execution of complex contour

cutting (external). (4 exercises-

12hrs.)


execution of complex contour

cutting (internal). (4 exercises-

16hrs.)


execution of tapering

configurations. (4 exercises-

16hrs.)

Discharge Machining.

History and Development

Advantages and

Disadvantages.

Principle of machine

operation

Types of EDM – sinker EDM

and wire cut EDM.

CNC EDM Wire cut machine

construction and its elements.

Mechanism of metal removal

Limitations of Wire cut EDM

process. Tool/electrode/wire

material. Functions of

Dielectric fluid and its

properties. Process

parameters.

CNC part programming of

EDM machining.

Care and Maintenance of CNC

EDM Wire cut machine.

1521-

1600

Plan, organize and

produce the work

in predictable/

routine

environment for

limited range of

machining

operations on CNC

EDM Die Sinking

machine by

applying

appropriate

cutting

parameters,

CNC EDM DIE SINKING MACHINE: (70

hours)

• Practice safety measures for

Personal and CNC EDM DIE

SINKING. Select, use, clean and

store personal protective

equipment. (2hrs.)

• Demonstration of CNC EDM Die

Sinking machine and its allied

equipment (2hrs.)

• Demonstration of features of CNC

EDM Die sinking machine. (2hrs.)

• Demonstration of Modes of

operation. (1hr.)

Related CNC EDM DIE SINKING MACHINE Theory:(10 hours)

Safety Precautions in CNC Die

sinking machine operation.

State the Safe handling of

tools, equipment & CNC EDM

machines.

Introduction to Electric

Discharge Machining and

spark erosion process.

History and Development

Advantages and

Disadvantages

58


measuring

instruments and

check for work

result.

• Practice of modes of operation.

(3hrs.)

• Practice of electrode loading and

unloading. (2hrs.)

• Set up and align the tool electrode

and work piece on EDM machine

(offset measurements).(3hr.)

• Set up of Power supply system

and parameters selection.

• (1hr.)

• Setup of fluid tank system and

Dielectric fluid selection. (1hr.)

• Practice flushing of dielectric fluid

and filtration and fluid treatment.

(3 hrs.)

Principle of machine

operation.

Types of EDM Die Sinking

machine.

CNC EDM Die Sinking machine

construction and its elements.

Mechanism of metal removal

on EDM Die Sinker.

Limitations of Die Sinking EDM

process.

Tool/electrode/wire material.

Functions of Dielectric fluid

and its properties.

Process parameters.

Produce

components on

EDM Die Sinking

machine.


execution of external profiles

(plain cavities) of simple

configuration.(2 exercises-6hrs.)


execution of external profiles

(angular cavities) of simple

configuration. (2 exercises-8hrs.)


execution of complex contours

having plain, angular and radius

profiles. (3 exercises-12hrs.)


execution of concave cavity

contours. (3 exercises-12hrs.)


execution of tapering

configurations (frustum).

(3exercises-12hrs.)

CNC part programming of

EDM machining.

Care and Maintenance of CNC

EDM Die sinking machine.

Project work / Industrial Visit

Revision

Examination

59


Core Module 1 : Workshop Technology: 320 Hrs

Project work/ Industrial Visit 40 Hours

Revision 16 Hours

Examination 8 Hours

Total number of Hours (Instructional

Hours+Project+Revision+Examination) 384 Hours

Core Module 2 : Metrology AND QUALITY ENGINEERING : 320 Hrs


Revision 16 Hours

Examination 8 Hours



Core Module 3 : CNC Technology: 320 Hrs


Revision 16 Hours

Examination 8 Hours



60


Core Module 4 : CAD/CAM: 320 Hrs


Revision 16 Hours

Examination 8 Hours



Core Module 5 : Advanced Manufacturing Processes: 320 Hrs


Revision 16 Hours

Examination 8 Hours



61



Elective Module 1 : Control Systems &Automation: 320 Hrs

HOUR


Professional Skills (224 hrs)

Professional Knowledge (96 hrs)


961-982 Perform

simulation

mechanism

dynamically,

design and

develop

independent

functional and

stable assembly

models.

• Operate, maintain and control

of air compressors ( 8 hrs.)

• Identify pneumatic

components: pressure gauge,

FRL unit i.e. Filter-Regulator-

Lubricator, Manifold, T-

connectors, plastic tubing and

different types of valves and

actuators. (4 hrs.)

• Dismantling, repair and

assembling of FRL unit (4hrs.)

• Compressed air generation

and conditioning, Air

compressors, Pressure

regulation, Dryers, Air

receiver, FRL unit,

Applications of pneumatics,

Hazards & safety

precautions in pneumatic

systems. (6 hrs.)

983-990 Perform operation

and control of

pneumatic

equipment in the

industry.

• Identify the parts of a

pneumatic cylinder (2 hrs.)

• Dismantling and assembling of a

pneumatic cylinder (4 hrs.)

• Pneumatic actuators: Types,

Basic operation, Force,

Stroke length, Single-acting

and double-acting cylinders.

(2 hrs.)

991-

1064

• Identify the parts of a different

types of Directional Control

Valves.(2 hrs.)

• Dismantling and assembling of

Directional Control Valves.(4

hrs.)

