POST DIPLOMA COURSE IN TOOL DESIGNgttc.co.in/.../08/Post-Diploma-in-Tool-Design_sylabus.pdf · 2020. 8. 4. · 1. Introduction to jig and Tool Design - M H A KEMPSTER 2. Jigs and

POST DIPLOMA COURSE

IN

TOOL DESIGN

SYLLABUS

GOVT. TOOL ROOM & TRAINING CENTRE

(An INDO-DANISH Project)

Rajajinagar Industrial Estate

Bangalore - 560 010

1

PREFACE

Tool is the backbone of any industry. It is a good tool that maintains the desired

quality and yields the required quantity of a product. To produce such a tool, it is

essential that the tool is made to a sound design based on a well considered

concept.

It was felt that the engineering support in the industries, particularly the small and

medium scale industries, needed imports of design technology to keep pace with

the change in trends in tool engineering. The engineering personnel and

technicians need to be groomed into the design concepts not only to adopt the

latest trends in the tool engineering but also they need this knowledge to maintain

the existing tooling at optimum service conditions.

GTTC with a strong foundation in the field of tool engineering and with their

constant endeavour to absorb the latest technology in tooling found it appropriate

to disseminate the same down the line.

With this in view, a course of instruction in the design of tools and dies has been

worked out for the Engineering personnel, in order to meet the demands of well

trained engineers in tooling line.

GTTC is conducting two years part time and one year full time courses in Tool

Design, is specially meant for Engineering Graduates and Diploma Engineers and

those who are working in different industries.

A. The contents of this course cover

1. Press tools of all types for sheet metal working.

2. Moulding tools for plastics - both Thermo Plastics and

Thermosets.

3. Die casting Dies for Aluminium, Zinc etc.,

4. Jigs & Fixtures as well as gauges.

5. Tool Room Practice, Estimation & Costing.

6. Exposure to Metrology and Measuring Techniques

POST DIPLOMA COURSE IN TOOL DESIGN

PREFACE

2

B. The objectives of the course is to acquire thorough knowledge and practical

experience in the design, development and manufacture of tools from the

point of view of.

1. Low cost of mass production

2. Consistent output from the tools

3. Long life

4. Easy maintenance of tools

5. Easy fabrication

6. Use of proper steels and other materials for the construction of tools

C. The faculty is drawn form various tool rooms of small scale/medium scale

industries & public sectors apart from our own tool room.

D. This course has been awarded the recognition as "Post Diploma in tool

Design" by the board of technical education, Govt. of Karnataka vide their

G.O.No. ED 82 TPE 82 Dated 5th October 1982.


PREFACE

3

Sl. CONTENTS Sheet No.

No.

1. Course Directives 1

2. Methodology 2

3. Evaluation and Examination 3 & 4

4. Programme Plan 5

5. Subject - PD- 101 Design Practice 6

6. Subject – PD- 102 Materials & Heat Treatment 7

7. Subject – PD- 103 Metrology & Measuring 8 & 9

Techniques

8. Subject – PD- 104 A Jigs & Fixtures - Theory 10

9. Subject – PD- 104 B Jigs & Fixtures - Design 11

10. Subject – PD- 105 A Press Tools – Theory 12

11. Subject – PD- 105 B Press Tools – Design 13

12. Subject - PD- 201 Tool Room Management 14 & 15

13. Subject - PD - 202 Cutting Tools 16

14. Subject - PD - 203 A : Plastic Moulds – Theory 17

15. Subject - PD - 203 B : Plastic Moulds – Design 18


CONTENTS

4

16. Subject - PD - 204 A : Die Casting Dies – Theory 19

17. Subject - PD - 204 B : Die Casting Dies – Design 20


CONTENTS

5

COURSE DIRECTIVE 1. DURATION AND COMMENCE:

This course commences in the month of August / Sept every year. The year is divided in four quarters, each quarter will have minimum 11 weeks programme.

The classes will be held from Monday to Friday between 6.00 P.M. to 9.00 P.M. (15 hrs/ Week) for Part Time and Full Time between 8.00 A.M to 5.30 P.M.

