TOOL & DIE MAKER (Dies & Moulds) (Common for Press Tools, Jigs & Fixtures) NSQF LEVEL - 4 1° Year TRADE THEORY SECTOR: Capital Goods & Manufacturing (As per revised syllabus July 2022 - 1200 of hrs) here twee DIRECTORATE GENERAL OF TRAINING MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP GOVERNMENT OF INDIA => NATIONAL INSTRUCTIONAL MEDIA INSTITUTE, CHENNAI Post Box No, 3142, GTI Campus, Guindy, Chennai - 600 032Sector; Capital Goods & Manufacturing Duration : 2 ~ Years Trades : Tool & Die Maker (Dies & Moulds) - 1" Year Trade Theory - NSQF Level - 4 (Revised 2022) ‘Developed & Published by National instructional Media institute Post Box No. 9142 ‘Guindy, Chennai 600032 NOMA, Email cherinal-nimig@nic.in Webstte-weww nim. gov in First Ecition: December 2022 Copies 600FOREWORD Tiit Govemmerit of india his set an embtious target ot imparting skills to 30 crores peorte, one out of avery four Indians, by 2020 to helpthem secure jobs as partof the National Skills Development Policy, Industrial “Training istivites (ITs) play m vital tote in hes process ésjpecsany in terre of pyowicsng Skilled manpower Keeping thisin ming and for providing the cusrert incusty relevant skiltraining to Trainees, (Tl syllabus has beenirecently updated with the help of Media Ce-relonment Committee membets of warious stakeholders. Wiz. Industries, Entrepreneurs, Acsdemicians ard represematives trom Tis The National Instructional Media Institute (NIM), Chennai, hss nw come up: with instructional ‘aterial fo sut the revised curncwum for Tool & Die Maker (Dies & Moulds) - Trade Theory- 1" Year (Revised 2022) n Capital Goods & Manufacturing Sector onder Yearly Pattem The WSOF Lavet -4 (Revised 2022) Trade Practical wil helpthe tainoes (0 get an intemationalequvalency siandardwnere thelr ‘skil profidency end competency will be duly recognized across the globe and thes wll ao increase the nope of recognition of prot teaming NSGF Level. 4 (Revisedt 2022) ines will also gettne opportinties te promote Ife long learring and skifi development, Ineve no cdubt thal wih NSGF Level = 4{Revised 2022) the-trainers and trainees of [)s. sndial stakeholders will ative mavarmum benef fram these Instractions| ‘Media Packages IMPs and that NINFs effort will 90-4 long way in improving the quailty ot Vocational kraming inthe sourtry ‘The Exboutive Detector & Staff of Nill and menibers of Meta Development Committee deserve appreciation for thelr contribution in bringing out ths publication ai Hind Ms. TRISHALJIT SETHI, Adc Secretary / Director General (Trarung) Ninsity of StallDevelopment & Entrepreneurship] Govemmentot Inds New Dain - 710.007 (iaPREFACE The National insirudional Medks Institute (MIMI) was estabfahed in 1886 st Chena by then Directorate Genera! of Emeloymert ara Treming (0.GE@ 7), Ministy of Labour and Employment, (naw reser Ovectorate General of Treining, Ministry of Skil Development and Entrepreneurship} Government of inci with techrical assistance {tamithe Get. of Federal Re-puttic of Germany, The prime atkective of thes Institute sto develon andprevide instructonal materials foc vanous trades as per the prescribed siilabi under the Crafteman and Appferticestip Training Schemes. The instrustionst materials are created keeping m mind, the mein objective of Vecatlonsl Training ander NCVDNAC inna whichis to heloan indhc.alta master sis ta do ajob. The Fsiructonat materials are {énerateain the form of inaiructional Media Packages (IMPs), An IMP cahaists a! Theory book, Practical book Testing Assignment book Insiructor Gul, Aucio Visual Aid (Wall charts and Trartrareneles} art other support materials The trade practical book consists of series of exercises to be complated by the bainees inthe workshop, Thesé exercises are desighedito ertsure that athe skils inthe prescribed syllabus are Covered: The trade (neory book provides related theoretical knowledge required to enable the trainee to-do-a job The testand essighmerts wil enable the insiructo’ to gve astig iments forthe evaluushon ol the performance ofa trainee The Wall charts and transparencies are unique, as they not only helpthe instructor to effectively presenta \opic txt aise hep im fo assess the trainee's undersianding The bretructoy guide enables the instructorto plan hes schedule of instruction. planthe rawimsteralrequarements day to day lessons andidemnnstrations. IMPa aise diebia with the compte’ skits required to he-chrvelopedto# eflacive teamwork Necessary care has alco been taken to include important skil areas of alled tradesias presoribed in the syllabus, The avallatiity