• Identify the parts of a flow

control valve (2 hrs.)


flow control valve (4 hrs.)

• Identify the parts of quick

exhaust valve (1 hrs.)


quick exhaust valve (4 hrs.)

• Identify the parts of time delay

valve (2 hrs.)


time delay valve (4 hrs.)

• Identify the parts of shuttle

• Pneumatic valves:

Classification, 3/2-way

valves (NO & NC types)

(manually-actuated &

pneumatically-actuated) &

5/2-way valves, Roller valve,

Shuttle valve, Two-pressure

valve , Check valves, Flow

control valves, One-way flow

control valve, Time Delay

Valves, Pressure Sequence

Valves, etc. (8 hrs.)

62


(OR) valve and dual pressure

(AND) valve (2 hrs.)


shuttle (OR) valve and dual

pressure (AND) valve (3 hrs.)

• Identify the parts of pressure

sequence valve (1 hrs.)


pressure sequence valve (3

hrs.)

• Construct a pneumatic circuit

for the direct control of a

single acting cylinder (2 hrs.)


for the speed control of a



for the indirect control of a



for the direct control of a

double acting cylinder (2 hrs.)


for the indirect control of a



for the speed control of a



for the memory control of a



for the control of a double

acting cylinder with OR logic.

(2 hrs.)


for the control of a double

acting cylinder with AND logic.

(2 hrs.)


for Automatic return motion of

a double acting cylinder. (2

hrs.)


• ISO symbols of pneumatic

components. Reading of

pneumatic circuit drawings.

(8 hrs.)

63


for the Rapid return motion of

a double acting cylinder. (2

hrs.)


for continuous back-and-forth

motion of a double acting

cylinder (3 hrs.)

1064-

1100

Construct

Pneumatic and

Electro–

pneumatic

circuits for

various industrial

applications,

check and

troubleshoot.

• Identify different parts of

solenoid valves (1 hrs.)

• Dismantling &Assembling of

solenoid valves (3 hrs.)

• Construct a circuit for the direct

& indirect control of a double

acting pneumatic cylinder with

a single & double solenoid valve

(3 hrs.)

• Construct Electro-pneumatic

circuits for following

applications: (20 hrs.)

(a) Sorting device

(b) Opening & closing device

(c) Lid fitting device

(d) Assembly station

(e) Cutting device

(f) Flap Control

(g) Tipping device

(h) Diverting device

(i) Hopper Control

(j) Gravity Feed Magazine

(k) Conveyor belt control

(l) Clamping device

(m) Stamping device

(n) Heat Sealing device

(o) Transfer Station

• Electro-pneumatics:

Introduction, 3/2-way single

solenoid valve, 5/2-way

single solenoid valve, 5/2-

way double solenoid valve,

Control components -

Pushbuttons (NO & NC type)

and relay unit, Logic

controls, etc. (8 hrs.)

1101-

1118

Perform operation

and control of

hydraulic

equipment in the

industry, pressure

relief valve (PRV).

• Identify Hydraulic components

– hydraulic power pack, Pumps,

Oil Reservoir, different grades

of hydraulic oils, Pressure relief

valve (PRV), Filters, different

types of valves, actuators,

accumulator, and hoses (8 hrs.)

• Inspect hydraulic oil levels, oil

reservoirs, clean and replace oil

filters. (3 hrs.)

• ISO Symbols of hydraulic

components, Hydraulic oils –

function, properties,

Contamination in oils and its

control.

Hydraulic Filters – types,

constructional features, and

their typical installation

locations, Hazards & safety

precautions in hydraulic

64


systems, Hydraulic reservoir

& accessories, Pumps,

Classification – Gear/vane/

piston types, Hydraulic

motors –Types, Pressure

relief valves – Direct acting

and pilot-operated, Pipes,

tubing, Hoses and fittings –

Constructional details,

Minimum bend radius for

hoses. (6 hrs.)

1118-

1123

• Identify the parts of a hydraulic

cylinder. (1 hrs.)

• Dismantling and assembling of a

hydraulic cylinder (3 hrs.)

• Hydraulic cylinders –Types,

different parts, Working

principles, care and handling.

(2 hrs.)

1124-

1133

• Identify the parts of different

types of Directional Control

Valves. (2 hrs.)


different types of Directional

Control Valves. (4 hrs.)

• Hydraulic valves:

Classification, Directional

Control valves – 2/2- and

3/2-way valves; 4/2- and

4/3-way valves; Check valves

and Pilot-operated check

valves, Flow control valves:

Types, Speed control

methods – meter-in and

meter-out. (4 hrs.)

1134-

1152

Construct and

maintain

hydraulic, electro-

hydraulic circuits

for a given

application, check

and troubleshoot.

• Construct a circuit for the

control of a hydraulic cylinder

using a 3/2-way valve, 4/2 &

4/3 way valves. (8 hrs.)

• Construct a hydraulic circuit for

the control of a conveyor

tensioning device using a 4/3

way valves, pilot operated non-

return valve. (6 hrs.)

• ISO Symbols, practice of

reading of circuit drawings,

understanding oil flow during

operation of circuits. (5 hrs.)

1153-

1190

• Construct a hydraulic circuit

for operation and control of:

(35 hrs.)