2. ELIGIBILITY :

First class Diploma in Mechanical / Industrial Engg. OR Degree in Mechanical / Industrial Engineering with minimum 50% marks in the final year / final two semester

3. ADMISSION : The application are scrutinized. The eligible candidate are called for written test,

Based on the performance in the written test candidates are called for interview and then the final selection of the candidate is finalized.

4. COURSE FEE :

Course fee (Full time) Rs 50,000/- (Part time) Rs 60,000/- (Sponsored) fee Rs 75,000/- for the entire course.

5. Student will be required to pay a convocation fee of Rs 750/- for certificate and marks cards to be issued after successful completion of the course at the convocation function.

6. Students who wish to appear for the supplementary examinations need to pay a

fee of Rs 250/- per subject in the subsequent semester.


SUB CODE :

COURSE DIRECTIVES QUARTER :

SHEET NO. : 1

6

METHODOLOGY The Trainees are given extensive theoretical and practical training in the various type of

tools and manufacturing process. Different components are chosen in a logical order in

different subjects and each design is made by the necessary tooling under the expert

guidance of faculty members.

Design components are given on Jigs & Fixtures, Press Tools, Plastic Moulds and Die

Casting Dies. Some of the live projects are fabricated by the trainees, so that they

visualize the manufacturing problems while designing.

The class room are equipped with adequate audio-visual aids (such as over head

projector, slide projector and film projector).

SOFTWARE EXPOSURE: SOLID WORKS - 2003

SUB CODE :

METHODOLOGY QUARTER :

SHEET NO. : 2


7

EVALUATION & EXAMINATION

Sub SUBJECT Duration of Marks

Code Exams in Hrs Sessional Exam Total

PD – 101 Drafting Practice DT 4 50 100 150

PD – 102 Materials & Heat Treatment WT 3 50 100 150

PD – 103 Metrology & Measuring WT 3 50 100 150

Techniques

PD – 104 A Jigs & Fixtures - Theory WT 3 50 100 150

PD – 104 B Jigs & Fixtures - Design DT 8 50 100 150

PD – 105 A Press Tools - Theory WT 3 50 100 150

PD – 105 B Press Tools - Design DT 8 50 100 150

PD – 201 Tool Room Management WT 3 50 100 150

PD - 202 Cutting Tools WT 3 50 100 150

PD – 203 A Plastic Mould - Theory WT 3 50 100 150

PD – 203 B Plastic Mould - Design DT 8 50 100 150

PD – 204 A Die Casting Dies - Theory WT 3 50 100 150

PD – 204 B Die Casting Dies - Design DT 8 50 100 150

Grand Total 1950


EVALUATION SUB CODE :

& QUARTER :

EXAMINATION SHEET NO. : 3

8

NOTE :

I. a) DT - Design Test

b) WT - Written Test

II. Minimum marks for pass :

a) Sessional and Theory - 50%.

b) Design - 60%


EVALUATION SUB CODE :

& QUARTER :

EXAMINATION SHEET NO. : 4

9

DESIGN PRACTICE

1. TECHNICAL DRAWING THEORY :

Different standards as per IS 696-1972 and SP-42, sheet sizes, layout and planning

of drawing sheets, scale, line and line types, lettering, method of projections,

conventional representation, sections, Dimensioning and Tolerancing, method of

indicating surface roughness for general engineering Drawing, Fasteners,

Welding and structural metal work, Abbreviations and Symbols.

2. TECHNICAL DRAWING DESIGN :

Sketching, Part modeling, Assembly, Exploded view of assembly and Drawing.

- 48 hrs

REFERENCE BOOKS :

1. Indian Standard Engineering Drawing practice for schools and colleges – IS

No. SP-46-1988.

2. Westerman Tables.


SUB CODE : PD - 101

DESIGN PRACTICE QUARTER : I

SHEET NO. : 6

10

MATERIALS AND HEAT TREATMENT

1. MATERIALS :

Introduction, Properties, Strength, Plasticity, Elasticity, Stiffness,

Elastic limit, Toughness, Hardness, Machinability, Endurance Limit

etc.

Tools Steel and its application, “IS” codification of steels, effect of

alloy additions, Tool steel over seas standards, properties, selection

and application, Example of commercially available tool steels, ISO

classification of carbides, material Testing.