of # complete Instructions! Media Package liv an institute helps both the trainer and fmanagement 5 lmpatt effective froaningt The IMPs are the outcome ofcoliectie efforts of the slat inembers of NIMl.and the members ofthe: Media Deveiopment Commifiess Specialy diawn fam Pubic and Preis sectorindusties, various raining insitutes under the Directorate General of Tairing (OGT), Govemment.ard Private The NIM woul ike to take this eppctinity to corhvay sincere thanks to the Directors of Employment 2 Training of venous State Governments, Training Departments of Industries both in the Pubtic and Private sectors, (Officers of DGT anaiDGT fret insizuses, probf reacers, indivigaal media devetopersand coordinators, but for whose active Support NIM Would not have been able to-bnng oUt this matenals,Sa_—SSaSa——_—_—_—_s_O_E Sa. ACKNOWLEDGEMENT Natona! instruchonal Media Insttte (NIN sncereyy acknowtedgns wih tanks forthe co-eperaton and contribution emended by the following Media Developers and thes soonsaring orgarssation to bring out ne IMP for the rade of ‘Too! & Die Maker (Dies & Moulds) - 1 Year Trade Theory -NSQF Level «4 (Revised 2022) under the Capital ‘Goods & Manufacturing Sector for Tis. (MEDIA DEVELOPMENT COMMITTEE MEMBERS. Sha A Vievarsotevan Assistant Oreatoraf Training (Ret). ATI, Chennai -32, Shri M Sarhpaths — Training Officer (Reta), CT, Chemis 32 Shel RNimai Faia Assistant Professor ‘SIM Institue of science and Technology Ramapurarn Campus, Chennst ‘Shai A‘Srinvasan ‘Consultant Solid Works, NIMICheninat NIMI- COORDINATORS ‘Shei Nirmaiya Natn = Deputy Director, NIM, Chennar-32 ‘Stei'V Gopataitishnan — Manager NIM, Chenneat=52 NIM) fecords ds appreciation of he Data Entry, GAD, DTP Operators for their excellent and devoted services in the process of Gevelopment of this instructional Materiat NIM #80 abinowiedge-s with harks, the invahiatie atforts ronde/ ee by ail other tat wie have Conte tid tv te de-veloprnent of this instructional Materia) NIM! is grateful to ail otsers who have directly or indirectly helped in developing this (MPINTRODUCTION TRADE PRACTICAL The trage practical manus! is mtented tn he-isectin workshop It consists ot a series of practical everoises tobe completed ty the trainees currathe ons yesrcourse of ihe Tool & Die Maker (Oles & Moulds) Trade supplemented and sunporied by instructions! informations to assist in performing the exersises These exercises are designed to ensure that al the skis in compliance with NSGF LEVEL -& The marualis divided into SIX modiuies: Mode? = Safety Mogue2 = Fitting MogueS = Timing Module 4 E Milling Modules = Grineting Module 6 = AutoCad 8 Pro-E The skill trashing inthe shop fidar is planned througha Series of practical exernises centfed amUnd ome pradtigal project. Hawever, there are few instances where the individual sxetcise does not form. bart of progeet \Whie developing the practical manusia sincere effortwasmade to prepare eachexereise which willbe easy lounderstsrctand carry outeventy below averagetreinee: However the developmentisamacoeptthat neve fs 2 Scope for further improvement. IMI, looks forwacd tg the suggestions from the experienced training foculty or impryingthe manual ‘TRADE THEORY Themenual tirade theoty consists of theoretica information orthe one year courseot the Too! & Die Maker Trade The conterts are sequenced doaceding tothe practical exercise contained in the manuaton Trade practical Attempt has been mace fo relate the theoretical sspects with the skill covered in each exercise to the extent possible. Ths co-relabon is maintained to help the trainees to develop the pereeptanal Capabilities for pertorcaing the sicils: The Trade theory hastobe taught aridieamtakongwithtne corresponding exefcisecontainadinthemanLial ontage practical The indicating about the corresponding practicalexercisearegiven in every sheeto! this, manuat ILWil be preferable ta teachvigarn the trade theory connected fo each exercise atleast one class before erlorringthe related skits mthe:shop fear. The ade theory is abe treated as an integrated part of each exercise The material is not the pupose of well learhing anc should be cohexdered 26 s./pplemertary to class ioom instruction. . )CONTENTS Lesson No, ‘Title of the Lesson Learning | Page No. Outcome ‘Module 1: Safety 14.07 ‘Guide lines to work with nations! skill training institute system: inchuding store's procedures 1 woo Salety and general precautions in ndustey/ehop floor 3 1.1.03 Firstar 5 1904 Disposal of waste material Az 11.06. ‘eoupetionsl satety and heatin 14 71.06 Satety signs 16 