(a) Cold store door

(b) Rotary Machining station

(c) Embossing machine

(d) Table of a surface grinding

machine

(e) Clamping of workpieces in a

vice.

• Applications of hydraulics in

industrial equipment.

Frequently used hydraulic

circuits in the industry.

Study, analysis and

exploring alternative

circuits using

minimum components for

same solutions. (3 hrs.)

65


(f) Bulk head door

(g) Assembly device for

pressing workpieces together.

1191-

1237

Construct circuits

using hydraulic,

pneumatic and

mechatronic

components for

various industrial

applications.

• Maintenance, troubleshooting,

and safety of pneumatic and

hydraulic systems (15 hrs.)

• Preventive maintenance &

troubleshooting of pneumatic

& hydraulic systems, System

malfunctions due to

contamination, leakage,

friction, improper mountings,

cavitation, and proper

sampling of hydraulic oils(4

hrs.)

• Operation & control of

Distribution station. (8 hrs.)

Introduction to Mechatronics,

Mechatronic elements,

Applications of Mechatronics,

Electronics for mechanical

engineers. (2 hrs.)

• Operation & control of Testing

station. (8 hrs.)

Study of different controls used

in Testing station. (2 hrs.)


Processing station.(8 hrs.)


in Processing station. (2 hrs.)


Handling station. (8 hrs.)


in Handling station. (2 hrs.)


Separating station.(8 hrs.)


in Separating station. (2 hrs.)

• Operation & control of Sorting

station. (8 hrs.)


in Sorting station. (2 hrs.)

• Operation & control of Pick

and place station. (8 hrs.)


in Pick and place station. (2 hrs.)

Project work / Industrial visit

Revision

Examination

66


Syllabus for Diploma in “Welding Technology”

Elective Module 2 : Welding Process & Power Source: 320 Hrs

Hour


Professional Skills

(Trade Practical)

(224 Hrs)

Professional Knowledge

(Trade Theory)

(96Hrs)


1-73 Perform welding

of Mild steel in

1G/1F, 2G/2F,

3G/3F and 4G/4F

positions by

Shielded Metal Arc

Welding process.

(SMAW).

Skills on SMAW Process (49 hrs)

• Weld Fillet “T” joint on M.S.

plate in Flat position.(3 Hrs)

• Weld Fillet Lap joint on M.S.


• Weld Fillet Corner joint on

M.S. plate in Flat position.(3

Hrs)

• Weld Single “V” on M.S. plate

in Flat position.(5 Hrs)


plate in Horizontal position.(3

Hrs)


M.S. plate in Horizontal

position.(3 Hrs)

• Weld Single “V” butt joint on

M.S. plate in Horizontal

position. (5 Hrs)


plate in Vertical position. (3

Hrs)


M.S. plate in Vertical

position. (3 Hrs)


M.S. plate in Vertical position.

(5 Hrs)


plate in overhead position. (3

Hrs)


M.S. plate in overhead

position. (5 Hrs)

• Weld Structural pipe flange

joint. (5 Hrs)

Arc physics, Arc welding Power

Sources etc. (24 Hrs)

• Arc physics: Electric Discharge

phenomena, arc discharge,

Arc temperature distribution,

Arc characteristics, Forces

acting on metal transfer, Arc

starting methods.

• Arc welding Power sources:

Characteristics, Working

principles of Transformers,

Rectifiers - Diode & Thyristor

control, Generators,

Inverters, Selection factors,

Maintenance.

• Shielded metal arc welding

(SMAW): Principles, Process

capabilities and limitations,

power source, Electrodes

&Classifications, welding

procedures, defects, causes

and remedy. Welding

positions as per ISO and

ASME. Safety practices.

• Safety on welding

• Autonomous maintenance of

welding equipments

67


74-

179

Perform welding

of Mild steel Plate

and sheets by Gas

Metal Arc Welding

process (GMAW).

Skills on GMAW Process(82 hrs)


Plate in Flat position.(3 Hrs)

• Weld Fillet Lap joint on M.S.

Plate in Flat Weld position. (3

Hrs)


M.S. plate in Flat position.(3

Hrs)

• Weld Single “V” joint on M.S.



Plate in Horizontal position. (3

Hrs)


M.S. Plate in Horizontal t

position.(3 Hrs)


M.S. Plate in Horizontal

position.(5 Hrs)

• Weld Fillet “T” joint on

M.S.Plate in Vertical

position.(3 Hrs)


M.S. Plate in Vertical

position.(3 Hrs)


M.S. Plate in Vertical

position.(5 Hrs)


Plate in overhead position.(3

Hrs)



position.(3 Hrs)



position.(5 Hrs)

• Weld Fillet “T” joint on S.S.

Sheet in Flat position.(3 Hrs)

• Weld Fillet Lap joint on S.S.


• Weld Fillet Corner joint on S.S.


Gas Metal Arc welding

(GMAW) (24 Hrs)

Principles, Process capabilities

and limitations, applications,

power source, Wire feeders,

Welding torch types and

configuration, Electrodes &

Classifications, Modes of metal

transfer, Shieding gases,

welding procedures, defects,

causes and remedy, and latest

developments

68


• Weld Square butt joint on S.S.