2. HEAT TREATMENT :

Iron – Carbon Equilibrium diagram, T T T diagram, Introduction to

Heat Treatment, Quenching and Quenching media, Heat Treatment

process, Hardening, Tempering, Stress relieving, Martempering,

Austempering, Sub - zero Treatment, Case hardening, Nitriding,

Cyaniding, Hard Chrome plating.

Heat Treatment – Tool Room Practice

Heat Treatment – Design Consideration

Heat Treatment – Defects and Remedies

Heat Treatment equipments, Furnace and accessories

– 48 hrs.

REFERENCE BOOKS :

1. Properties of Engineering materials by R A HIGGINS

2. Material for Engineers by M H A KEMPSTER

3. Heat Treatment by Laktin


MATERIALS SUB CODE : PD - 102

& QUARTER : I

HEAT TREATMENT SHEET NO. : 7

11

METROLOGY AND MEASURING TECHNIQUES

INTRODUCTION

Definition of Metrology, Need of Inspection, Precision and Accuracy,

Repeatability, Classification of Measurement, Geometry of Form or Shape

LINEAR MEASUREMENTS

Calipers and its types, Surface Plate, V-Block, Straight edge, Micrometer, Height

gauge, Slip gauges

COMPARATORS

Introduction, Mechanical Comparators, Electrical and Electronics comparators,

Pneumatic Comparators, Optical Projectors and Comparators

ANGULAR MEASUREMENTS

Introduction, Instruments for Angular measurements, Vernier & Bevel Protractors,

Sine bars and Sine Table, Auto-Collimator

SURFACE MEASUREMENTS

Introduction, Different Surface Textures and Definition, Surface Roughness,

Touch, Visual & Scratch Inspection

LIMITS, FITS AND GAUGES

Introduction, Tolerance, Interchangeability, Definition of Limits, Fits Definition

and Types, Gauges, Types and Definition


METROLOGY SUB CODE : PD -103

AND MEASURING QUARTER : I & II

TECHNIQUES SHEET NO.: 8 & 9

12

GEOMETRIC DIMENSIONOING AND TOLERANCING - GDT

Introduction, Symbols and Abbreviation, Datum, Tolerance of Location, Practical

Application

- 48 hrs

REFERENCE BOOKS :

1. Engineering Metrology – R K Jain

2. Engineering Metrology – K J Hume

3. Interpretation of Geometric Dimensioning and Tolerencing

– Daniel E Puncochar


METROLOGY SUB CODE : PD - 103

AND MEASUREING QUARTER : I & II

TECHNIQUES SHEET NO. : 8 & 9

13

JIGS AND FIXTURES

THEORY :

INTRODUCTION :

Definition of Jigs & fixtures, Difference between Jig & fixture, Advantages, Steps

for design.

LOCATION

Degree of freedom, 3-2-1 principle, Choice of location, Redundant location,

Diamond pin calculation, Locating methods and chip control.

LOCATING DEVICES

Surface location, Rest blocks, pins, V-blocks, Equalizers, Profile locators.

CLAMPING

Basic principles, cutting forces, Rigid clamping, Wedge clamping, Cam clamping,

Quick action clamps, Toggle clamps, Simultaneously acting clamps.

GUIDING ELEMENTS

Jig bushes, Standards, Setting gauges.

INDEXING JIGS & FIXTURES

Indexing methods, Linear, Rotary, Indexing jigs, Indexing fixtures.

DESIGN OF JIGS AND FIXTURE BODIES AND OTHER ELEMENTS

TYPES OF JIGS AND FIXTURES

Plate jigs, Box jigs, Indexing jigs, Milling fixtures, and Indexing-milling fixtures,

turning fixtures, Grinding fixtures, Universal jigs and fixtures, welding fixtures,

Broaching fixtures.

- 52 hrs.


SUB CODE : PD – 104 A&B

JIGS & FIXTURES QUARTER : I II III IV

SHEET NO. : 10

14

DESIGN EXERCISES :

Drill Jig, Drilling and Reaming jig, Milling fixture, Indexing jigs, Indexing milling

fixture, Turning fixture, welding fixtures, Turning mandrel, Grinding mandrel,

Broaching fixtures.