4407 ‘Response to-emergencies 18 44.08 Iinportance of house keeping 19 71.0514 Operation of electrical mains 1 2 1142 ‘Games to improve your memory B 1s ‘Matrvation a Module 2 Fitting 12.15, Bareh vice Tt 1216 Elements of a fie 2 1297 ‘Harrmers S 4248-49. | Unearmeseurement ad 4220 Verner calipers 5 1204 Masking rhedia oA 4222 'V Blogs. oe 1223 Daal lest incieators 6 1224 Mase production and interchangeable manufacture: ar 1225 ‘The Indian standard systern of ims andifits - lenrinology, a 1226-27 | Geometries! toletanong 105 4.228 Physica and mechanical properties of metals n2 4220 Heat reatmentiof piss carborstesis ne 1230 Gefininon of machine and machine toot 14 Module 3: Turning 1431-33 | IntreduetiontoLatne 128 1434 Lame operations -facing 135 4335 Lathe cutting tools 44a 4938 Different Types and Specificabons of Carte Tools. 148), 433738 | Types of chips, chip brakers and too! Ite +51 (oi)Lesson No, Title of the Lesson Leaning | Page No. Outcome 1338 Lathe caving mecharesm fora gear types 465 1340 ‘Orihogotial cutting and oblique cutting 461 1341 Lathe accessories - work hokting davioes Four juwohuck 5 42 1342 Koutliog. meaning necessity types, grades of cuter end speed forknuring 168 1343 Casting Too! Matetiats a4 1344 Typesottaper 7 11345 Sine bar-Desooption anduses 183 Module 4; waiting 1445 ‘Miting necrines 19 aa? Construction and specication 192 ade DeWviti andifeed mechanism of ming machine 188 1.449°50° | Diterenttypes of milling cutter ad their uses - cutter nomenclature 19 1451 Miling cutter jratenals 2oT 1457 Von holcing devices 208 1489 Miling cutter hokGing devices 6 20 4444-55 | Miling process a3 1456 Cutting seeedanctees 28 1457 Machining time for miting = 1458 Mlltng machine operations 2 1489-60. | Miling attachments, 224 1481 Coolants 28 1462 Indeoang or cvigra head a Module 5; Grinding 4563-66. | Introductonto:grinding machine types: cid 1567-68 | Grinding wheels, rypes. appecation 7 23 1599.72 | Marking system andiselection of grinding wheel 8 25 1873-74) | Procedure tar mounting of ginding wheels: bdlancingget 8 gondngwheets aT 1575-80 | -Gpncing wheel -Abrasives - Bond ‘Grade- Grt-structure 28 8: AutoCad 8 Pro -E 4581 ‘Auto Gadot dx screen components 10 28 1642-83 | Inteducpemio creo 20LEARNING/ASSESSABLE OUTCOME On completion of this book you shall be able to ‘SLNo. Learning Outcome Refer Ex:No 1 10 Plan and organize the work to make job as per specification applying different types of basic fitting operation and check for dimensional accuracy following safety precautions. [Basic fitting operation — Filing, Marking, Hack sawing, Drilling, Taping, chipping and Grinding efc. Accuracy: # 0.4mm) Make different fit of components for assembling as per required tolerance observing principle of interchangeability and check for functionality. [Different Fit Open, Angular, & Square Fit; Required tolerance: £0.08 mm, angular tolerance: Adegree.} Set different shaped jobs on different chuck and demonstrate conventional lathe machine operation observing standard operation practice. [Different chucks:3 jaws & 4 jaws, different shaped jobs: round, square, hexagonal] Prepare different cutting tool to produce jobs to appropriate accuracy by performing different turning operations. Different ‘cutting tool - V tool, side cutting, parting, thread cutting (both LH & RH) Appropriate accuracy: £0.06mm, Different turning operation — Plain, facing, drilling, boring (counter & stepped), grooving, Parallel Turning, Step Turning, parting, chamfering, U -cut, Reaming, intemal recess, knurling. Set the different machining parameters to produce threaded components applying method! technique and test for proper assembly of the components with an accuracy of £0.05 mm, [Different threads viz., metric) BSW/ Square) Set the different machining parameters and cutters to prepare job by performing different milling operation and indexing. [Different machining parameters — feed, speed and depth of cut. Different milling operations — plain, stepped, angular, dovetail, T-slot, contour, gear milling] Produce components of high accuracy by surtace grinding operation. [Accuracy of +/- 0.02 mm] Produce components of high accuracy by cylindrical grinding operations. [Accuracy of +/-0.02mm.] Sharpen different cutter or multipoint cutting tool. [Different cutters end mill cutter, side & face milling cutter, single angle ‘cutter, Reamer] Develop isometric drawing and solid modelling of mould using CAD & Pro-E. 1.4.01- 227 1.2.28 - 1.3.30 1.2.31 - 1.3.33 1,3.94-1,3.43 1.3.44 -1.3.45 1.3.46 - 1.4.62 14.63 -1.5.72 18.73-1.8.77 