Aluminium .Sheet in Flat

position.(4 Hrs)

• Weld Fillet Lap joint on

Aluminium sheet in Flat

position.(4 Hrs)

• Weld Square butt joint on

Aluminium sheet in Flat

position.(4 Hrs)


Aluminium plate in Flat

position.(5 Hrs)

• Weld of sheet metal by

GMAW brazing process.(6

Hrs)

180-

219

Perform welding

of Mild steel Plate

by FCAW process

(FCAW).

Skills on FCAW Process(16 Hrs)


M.S.Plate in Flat position.(4

Hrs)


M.S.Plate in Flat position.(4

Hrs)


M.S.plate in Flat position.(4

Hrs)


M.S.plate in Flat position.(4

Hrs)

Flux cored Arc welding (FCAW)

(24 Hrs)


and limitations, power source,

Wire feeders, Welding torch

types and configuration,

Electrodes & Classifications,

Metal transfer, Shieding gases,

welding procedures, defects,

causes and remedy.

220-

320

Perform welding

of Mild steel

Stainless steel &

Aluminium sheets

& pipes by Gas

Tungsten Arc

Welding (GTAW).

Skills on GTAW Process(77 Hrs)


M.S.Sheet in Flat position.(3

Hrs)



Hrs)


M.S.Sheet in Flat position. (3

Hrs)



Hrs)

• Weld root run on Single “V”

Gas Tungsten Arc welding

(GTAW)(24 Hrs)


and limitations, applications,

power source and polarity

effects, Welding torch types

and configuration, Tungsten

electrodes & Classifications,

Shielding gases, welding

procedures, developments,

defects, causes and remedy.

69


butt joint on M.S. plate in Flat

position.(5 Hrs)

• WeldSquare but joint on M.S.

plate in horizontal position. (3

Hrs)

• WeldFillet “T” joint on M.S.

Sheet in horizontal position.(3

Hrs)


M.S. Sheet in horizontal

position.(3 Hrs)

• WeldSquare butt joint on M.S.

Plate in vertical position.(3

Hrs)


Sheet in vertical position.(3

Hrs)


M.S.Sheet in vertical

position.(3 Hrs)


Aluminium Sheet in Flat

position(4 Hrs)


Aluminium sheet in down

hand position.(5 Hrs)


Aluminium Sheet in down



Aluminium Sheet in down


• Weld Single ‘V” butt joint on

Aluminium plate in down



Aluminium Sheet in horizontal

position.(5 Hrs)


Aluminium Sheet in Vertical

position.(5 Hrs)

• Weld Titanium metal by

GTAW.(8 Hrs)

Project Work/ Industrial Visit

70


• A miniature model of wind Turbine or any other involving all the above process

welding in it. (40 Hrs.)

Revision

Elective Module 1 : Control Systems &Automation: 320 Hrs


Revision 16 Hours

Examination 8 Hours



Elective Subject 2 : Welding Processes and Power Sources : 320 Hrs.

Revision 16 Hours

Examination 8 Hours


Hours+Revision+Examination) 344 Hours

71


9. SYLLABUS – EMPLOYABILITY SKILL

1. Leadership Skills

Duration : 20 Hrs.

Interact with people and convince

them.

Leadership - Define leadership, types of leadership, leadership

Traits, Functions of leadership, styles of leadership. Resolving

Individual differences among people.

Assess risk and take the initiative. Risk Analysis tools; estimate the risks that you could face in

your role. In turn, this helps you manage these risks and

minimize their impact on your plans. Break-even point

analysis.

Risk Value = Probability of Event x Cost of Event.

Think differently with the innovative

mindset.

Success stories / Best Practices – Inspection, inspect Demo

displacement. Innovation has become one of the most

popular buzz words of the Digital Age. Re-evaluate the true

meaning of a concept than when it is being touted by

individuals and companies around the world. Spark

innovation, maximize productivity, and increase profitability

as a result of implementing the Big Five behaviors.

Handle the pressure. Stress management - Define Management, Type of stress

Management, How to improve stress in workplace, Team

leader in workplace.

Ability to gather the client’s

requirement.

Manage relationships with client who may be confused with

the services requirements.

Build healthy client relationships and use customer centric

approach.

2. Entrepreneurship Skills

Duration : 20 Hrs.

Identifying opportunities not obvious to

others.

Self Employment as a Career path - Define Entrepreneurship,

Strategy of entrepreneurship, Market Research.

Implementation of self Employment in workplace Ps, Mange

self employment in workplace.

Quality consciousness – its relevance.

Assessing the competitive advantage of

ideas.

Study of Competitive Advantage Model. PEST factors for

external changes and implement VRIO resources for getting

an edge over the competitors.

Identifying customer or client

requirements.

Ensure that environmental conditions are suitable for the

client and the services to be carried. Deal with clients lacking

the technical background to solve the problem on their own.

Determining the commercial viability of

ideas. Immediate or temporary solutions to resolve delays.

Demonstrating sensitivities (political, 5 Strategies of handling sensitive issues (political,

72


commercial, environmental, cultural, and

so on).

commercial, environmental, cultural, and so on) at workplace

–

1. Define the issues, 2. Develop Policies Adhering to

Company Goals, 3. Communicate Policies, 4. Hold People

Accountable and 5. Continue to Evolve.