- 212 hrs

REFERENCE BOOKS :

1. Introduction to jig and Tool Design - M H A KEMPSTER

2. Jigs and fixtures – T M H GRANT

3. Hand Book of Fixture Design – FRANK W WILSON

4. Jigs and Fixture and gauges for Limited Production

5. Hand Book of Jigs & Fixture Design - BOYES

6. Jigs and fixture – JOSHI.


SUB CODE : PD – 104 A & B

JIGS & FIXTURES QUARTER : I, II, III, IV

SHEET NO. : 11

15

PRESS TOOLS

INTRODUCTION :

Elements of press tools, classification of press, press brakes, shearing theory,

cutting force, elements of press tool, clearance between punch and die, shut height

and daylight, press tonnage calculation.

STRIP LAYOUT

Basic rules, economic layout, bridge size, calculation of plug/point/centre of

pressure.

PRESS TOOL OPERATIONS

Piercing, blanking, slitting, cropping, trimming, shaving, lancing, bending, curling,

calibrating, drawing, Embossing, coining, flanging, fine blanking.

DESIGN OF PRESS TOOL ELEMENTS

Die plates, punches, punch holder plates, stripper plates, calculation of stripping

force, bolster plates, ejectors, shedders, material stops, pillar, bush, slender

punches, stock guides, stock feeding devices and die sets.

TYPES OF PRESS TOOLS

Progressive tools, stage tools, compound tools, combination tools, cam actuated

dies, horn dies sub press dies, inverted dies, bulging dies, levering dies, trimming

dies, shaving dies, riveting dies, assembly dies, lamination dies.

BENDING AND FORMING DIES

Theory of bending, development of bend, spring back, correcting spring back,

bending tools, U-bending, V-bending, forming tools, bending on press brake,

bending force calculation.



PRESS TOOLS QUARTER : I II III IV

SHEET NO. : 12

16

DRAWING

Theory of drawing, blank development, strain factor, calculation of number of

stages of drawing, circular draw, rectangular draw, force calculation, lubrication,

defects and remedies, ironing.

EXTRUSION

Forward, backward, combined extrusion, Modern metal forming techniques.

- 72 hrs

DESIGN EXERCISES :

Strip layout, piercing and blanking tool, progressive tools, stage tools, bending

tools. Forming tools, draw tools, compound tool, combination tool, fine blanking

tool etc.

- 292 hrs

REFERENCE BOOKS :

1. Basic Die Making – OSTERGARD

2. Advance Die Making – OSTERGARD

3. Die Design Fundamentals – PAQUIN

4. Progressive Dies – DALLAS

5. Die Design Hand Book – ASTME

6. Progressive Dies - FTA



PRESS TOOLS QUARTER : I II III IV

SHEET NO. : 13

17

TOOL ROOM MANAGEMENT

MANAGEMENT SCIENCE

Definition, Theory and Practice, Tools of Management Science, Functions of

Managers, Key Ideas and concepts, Social Responsibility of managers and Ethics.

PRODUCTION AND OPERATION MANAGEMENT

Definition, Classification of Decision area, Plant layout, Process layout, Production

system, Productivity, Concept of optimization, Operation Research, Present

Scenario

PLANNING AND CONTROLLING

Nature and Purpose of Planning, Objectives, Strategies, Decision making, Process

Planning, Flow process chart, Group Technology, Process Controlling and Control

Techniques.

WORK STUDY

Foundation of work study, Method study, Time study, Main components of

Method study, Involvement of workers, Work sampling, Applications

STAFFING AND LEADING

Human Resource management performance Appraisal and Career Strategy,

Incentive schemes, Job Evaluation, Motivation, Leadership, Communication

UNION AND INDUSTRIAL LEGISLATION

Trade unions, Industrial disputes, Lockout, Strikes, Labour Acts, Types of Labour

laws, Factories Act, Wages Act, Compensation Act, Dispute Act, ESI Act


SUB CODE : PD- 201

TOOL ROOM MANGEMENT QUARTER : VII VIII

SHEET NO. : 14 & 15

18

TOOL ROOM PRACTICE

Engineering Tolerance, Fits, Conventional Machining methods for tool production,

Milling Turning, Grinding, Advanced Machining methods CNC Milling, CNC

Turning, Jig Grinding, Jig Boring, Non conventional machining methods EDM,

WEDM, Electrode manufacturing process

ESTIMATION AND COSTING

Estimation, Manufacturing cost, Processing cost, Material cost, Estimation of Tool

cost for Drill Jig, Press tool, Injection moulding tool and Die casting tool

- 48 Hrs

REFERENCE BOOKS :