1.6.78 1.6.79 -1.6.83 oeSYLLABUS Protessional Skills Hint ‘atarknca Professional Knowledge Learning outcome (Trade Practical) (Trade Theory) With indicative Hours [Frofessional | Plan end organize the | 1 Introduction of trade sill end vrork| AR necessary guidance tobe provided skin 138 | Worktomake jobasper | appiication. (O2nrs.) tothe newcomers to become familiar rs specification applying:| > - Safety amuude develooment ofthe] with the workin Industral Training Froressonal| “Meter! Wypes of basic |" irainte by educating Beto use| nstute system Inclucng stares ecweage | ORME epefation a | Personal Protective Equipment] plocclses: Safe working pracioes ie (PPE) ths) Soft Skis, ts importance and Job senuracy fokowing safety area after completion of precautions [Basic | 2 Fist Ad Meined and basic t@iNiNg | cing timontance of safely and fitting operation = Fitog. Grin Taping chipping and Grinding #tc Aopurecy: + Osmm} nos cscimace (Ohes ) 4 Sate disposal of waste matensis| like cotton waste. metal chips! Dumrsete (Othe) 5. Hagerd identification and] ‘avoidance, (O2nK8 } 6: identification’ of safety. signs for Danger, Warning, caution &| personal safety message (07 he 7. Preventive measures torelectncal Botidtents-& afer to be taken in such accidents. (Ochre) 8 Use of Fre extinguaners. (05s 9 Practice and understand] precautions to be fatlowed while working ifiting jos: (02 his) 10) Importance of tiade training, List of tools. & Machmery used in ine! trae (01 br) ‘1 Sate Use ot toois and equipments sed in the trace (010) 12 Knowing psmes and memary trairang- (10 has.) 13 Motivational talk by experts. (e2s}) 14. 5S training. (02 hrs) 18. identification of tools Requipments as per desired specifications for filing and marking, visual inspection of raw material for rusting, scaling, corrosion etc. (03 hrs.) 48 Familarisation of beneh vice. (othe 17 Filing: Wesiiterent’sector and Treasure with ateet rule (25 hrs.) 18, Mark with scrinerand stes) rule (04 he) 19 Measuring practice wilh siee! Jule, outside & inside calipers (06hes.) General precautions observed inthe industryshop floor. Introduction of First aid. Gperetion of electrical mains and electrical sataty Introduction of FPEs Response to emergencies ®-9 power failure, fre, and system fallure.mportance of housekeeping &. good shop floor practices. Introduction to 5S concepre its. application Occupationa| Safety BHealthiHealin, Soiety and Environment guidelines, lsgreiations /S reguiations as applicable (08 tvs) Bench: work — Meta working and tools and devices —Work bench — vices = files — hacksaw «hammer — spenners—screw divers Unter measurements-Ms units, steel Tule dividers, Punch —types ard uses Description use and care of marking table. (05 Hrs } a20 Del punching and letter and purnber puncreng (05 tins) Vernier caliper —its parts, principles reading, uses andicare |Cuitsicle micrometer — its parts, pinciptes, eacing uses andcate, verter height gatige Marking toots — seriber Marking out — Coordinates system, Rectangulat ~ Polar “Rises lot marking Bevel protractor, combintion set- their lcontponerits, uses and cares: Pedestal grinder star wheel oresser, safety Precauions, care and martenance, (12 } 24.Grinding. centre punen, dat punch, fist chisel ond scriber (10h) 22 Dall gnnding practice: (10hrs:) Marking media, special application [Surface piste and auxiliary marking equiomert, 'V block, angle planes paral! block, description, types uses, accuracy, lcare and maintenance. Cri Tap, Oiesypes Sapplication. Determination of tapdriteze: Reamei- material, types {Hand and aching reamet), prts. and their uses, stemmirang hole size for earning, Rearing procedure. Drilling machinestypes and |theit application, construction of Pillar & Radial driling machine CCountersiink, counter bore fd epcitacing ‘and nomenciature Cutting Speed, depth of cul and Drilling time lcalculations. (0SHrs ) 23. Drill Plate fling to an ateuracy of | 20.05mm (10hes) 24 Marking for centre punching cling, rearneg,tappang, courter| boring, caunterssinking (02-hrs ) 25-Centre punching deiling, marteg, fapping: counter boring, courter sinking on dell plate: (12h) 26 Die pass on standard matenl| (M8) (08's) 27. Cutting too filing snd gnning on| standatd matecal (10 hes) isl test indicator-its parts, types, canstnuction and Uses Ihtecchengeatiiny Necessityin Engineering field, Lim Defintans types, terminology of linda and fts-basic size, actuateie, deviation, high and iow lint, 2e%0-ink. toiwtance Zone, showances.Dillerent standard systerns of fits and limite. Geometrice! tolernce Bntish stenaard