Identifying opportunities for setting up

business.

Define marketing, Tools of marketing, 7 Ps define market

strategy, important of market strategy, use of strategy in

trade theory (Labour Market Information).

3. Organizational Skills

Duration : 20 Hrs.

Project deadlines.

Training & Managerial responsibilities Introduction &

discussion on managerial responsibilities.

Work under pressure and tight

deadlines.

Basic quality Concept & 5’S

Colour Dynamics

Organize the workload to meet with the

timelines.

Follow the organisation’s policies and procedures for working

with colleagues.

Prioritize the tasks.

Time management - Workplace time Management, maintain

Time management, Benefits of Time Management in

workplace, Time management schedule.

4. Creative Abilities

Duration : 30 Hrs.

Visualize a business idea end-to-end

Boosting Morale - Boosting ethics & Development work

environment, ethics theory, Development of work

environment & training process, knowledge of presentation &

self motivation.

Conceptualize an idea

Five Dimensions to conceptualize your idea to make it a

successful innovation. When conceptualizing an idea, it is

essential to ask questions like what is the problem that the

idea solves, who is the consumer for the idea, does the idea

solve the consumer’s problems and how will the solution be

delivered to the consumer. It is very important to direct the

thinking to specific dimensions and search answers to certain

questions that help in evolving the idea from the initial thought

through the various stages of innovation.

73


Transform notions into business ideas

The single most effective way to come up with a business idea

is to solve a problem. Next step, you bring the idea to life.

Whether it's code, carpentry, or culinary, a project is a

created idea. When the project is nearly complete and it's

time to begin putting the project into the hands of real

people. Once your project is perfected through testing, it's

time to come up with a way to make money from it. Growth -

Get the word out about the thing.

5. Strong digital Skills

Duration : 20 Hrs.

Write strong and effective emails for

communication.

Write memos and e-mail to customers, co-workers, and

vendors to provide them with work updates and to request

appropriate information.

Use digital tools like laptops, palmtops,

mobiles, fax machines, printers,

projectors, conferencing tools

effectively.

Operate all types of digital tools like laptops, palmtops,

mobiles, fax machines, printers, projectors, conferencing tools

effectively.

Strong understanding of emerging

technologies.

Attributes that feature in the emergence of novel

technologies are: (i) radical novelty, (ii) relatively fast growth,

(iii) coherence, (iv) prominent impact, and (v) uncertainty and

ambiguity. The framework for operationalising emerging

technologies is then elaborated on the basis of the proposed

attributes.

Good understanding of information

security aspects.

Understanding and adhering to the Information security

aspects of the organization based on ISP.

Information Security Policy (ISP) is a set of rules enacted by an

organization to ensure that all users or networks of the IT

structure within the organization’s domain abide by the

prescriptions regarding the security of data stored digitally

within the boundaries the organization stretches its authority.

Convert textual content into graphs,

images, charts, diagrams and flow

charts.

Create or convert textual contents into graphical

representation, charts, diagrams and flow charts. Learn to

make graphs and charts in MS excel. Use of digital camera and

other imaging tools. Use of MS-Powerpoint for developing

diagrams and flowcharts.

74


6. Self-Management

Duration : 20 Hrs.

Having a personal vision and goals Decision making pertaining to the concerned area of work.

Decision making process.

Being able to evaluate and monitor

his/her own performance

Identifying the strengths - SWOT Analysis. Define Swot

analysis, Important of swot analysis, characteristics of swot

analysis, Example of swot analysis related with Trade

development in detail

Having knowledge and confidence in

your own ideas and vision

Apply, analyze, and evaluate the information gathered from

observation, experience, reasoning, or communication, as a

guide to thought and action.

Articulating your own ideas and vision Use of multi-model strategies of articulation such as audio

visual tools, kinaesthetic learning tools, etc.

Taking responsibility

7 thoughts on taking responsibility at workplace-

1. There is always a price to pay. 2. Build your self-esteem.3.

Give yourself the permission to work as you want.4. Taking

actions 5. Understand the limits of your responsibility. 6.

Don't forget to take responsibility in everyday work life. 7.

Aim to be your best self.

7. Plan and organize the work related to the occupation

Duration : 20Hrs.

Use documents, drawings and recognize

hazards in the work site. Prepare and organize service feedback files/documents.

Plan workplace/ assembly location with

due consideration to the operational

stipulation.

The best way is to plan for workplace/ assembly location is to think of any emergency situation before it happens. Think clearly and logically in a crisis, so it is important to do so in advance with due consideration of the operational stipulation.

Communicate effectively with others

and plan project tasks.

Question-answer session to be conducted appropriately in

order to understand the nature of the problem and make a

diagnosis of the task.

Assign roles and responsibilities of the

co-trainees for execution of the task

effectively and monitor the same.

Guidelines for delegating roles and responsibilities to co-

trainees:

1. Identify key opportunities for delegation, 2. Establish a

clear set of objectives for each task, 3. Play to your

coworker's strengths, 4. Construct a timeline, 5. Use follow-

up tasks to keep your workers on point, 6. Establish authority

and respect, 7. Use a feedback loop to make future

delegation easier.