01. Essentials of Management - Harold Koontz

Heinz Weihrich

02. Production and Operation Management – S N Chary

03. Industrial Engineering and Management – O P Khanna

04. Estimating and Costing – J S Charaya & G S Narang

05. Mechanical Estimating and Costing - D Kannappan

A G Augustine

D Paranthaman

06. Industrial Organization and Engg. Economics -- Banga and Sharma


SUB CODE : PD- 201

TOOL ROOM MANAGEMENT QUARTER : VII VIII

SHEET NO. : 14 & 15

19

CUTTING TOOLS

PRINCIPLES OF METAL CUTTING

Types of Tools, Single point tool, milling cutter, Drills, Broaches, Form Tools,

Thread cutting tools, Geometry of single point and multi point cutting tools, tool

wear and tool life, relation between effective setting and geometric angles of the

cutting edges, role or coolants. 12 hrs

TOOL MATERIALS

HSS, Cemented carbides, coated carbides, Ceramics, CBN, Diamond,

Polycrystalline Diamonds. 08 hrs

TURING TOOLS

Index able Inserts, Chip breakers, ISO classification of inserts and tool holders.

06 hrs

MILLING CUTTERS

Standardization, geometry, Face Mills, Shoulder Mills, End Mills, Deep shoulder

Mills, T-Slot cutters. 06 hrs

DRILLING

Drills with index able inserts, Deep hole drills, carbide tipped drills, Core drills,

Counter pores, and Counter sinks. 06 hrs

BORING

Types of boring tool, Boring heads, Cartridges. 06 hrs

REAMER

Types of reamers, Geometry of flutes. 08 hrs

Total 52 hours


SUB CODE : PD -103

CUTTING TOOLS QUARTER : I & II

SHEET NO.: 16 & 17

20

Reference Books:

1. Metal cutting theory and Cutting tool design – ARSHINOV M I R Publications

2. All about machine tools – HEINRICH GERLING

3. Production technology – HMT

4. Tool design POLACK

5. Metal cutting tool handbook – USCTI


SUB CODE : PD -103

CUTTING TOOLS QUARTER : I & II

SHEET NO.: 16 & 17

21

PLASTIC MOULDS

1. INJECTION MOULD

Introduction to injection moulding process, Injection moulding materials and their

properties, Injection moulding machines, Injection mould – initial design

considerations, parts of “ Two Plate” mould, parting line and flash face selection.

Design Manufacture, material and Heat treatment of Sprue bush, Register ring,

guide pillar and bush.

Design, manufacture, material and heat treatment of core and cavity, feed systems,

Ejection methods, cooling arrangements, shrinkage allowance, design of “Three

Plate” moulds, mould design for threaded components.

Common defects in moulded parts and the remedies.

2. COMPRESSION MOULDS

Principle and Techniques, Materials and their properties, moulds and machines.

3. TRANSFER MOULDS

Principle and Techniques, materials and their properties, mould and machines.

– 72 hrs.


SUB CODE : PD–202 A&B

PLASTIC MOULDS QUARTER : V VI VII VIII

SHEET NO. : 18

22

4. DESIGN EXERCISES :

2-plate mould, 3-plate mould, mould with stripper plate ejection, mould with

side cores, mould with threaded parts/ loose inserts, Hand moulds, Compression

moulds, Transfer moulds. - 302 hrs.