sysiem BIS system (106s) Skil 110 Hrs: Professions innowledige Hrs Marking ferent of components. for assembling as pet required tolerance! observing pnncinie| of interchange ability and check for functors, [Different Ft Open, Apguiar & Square! Fa, Requredtolerance: +005 rom, angular tolerance 1 Segre | NOS CScnoapg +28: Make Male & Female ‘Open’ ting | Wihaceuracy £0.08 rem (25 hrs.) Intreduction about metais, aitterence between Metatand Non Metal, properties: fof metal, Clessitication of metals and its |applications, pig — Iron, cast ron, wrought iron, steel-plain carbon ste! (Low eartion, steel, medium andthigh carbon steels, high Spied tee), tainjess steel, camides, etc) (04 Hes.) 28 Make male & female for square| fit with accuracy + 0.05 thm (Soh) my, Heat treatment of metals, process such a8 annealing, nit riding, hardening, empering, case hardening carburizibg.cyanicing, Meme hardening Induction hardening, purpases and its jefflects.an the propeities of steel. (08 Hrs.)38, Angular filing with mote & | Getingtoknow ire lathe with main femele (S0.nre:) ‘components, ever positions and Assembly tit with male & female | vanous lubrication nents as well, by cowelling ana screwing (25 | Defintonof machine & machine tool is.) and it classitication (08 Hrs } Professona! | Set different shaped |51 dermify & function of ciflerent | Ihtreduction to lathe Centre isthe ‘Sidi 32 Hrs: | jobs.on different chuck. parts of lathe Practice on | construction, detail functiorrot parts. Proressionat [299 demonstrate | operational lathe (cryridierun), | specification, Safety points to be Krowiedge [conventional lathe | (10ne}) Sbseredwhile workengona lathe (07 oT He Machine operation 139 setting athe on diferent speed | HS) observing standard | toed (oh ) operation practice (ork 33: Profile tiring using hand tote: aie Be 3 sive | radius external and Imernal shaped jabs. found, | 0hre) ‘square, hexagonal] NOSCSC/NGS16 Professional | Prepare different cutting | 34 Gnnding of RH and LH tools, | Ditferenttypesot Lathe operations - SH SE:'HiS : | fool to produce jobs to | parting teal, Round nose lwol. | facing: tuning. parting-off, grooving, Professional Somes skier (e8hrs) chamfaring, boring etc: Lathe cutting IKrowedge [performing different | 35 Ghecianjotangies with angle | t00!-Olflerent types, shapes end ot te: lurning operations..| ~ gauge/ seve protect (2Fre) | sillerent angles (clearance, rake et) [onerent citing oot -' | 36, Grinding: of ‘Vt tots. for | specication of ithe toots too}, side cutting. |" cacing oF Aetna’ cnnion | TYPESO! chs chip breaker Too! Me, parting, thread cutting | ee oars) factors afecting tool ite, (10Hrs) (both LH & RH), 5 Srerepilate seaurecr | 37 Plan tuming (notin 4 Jaw 40.06mm, Diferent | chuck). selene a erie fuming operation—Piain, | shoulder; charrferinginbetween facing. drilling boring:| Santres:as. per dimensions. (counter & stepped), | (Bhs) Qrooving, Parallel Turing | 38, Piltarturming between centres: Step Turning, paring, | _ (7 hs) chamfering, U -cUl, (35 Bushiurning. ailing andboring | Driving mechanism speed and teed Rearing eke] rearmng (14 rs.) mechanism ot Lathe Concept of recess, 40 Tuning andi passingma: | Orthogonal anc Oblique Cutting RESEICINEIS standaramatorial (O3fire,) | CAUCRS & afferent types.ot ab botang 4 Rinpunehtutning sretinuring | Cetices 20 athe tnd acvariages of Poteet . | Mounting ana dismaunting of 42 Using 4— jaw chuck fate both | chucks. Knufling:types, grade:& Its side of a plate thickness as per necessity. Vernier Bevel Protractor — ceed Ci tya) paris reading and uses, (04 Hes) 43 Tapertuming male andtemalé | Various material for single paint Work pieces and assembly, | cuthng tools, tip tools: their brazing: (nes) and grinding process. (07 Hrs) Professional [Set the afferent] a4 Extermalthreadcutingonstep | Calculations of taper turning by of Skit 25 His ; | macrirwng to] “tumed wark piece. (Metric, | settngtat stock Profissiona: |Pfouce threaded! —BSWa Square Tread) (15hrs)) | Sine Bar — description & Uses Kowiedge |compensnis APPIV(NG| 48 Turrijob for inlemnel thiead and | Slipgivoe description andiuses {05 6H ‘Tmathodi technique and] “ culinternal thread (10 hve); | Has) test for proper, assembly of the components with an acourasy of + 0.08 mm. [Diferent threads viz, matric BSW Square) NOS CSCHIRE(Professional | Set the different ‘Skil 4128 Mrs Professional Knowledge aH) mecnining parameters and cutters to prepare jeb by performing different milling Operation and} indexing, [Dilerent machining Parameters — feed speed anid capi of cad Bitferert