75


8. Effective communication (written and verbal)

Duration : 10 Hrs.

Interact with stakeholders, whether it is

internal in an organization or external

with partners or clients, is fraught with

opportunities for misunderstanding.

Communication process & elements of communication.

Maintain clear communication with colleagues (by all means

including face-to-face, telephonic as well as written). Pass on

information to stakeholders in line with organisational

requirements both through verbal as well as non-verbal

means. Principles of effective communication, body language,

handling nervousness/ discomfort and dealing with barriers.

Prepare and give formal presentations

and informal presentations during

meetings.

Different Types of Communication Aids: Projected/ Non

Projected using different types of board in a class room

session. Black board, White board, Flannel board, Magnetic

board etc.

Application, use & maintenance of OHP, Digital Camera, LCD

projector and Smart board. Preparation of slides in MS-

Powerpoint and presentation of the slides.

Handle FAQ session during meetings.

9. Emotional intelligence

Duration : 10 Hrs.

Work well, interact successfully with

others.

Work with colleagues to integrate work. Work in ways that

show respect for colleagues.

Work with clients.

Getting it right from the very beginning, you’ll most likely see

things flourish. Spending ample time collecting information,

allow client to share their knowledge and participate in the

project.

Connect with people from different

cultural backgrounds.

Adopt a flexible attitude, learn about the culture beforehand,

expect differences, understand hierarchies, be upfront about

difficulties in communication, be respectful & tolerant and be

patient.

76

Diploma in IT, Networking and Cloud

List of Tool & Equipment

LIST OF EQUIPMENT FOR MODULE 1 (WORK SHOP TECHNOLOGY LAB)

Sl.

No. Description of Equipment

specification Quantity

required

1. Lathe machine

Centre height 150 mm and centre

distance 1000 mm along with 4

jaw chuck, Taper turning

attachment, steadies, auto feed

system, safety guard, motorized

coolant system, with lighting

arrangement and set of lathe tools,

Motor Capacity -5.5 KW

10

2. Horizontal Milling Machine.

Table Length x width 1200 x 300

mm having motorized up & down

movement along with auto feed

arrangement and 150mm

Universal vice, Motor Capacity -

7.5KW

03

3. Vertical Milling Machine.


mm having motorized up & down


arrangement along with 150mm

universal vice, Motor Capacity -

5.5KW

04

4. Universal Milling Machine


mm having motorized up &down


arrangement along with 150mm

universal vice and with Motor

Capacity -7.5KW along with

following attachments such as:

a.Vertical head

b.Slotting attachment

c.Rack cutting attachment

d.Rotary table

e.Dividing head

f.Adaptors, arbors and collects etc.

for holding straight shank drills and

cutters from 3 mm to 25 mm

03

ANNEXURE-I

77


5. Pillar type Drilling machine 20 mm capacity with drill chuck &

key, 0.75 KW 02

6. Radial Drilling Machine

Drilling capacity in steel 50mm,

max drilling radius 1500 mm

motorized, main motor 3.6/4.5 KW

02

7. Tool and Cutter Grinder

Center height 130mm, admit 600

mm between center, fully

motorized work head and total

power- 3.0KW.

02

8. Drill point Grinder

For re-sharpening of drills sizes up

to 13mm, Portable and Table top

model for easy handling, Suitable

for H.S.S. and Carbide Drills, Power

supply – 220V &1Phase.RPM of

motor – 4500(minimum).

Drill Centre point angle: 90-136

Degrees.

01

9. End mill Grinder

For resharpening end mills of 2,

3, 4 flutes (sizes from 4 to

13mm),Portable and Table top

model for easy handling, Suitable

for H.S.S. and Carbide End mills.

Power supply – 220V &1Phase,

RPM of motor – 5500(min.), Power

- 400W (min.).

01

10. Gear Hobbing Machine

Max work piece diameter- 500mm,

max module- 8mm, max work

table speed- 8 rpm, main motor-

6.5 KW

02

11. D.E. Pedestal Grinder 250 mm wheels(one fine and one

rough wheel), 0.75 KW 01

12. Power hacksaw machine. Max diameter 300mm, max square

250 mm, main motor 1.5 KW 01

13. Cylindrical Grinding machine

Swing over table- 200mm, grinding

length - 400mm, max swivel of the

table: -20

to +350,grinding diameter

min/max (OD)- 6/100mm, spindle

motor power- 5.5KW, work head

motor power- 0.37 KW

04

14. Universal Cylindrical Grinding

m/c

Swing over table- 200mm, grinding

length - 400mm, max swivel of the

table: -20

to +350, grinding

diameter min/max (OD)-

6/100mm, grinding diameter

03

78


min/max (ID)- 6/85mm, spindle

motor power- 3.7KW, work head

motor power- 0.37 KW, internal

grinding head motor power- 1.5

KW.

15. Surface Grinding Machine

Grinding machine plain surface,

wheel dia. 175 mm (or near) with

reciprocating table having

longitudinal table traverse 200 mm

(or near) fully automatic, machine

to be fully motorized and fitted

with guards and pumps, tank and

pump fittings and also to be

supplied with magnetic chuck 250

x 112 mm., Motor Capacity- 3.0

KW

03

16. Work Tables 2400 x 1200 x 900 mm 10

17. Measuring Table with surface

plate

1000 x 1000 mm with Stand and

Cover 03

18. Class Room Tables and Chairs 20+20

19. Faculty Table and Chair 6+6

20. Storage Cabinets 20

21.