REFERENCE BOOKS :

1. Injection mould design – R.G.W. PYE

2. Injection mould design fundamentals – GRANVILL & DENTON

3. Hand book on plastic from C I P E T

4. Plastic Tooling – WILLIAM P. BENJAMIN

5. Plastic Technology – WILLIAM J PATTON


SUB CODE : PD- 203 A&B

PLASTIC MOULDS QUARTER : V VI VII VIII

SHEET NO. : 19

23

DIE – CASTING

INTRODUCTION :

Classification of Castings, Sand casting, Metal mould castings, Plastic moulds

casting, Investment casting, Gravity die casting, Pressure die casting, Advantages

of Die casting, Die casting process, vacuum casting.

DIE CASTING ALLOYS

Low fusion alloys, High fusion alloys, Properties.

DIE CASTING MACHINES

History of die casting machines, Hot chamber machine, cold chamber machine,

Horizontal machine, Vertical machine, Die Locking, Toggle locking, Hydraulic

locking, Injection system, knock out pins and plates, ejector systems furnaces,

ladling or metal in to hot chamber.

FEED SYSTEM

Gates, Runners, Taper tangent runner system, Impressions layout, Spreader, shot

sleeve, shot weight calculations etc.

DIE CONSTRUCTION

Cores Cavities, pillars and bushes, ejectors, bolster plates.

COOLING SYSTEM

Core cooling, Cavity cooling, cooling of shot sleeve, cooling of spreader, baffles,

cooling calculations.

TYPES OF DIES

Single cavity dies, Multi cavity dies, combination dies, unit dies, trimming and

finishing of components, Inspection of components, safety, SPC & visual control

techniques.


SUB CODE : PD – 204 A & B

DIE – CASTING QUARTER : I II III IV

SHEET NO. : 20

24

DIES WITH SIDE CORES

Construction, Actuation of side cores.

DIE CASTING DEFECTS AND REMEDIES

- 52 hrs

DESIGN EXERCISES

Cold chamber dies, Hot chamber dies, single cavity dies, Multi cavity dies, Dies

with side cores etc.

- 196 hrs

REFERENCE BOOKS :

1. Die casting - Buhler

2. Die casting die design - Burton S.

3. SMED



DIE – CASTING QUARTER : I II III IV

SHEET NO. : 21

25

Sl. No.

Contents Sheet No.

1 Course Directives 1

2 Methodology 2

3 Evaluation and Examination 3 & 4

4 Programme Plan 5

5 Subject – PD – 101 Design Practice 6

6 Subject – PD – 102 Materials & Heat Treatment 7

7 Subject – PD – 103 Metrology & Measuring Techniques 8 & 9

8 Subject – PD – 104 A Jigs & Fixtures – Theory 10

9 Subject – PD – 104 B Jigs & Fixtures - Design 11

10 Subject – PD – 105 A Press Tool – Theory 12

11 Subject – PD – 105 B Press Tool – Design 13


CONTENTS

26

Sl. No.

Contents Sheet No.

1 Course Directives 1

2 Methodology 2

3 Evaluation and Examination 3 & 4

4 Programme Plan 5

5 Subject – PD – 101 Design Practice 6

6 Subject – PD – 102 Materials & Heat Treatment 7

7 Subject – PD – 103 Metrology & Measuring Techniques 8 & 9

8 Subject – PD – 104 A Jigs & Fixtures – Theory 10

9 Subject – PD – 104 B Jigs & Fixtures - Design 11

10 Subject – PD – 105 A Press Tool – Theory 12

11 Subject – PD – 105 B Press Tool – Design 13


CONTENTS

27

Sl.

No.

Contents Sheet

No.

1 Subject - PD- 201 Tool Room Management 14 & 15

2 Subject - PD - 202 Cutting Tools 16

3 Subject - PD - 203 A : Plastic Moulds – Theory 17

4 Subject - PD - 203 B : Plastic Moulds – Design 18

5 Subject - PD - 204 A : Die Casting Dies – Theory 19

6 Subject - PD - 204 B : Die Casting Dies – Design 20


CONTENTS

Documents

POST DIPLOMA COURSE IN TOOL DESIGNgttc.co.in/.../08/Post-Diploma-in-Tool-Design_sylabus.pdf · 2020. 8. 4. · 1. Introduction to jig and Tool Design - M H A KEMPSTER 2. Jigs and