ming operations —piain, stepped, angular, dovetail, T-siot, ontot, gear milfing) NOS cSCANOstE: Produce components of high acouracy ty. surface gtinding operation [Accuracy of +/- 0.02mi} NOScscNes18 48 loenttication of milinig machine. (02 ws) 47 Demonstrate working puncte of Milling Machine. (02 hrs.) 4B, Sel vice & jobron the table of Milling Machine (a3brs) 49, Set atbor on the spindle of miling machine. (04hrs } £0. Set ine cutter on arbor (o2nes.) 51, Safety points to be observed while ‘working ono miléng machine (02 hrs.) Milling Machine importance, types construction and specification’ Driving and feed mechanism of Lda Litt Different milling utter angies| Miling cxtter materials (05 Hrs ) 52 Demonstvate Up Miling and down Milling Process: (04 hrs.) $3, Perform sequence of milling for six faces of 2 solid block 2 numbers (13 hrs) $4. Check the accuracy with the heip off epee ti net height gauge (02 tes 55, Perform Step ming using side’ and face cutter checking with depin micrometer, (05 hrs.) Job holding devices-vioe, clamps: \ bieek. parallel biock ete Miling cutter holding devices, mina process ~ Up: mailing and Dawn miliog, (02 Hrs } 56 (Milling Blank piace (Dtain miling) \ (1D. hrs) 57. Slot milingwith site and face cutter (08 hs) 58.90" anguiar miling with equal angle ssutten (08 hrs.) ‘59. Dove tai iting, (09 tis} 60. Tee stot miling. (08 hrs.) Calculation of cutting speed feed mschiningtie for miling machine Miling machine operations. Miting machine attachments — vertical meling attachment, (03 Hrs } 4. Concave arid Convex nilling. (1815) Intrecuction to coolant & lubecant- ference beyweenther, types and uses of each, (03 Hrs.) 62 Simple indexing peactioe {30H ) 63 Kdentification of different types of ‘atinaing machine. (02 hrs.) 64 Wheel balancing & tuing (06trs:) 65 Dressing of ginding wheel (02tvs.) 80 Grinding of block (ex sides) in’ sutace (grinding machine within accuracy of 4001 mm (15hrs } 67 Grinding of step block in surface Stinding machine with anaccuracy of £00) mmm (5nre) Dividing heed — introduction, construction, types. Simple and universal divicing head tndesting [metneds — direct Incereng, simple indexing, angular indexing, tts ‘alctistions. (05: Hrs.) Grinding machine introduction, types, Surface & Gyinarical grinding | Mastine- their parts, functions, specication, and uses. Safely points tobe observedwrile worteng ‘ona Gtinding machine (05 Hrs') ‘pati)68. Grinding of slot back in-surface Grinding machine with an accuracy bf£0.01 mm (15 tes ) 69. Set and pertorny'angiar grinding Using Sine plate to stranded angle 8mve) 70 Make slide Mt (maleifemaia) (t2rs } 7), Pertorm form grincing. (08 hrs.) Grinding wneel shapes and sizes Stanciard marking system, Selection of ‘pining whee! (G4 Hrs) 72 Teper angie grinding fitting (1Shrs) Professional | P fa @ ue e| Cylindrical grinding: Procedure for mounting of gripding Ski 66 Hie. | components of | 73 External Paralle| grinding | Wheels, balancing ot grncing wheels, Protessonai | Hot accuracy by | (Bothnokéng inchuck/ collet arid in | Dressing. esol oresser Glazing end oyircicat grinding | between centres (17 Fis.) Lacing of wheels — te Cauces end Koowtede® | operations femedies Roughness vaiyes and Seite: [aoutnag of «| a cmnaeonreiog fos bre symbols. Explain the impartance and 903mm] necessity of quality. (04 Hrs), Nos.cscosi3 Cylindrical grinding: ‘Abrasives ttstypes, Bond Grade. Gi 75.internal Parallel grinding (Bath | #rusture (04 Hes ) aking inchickicollet) (20h ) 7B Grinding of step in Cylindrical ‘grincing machine with an Bocuracy Of 40.01 mm (15 hes.) - 77 Grinding of exter laper in (Cylindoca( grinding machine withan accuracy of 20.07 mm. (40hirs.) Professional | Sharpen ailterent| 78 Demonstrate enc prachce of ninding | Too! & cutter gnnder‘construction, use [Skit 30 His, |cutter or muipoint| of end mil cutter of cifferent sizes | Sodspecttcation (04 Hrs ) Professional (Cutting tool | by using fool & cutter grinding [Different cutters—| machine. (30nrs ) Knowledge 04 ae ‘end mil cutter side & face milling outer singe arale| ‘cutter, Reames] |NOS.CSCINDS16 [Professional |owelopicomeinc | 70. Prepare simple mould design | AutoCAD: introdustion to AutoCAD, [Skit 108 Hrs. drowing andsoid | craunrgewithtesiceofAtOCAD ve, | creating frstkawing learning the tools Frofessional | modeling of moult | Base andadverced 20 drafting crew | {rade, organiaing the work, drawing the Knowledge 28| using CAD&Pro-E| commands, Constraints. Modify | trst mould (14F4rs.)) Hrs. NOS CSCHoda commands, Layers, Line types: lock, Texts, Alinbute. Table