Cutting tools, tool holders,

Grinding wheels, work

holding devices, measuring

instruments and other allied

machine accessories.

CTS Machinist measuring equi tool

list pg 64

Assorted.

To be

purchased

along with

the each

particular

machine.

22. Raw material storage racks Rack sizes from CTS Machinist

trade 03

23. Teaching Aids assorted

LIST OF EQUIPMENT FOR MODULE 2 (METROLOGY & QUALITY ENGINEERING )

S. No. Description of the measuring machine / equipment

Specification Quantity

01 Gear roll testing machine with PC System 01 No.

02 Profile projector with PC System 02 Nos.

03 Optical Dividing Head with PC System 01 No.

04 Floating Carriage Micrometer with system 01 No.

05 Quick height gauge 01 No.

06 Mechanical comparator (different) 05 Nos.

07 Electrical Comparator 02 Nos.

79


08 Electronics comparator 02 Nos.

09 Pneumatic comparator 01 No.

10 Optical comparator (different sizes) 02 Nos.

11 Tool Maker’s Microscope 01 No.

12 Monochromatic light source (different sizes) 02 Nos.

13 Autocollimator 01 No.

14 Combination fixture 01 No.

15 Roundness measuring machine 01 No.

16 Form / Profile measuring machine 01 No.

17 Contour measuring machine 01 No.

17 Vision measuring machine 01 No.

18 Scanning Electronic Micrometre 01 No.

19 Hardness testing machines (Brinell / Vickers / Rockwell)

01 No. each

20 Non-Destructive Testing machines (different) 04 Nos.

21 CNC-CMM 01 No.

22 Surface measuring machine (Different) 02 Nos.

23 Universal Testing Machine 01 No.

LIST OF EQUIPMENT FOR MODULE 3 (CNC TECHNOLOGY LAB)

Sl. No.

Description of Equipment Specification Quantity

required

1. CNC Vertical machining centre. 08

2. CNC Horizontal machining centre. 02

3. CNC Turning Centre. 5

4. CNC Turn Mill Centre. 05

5. CNC Universal Cylindrical Grinding machine.

2

6.

CNC Simulation software (Turning) CNC Training Machine- Machine operation Simulator for Turning

20 Licenses.

2 no.

7.

CNC Simulation software .(Milling) CNC Training Machine- Machine operation Simulator for Milling

20 Licenses.

02 no.

8. CAM software 20

12. Tool Pre setter 02

14. Work Tables 10

15. Measuring Table with surface plate 03

16. Tool trolley 20

17. Computer (Server)+UPS 01

18. Computer Work Stations with 27”monitor

20

19. UPS/INVERTER 02

20. LCD/LED Projector 02

80


21. Laptop 3




25. A3 size Printer and Scanner 3+1

26.

Cutting tools, tool holders, Grinding wheels, work holding devices, measuring instruments and other allied machine accessories.

Assorted. To be

purchased along with the

each particular machine.

27. Raw material storage racks 03

28. LAN Network to the Simulation Lab. As per the

requirement.

29. CC TV net work with 48”LED TV 03 sets

30. Interactive Board 03

31. Teaching Aids assorted

81


LIST OF EQUIPMENT FOR MODULE 4 (CAD/CAM LAB)

Sl. No.

Description of Equipment Specification

Quantity required

1 Different Solid models Set of Regular models 05 Sets

2. AutoCAD software- Mechanical

Education- Latest version- Floating

license (Perpetual) 20 Lic.

3. PTC- Creo (Pro-e) Education- Latest version- Floating

license (Perpetual) 20 Lic.

4. Mastercam Education- Latest version- Floating

license (Perpetual) 20 lic

5.

Server Intel® Xeon® E5-2609v4, 16GB

DDR4 RAM, 3 x 1TB SATA HDD 01 No.

6.

Workstations with 27 “ Monitor

Intel® Xeon® E3-1240 v5 (3.5 GHz,

up to 3.9 GHz with

Intel Turbo Boost Technology, 8 MB

cache, 4 cores) 8 GB DDR4-2133

MHz Memory X 1TB HDD

20 Nos.

7.

UPS / Inverter Capacity :- 10KVA-72 Offline UPS

of single Phase In & Out, Batteries :-

Power Safe SMF capacity:12 V /100

AH X 15 Nos with 3 Hrs backup and

Battery stand.

01 No.

8..

LCD Projector Full HD Projector WUXGA,

Resolution: 1920 x 1200, Aspect

Ratio16:10- Remote operated.

01 Nos.

9.

Interactive board Dimension:- 1360mm X 125mm

X830mm

Panel Size :- 55 “ wide diagonal

LED, Full HD, Aspect Ratio: 16:9

Interface: - USB, HDMI, LAN PIP,

Print function.

01 No.

10. White Board Size :- 1200mm X 90mm 01 No.

11. Laptop Core I7, 8 GB Ram, 1 TB 02 Nos

12.