Dimensioning, Isometric, Solid modeling, View port (58 hrs, BO Prepare solid: maadeling of simple mould with Pro-E [Sketeh. Part (solid, surface, tree. style; Nexibhe madelling. sheet metal ), Assembly, Creo drecl, Creosinaiste) (25 tre) 81.Creating (NO assembly and mould cavity) drawing, (10 rs) 52 Partdranveg ottne universal coup ‘assembled all the parts and sol mmadeling and denoted by poloured combination (15te3 } Pro-&:Famalianzavanot intertace/ Windows, Siketoting, basicmodetng, evenced modeling. asserting, drawing, -stxface modeling, manufacturing = mould designawareness, (14HrS | tov)CcG&aM Related Theory for Exercise 1.1.01 Too! & Die Maker (Dies & Moulds) - Safety Guide lines to work with national skill training institute system including store’s procedures - ‘Objectives: Af the end of this lesson you shall be able to + state whot is ITI and bret the objectives of 111 * describe the organizational chart + st out the infrastructure available in ITI * explain the job opportunities and cartier development after complation of courses. + brief tire examination pattern and soft skilts. Introduction to ETI Industrial Training tnsttutes ((7) ard Industral Training enters {1710} comes under Grettsman training Seneme (GTS) to provide Vocatioral treiring in various trades functioning under Directorate Generalof Training(OST), Ministry of Skit Cevelopment and Entrepreneurshi Govemmmentot india [TigandiTCs areoneand the same: (Tle are govérnedty the statevunion gavernment wheress, the ITCs are sett- Ainencing institutions to provide seme training coursesas. ITF. Tredetest fot Tland!TCirainees arecomrronandthe National Trade Gentticae issue by the National Coure for Vocabonal Traming(NCVT}is ofthe same standard The abjectives of an Im ‘The objective of an IT lietoensunnga steady fowat sialad \Wworkers.antto reduce unemplaymentamong the educsted {youth by training & equipping for suitable induetriat ‘employment andas wellas for se'f employment The instaute imparts trang in-engineenng ane nen ‘engineering wo years/one year trade courses approved by the Governmentof india mconauttation withthe Naboral ‘Councilor Vocationat Training, Netw Delt ‘Structure of 1 Therstructune of industraltraining institute chown inthe: following chart tt may vary state to state It explain the information order figwfromhighersuperiot offciaistothe ‘groundievetoicials. The workinghouremay difer ciateto ‘slate ‘The trade master ls the overall ip-chaige for the parteular ade the trainee has to report to trad master inevery Fithare is a store endtheimcharge of the'storeis siofekteper tor inward.and eutward movement of foots sequiomertandoonsumatiea Theinetructorwillinderttne ‘halting requirement for he training purposes Asst raningortcer Jaron Tawing Offer Workshop Asst Government Industrial Training institute Assistard / Account / Store Keeper| | Glunior Assistant Typeet Record Clerk [otfice Asst J Weichman (SweeperInfrastructure available in {TT's Toprovide 100% practical irainingtothe: equipments, machineries and classroom faciities are available a T?s.Continvous learning process! programs are conducted in reguiat infervais.3s per the insiructions pwenbytneDGT ‘The following facilities are available in (TI's - Hostel faciives + Libraries = Soft skis Ib computes tabs - High end elaestocims femart Sass + Stores = Sports + Wil enabled campus. + Inckvsirial isits/ Indusinalist questiecture + intemnshiptrainingein the job training = Apprentice proatacns = Campusinierview ete ‘CTS Admission Process ‘Online counseling \s condycted Statewide selection ie mada ch meritbesis duly fallowingrutes of reserv ‘The candidates exercise the option of choosing the (71 and trade of thelr choice Students behveen the age of 14 - 40 ate admitted in Industrial Training Institules. Admmesion is made during: the month of August every year Craftsman Training Scheme Exam System Final Trade Test is conductedon All india basis andthe ‘question papers are issLedto all Trade Testing Centres onthe same day by the NCVT. Passed-out candidates areissued with National Trade. Cerificate (NTC) under the seal snd avthonty of NCVT by DEF, New Delhi Job area after completion of training This highlights thé employability aspecton completion ff training. The trainee should be aware of vanous prospects available in presen| market scensno along witfheco pefor self-employment For example atraines wi NTC engineering trade may opt for various jobs available inifferent incstries inindia and strand ‘After suecessful completion of raining in any one ct the engineering trade one can seek appointment in ‘engineering workshop Factories (Public Sector. Private ‘Seetotand Government industries) in india and abroad as technician / Skilled worker. Self employment Che can start is own factory / ancillary unit or design Products manufacture and become an entrepreneur Further learning scope “Apprentice training in designated trade + Croft instructor certincate course + Diplomainretevant Engineering. Skill competition All India Skill Competition for Craftsmen scheme at tional level was introdused to fester a healthy, competition amang the traineesof Tis /ITCs Indie Skt) competition is organized by National Skil Development Corporation , India sill competition the country’s biggest ski! competition is designed to demonstrate he higheststancards of siifing andotfers 2 plattorm to. young people: to: show their tafent at pabonallevetand internationalievets The competition isnowheld every yearin 1Strades ve Instrument Mechanic, Electronic Mechanic. Welder Fitter, Tumer, Machinist, Mechanic Motor Vehicle, Foundry man, Electrician, Cuting & Sewing, Computer Operator &yograriming Assistant. Draughtstnan (Greil), Draughtsman (Mechanical), Mechansc Diesel and Mechanic Refrigeration & Air-Conditioning: The best tremeenfeach of the abovetrages atthe State level competition Competes at the All Indra’ Skil) Competition Awards The best Crattimen ineach ot the above 15 trades at tne All insta levelere awarded mert oertificates.anda cash prize of Fes: 50,000/- each TFs whose trainee stands first in the competition al the All India Skill Compettion fs awarded a mer certificate and declared as the bestT! Approach on softskills Soft shits - refer tothe cluster Of personabity traits seclal graces, facility with language, personal habits, (riendiness. and optimize that make people to varying. degrees. The same can also be defined as.abilty 10 Interact communicates positively and productively with others. Sometimes called "character skill” Mate and mare business are considering soft skis 8s snimportantjobertens. Softskils are used in personal andprofessicnallfe Hardsiilis techrcal skills donot matter without saft skits 2 G8 M: TDM (Dies & Moulds) (NSOF - Revised 2022) - R.Theory for Ex. 1.4.01CG&aM Related Theory for Exercise 1.1.02 Too! & Die Maker (Dies & Moulds) - Safety Safety and * state the importance of safety eral precautions in indust Objectives: At the end of this iesson you shall be able to floor * list out the safety precautions to be observed ina industryishop floor * list out the personal safety precautions to be observed in machine shop * fist out the safety precautions to be observed While working on the machines. Generaty accidents\donot happen: they are caused. Mast scaidents are avoidable A good craftsman, having & homwledge of various safely precautions, can avaid acodents to himself endito bis felow wotkersand protect the equipment trem any damage To.achieve this, tte esseniialthatevery person should follow safely procedure (Fig) Salety in a workstop can be trosdly clashed into 3 categories ~ General safety ~_ Personal safety. = Machine safety General safety Keep the tloor anal ganaiays tlean and oir. Move with esrein tne wosieahop, do not tun. Dai leave the mactshe whish isin notion: ‘Don't touch ior handle amy equipments machine unless authorised to do'so. (Dott walk under suspended loads: ontrack practical jokes wile om work Use the appropriate toots for the jab, ‘Seep the tools al their proper place. Wipe out spit cil immecnately Replace wom ou4 oF damaged looks mpmriediatey, Never direct compressed air al’ yourself or at yout ‘co-worke, ‘Ensure adeguate light inthe Workshop ‘Clean the machine only when it's hot in mation. ‘Sweep away he metaleuttings ‘know everything about the machine before you Start Personal safety ‘West a one piece everall orboller sut ewp the overalbuttons fastened Dorit use ties and scarves ‘Roll upthe sleeves tightly abee the elbows ‘Weer salety shoes of boots ‘Cut the hair shor. ‘Dorn weer a ning, watch or enain. Never learionthe machine. Dorit cles hands in tne coolant fui Dod vemnave guafds wheit the machine isis motion Dont use cracked or chipped tenis. Dont start the machine unt — theworkputce is securely mounted ~ theteed ot mchunery ie the neutral = the workarea se dear nant Bont adjust clamps or holding devices while the meichine Is in ration (Never touch the electrical equipment with wet hands. ‘Dorit use any faulty electnea equipment Ensure that electrics) connections ate mage by an suthoraedelectreanenly ‘Concentrate on your work Rave a calmattitude