Scanner Flatbed with transparent materials

adapter (TMA), 584 x 318 x 89 mm

(23.0 x 12.5 x 3.5 inches) 4800 dpi

01 No

13. Printer A3 size -laser printer colour 01 No

14. Trainees chair – lab Without arms mounted on castor

wheels, adjustable height 20 Nos.

15. Trainees Chair – Class Room

S-type 20 Nos

82


16. Faculty Chair / table Revolving chair with arms 03 Nos.

17 Cabinets for storing Size 30"W x 16"D x 71.5"H with 4

shelves 03 Nos.

18 Split A/cs Each 2 Ton 06 Nos.

LIST OF EQUIPMENT FOR MODULE 5 (ADVANCED MANUFACTURING PROCESSES)

Sl. No.

Description of Equipment

Specification Quantity required

1. CNC 5 axis Vertical Machining centre.

02

2. CNC EDM Wire cut machine 05

3. CNC EDM Die Sinking machine 05

4. UG - CAM Software 10

5. Work Tables 08

6. Measuring Table with surface plate 02

7.

Cutting tools, tool holders, Wire feeding spools, die electric medium, work holding devices, measuring instruments and other allied machine accessories.

Assorted. To be

purchased along with the

each particular machine.

8. Tool trolley 14

9. Computer Work Stations with 27”monitor

05

10. UPS/INVERTER 02

11. LCD/LED Projector 01

12. Laptop 02




16. A3 size Printer and Scanner 1+1

17. Raw material storage racks 02

18. CC TV network with 48”LED TV 02 sets

19. Interactive Board 03

20. Teaching Aids Assorted

LIST OF EQUIPMENT FOR MODULE 6 (CONTROL SYSTEMS AND AUTOMATION

83


S.No. Description Specification Quantity Required

1. Basic pneumatic training kit 10

2. Advanced pneumatic training kit 10

3. Basic electro-pneumatic training kit 10

4. Advanced electro-pneumatic training kit 10

5. Basic hydraulic training kit 10

6. Advanced hydraulic training kit 10

7. Basic electro-hydraulic training kit 10

8. Advanced electro-hydraulic training kit 10

9. Desktop Computer systems for Fluid Simulation (hydraulics & pneumatics)

21 sets

10. Fluid Simulation software for (hydraulics & pneumatics)

21 licenses

11. Mechatronics Simulation software 21 licenses

12. Modular Production System –- Distribution station

2 sets

13. Modular Production System –Testing station 2 sets

14. Modular Production System – Processing station

2 sets

15. Modular Production System –Handling station

2 sets

16. Modular Production System –Separating station

2 sets

17. Modular Production System –Sorting station 2 sets

18. Modular Production System –Pick and place station

2 sets

19. Modular Production System –Fluidic muscle station

2 sets

20. Modular Production System –Storing station 2 sets

21. Class room furniture ( Tables & chairs) 21 each

LIST OF EQUIPMENT FOR MODULE 7 Welding Processes & Power Sources

S.No Item Description Specification Qty

1 Inverter based DC welding machine with accessories for MMAW application

400A at 60% duty cycle, OCV 60 – 80 V, IGBT Control, IP23 Enclosure Conformity to IEC 60974 & CE

10 sets

2 MIG/MAG welding machine with accessories (Air cooled torch, Gas pre-heater, Nozzle and contact tips)

350A at 60% duty cycle, IGBT controlled digital welding system Degree of protection: IP23 Synergic Wire feeder

8sets

84


2. Furniture

S No. Name of the Item with Specification Specification Quantity

1. LED projector

2. Smart board

3. Magnetic board

4. Personal computer with multimedia and

accessories.

5. Printer (Colour and Black & White)

6. Chairs

7. Trainees tables

8. Work tables

Wire Feed mechanism: 4 roll Conformity to IEC 60974 & CE

3 Pulsed MIG welding machine 400 A, IGBT controlled digital

welding system, Synergic Wire

feeder

Wire Feed mechanism: 4 roll

2 Sets

4 AC/DC GTAW welding machine with accessories (water cooled torch 300 A, Argon regulator, Gas hose, water circulating system)

300 A at 60% duty cycle, IGBT Inverter control, In built HT unit Pre flow & post flow control, pulse control & Remote control (as per IEC 60974)

10 Sets

5 Welding Simulators for GTAW/GMAW Virtual Arc type,230V, AC, 1Ph,

50Hz, GTAW/GMAW, Green

learning with no real arc & smoke.

Display, LED/LCD Monitor.

5 sets

85


9. Faculty chair

10. Faculty table

11. Air conditioners

12. Temperature measurement gauges / metre

13. Humidity measurement gauges / metre

14. Almirah (cupboard)

15. Trainees locker

16. Book Shelve

17. Shoe Stand

18. Laptop with accessories

3. Teaching Aids:

S No. Name of the Item with Specification Specification Quantity

19. Wall charts form (NIMI) 02 Sets

20. SPC software 06

21. Theoretical software 03

22. Practical software 06

86


Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry / ITI

Trade Name: Examination: Duration of the Trade/course:

Learning Outcome:

S N

o.

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

To

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Ass

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2

ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT

competency based curriculum advanced …atimumbai.gov.in/parent/pdfs/syllabus of...

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