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 including
surface roughness for general engineering drawing, fasteners,
welding and structural metal work, abbreviations and symbols.

2. TECHNICAL DRAWING DESIGN:

Sketching, part modeling, assembly, exploded views of assembly
and drawing.

REFERENCE BOOKS:
1. Indian Standard Engineering Drawing practice for schools and
colleges IS
No. SP-46-1988
2. Westerman tables.

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
overseas 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 process, hardening, tempering, stress reliving,
martempering , austempering, Sub- Zero Treatment, Case
Hardening, Nitriding, Cyaniding, Hard Chrome plating.
Heat Treatment - Tool Room Practices
Heat Treatment- Design Consideration
Heat Treatment- Defects and Remedies
Heat Treatment equipments, Furnace and accessories

REFERANCE BOOKS:
Properties of Engineering materials by R A HIGGINS
Material for Engineers by M H KEMPSTER
Heat Treatment by Laktin

METROLOGY AND MEASURING TECHNIQUIES

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.

COMPARETORS:
Introduction, Mechanical Comparators, Electrical and Electronics
Comparators, Pneumatic Comparators, Optical Projectors and
Comparators

ANGULAR MEASURMENTS:
Introductions, 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.

GEOMETRIC DIMENSIONING AND TOLERANCING-GDT:

Introduction, Symbols and Abbreviation, Datum, Tolerancing of
Location, Practical Application.

REFERANCE BOOKS:
Engineering Metrology-R K Jain
Engineering Metrology-K J Hume
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Interpretation of Geometric Dimensioning and tolerancing- Daniel

E Puncochar

JIGS AND FIXTURES

THEORY:
INTUDUCTION:

Definition of jigs & fixtures, Different between Jig & Fixture,

advantages, steps for Design.

LOCATION:
Degree of freedom, 3-2-1principle, choice of location, redundant
location, Diamond pin calculation, locating methods and chip
control.

LOCATING DEVICES:
Surface location, Rest blocks, Pins, V-blocks, Equalizers, Profile
Locaters.

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, Liners, Rotary, Indexing jigs, Indexing fixtures.

DESIGN OF JIGS AND FIXTURE BODIES AND OTHER

ELEMENETS TYPES OF JIGS AND FIXTURES:
Plate jigs, Box jigs, Indexing jigs, Milling fixtures, and indexingmilling fixtures, turning fixtures, grinding fixtures, universal jigs
and fixtures, welding fixtures, broaching fixtures.

DESIGN EXERCISES:
Drill jigs, Drilling and Reaming jig, Milling fixture, Indexing jigs,
indexing milling fixture, turning fixtures, Welding fixtures, Turning
mandrel, Grinding mandrel, Broaching fixtures.

REFFERENCE BOOKS:
Introduction to jig and Tool Design- M H A KEMPSTER
Jigs and Fixtures- T M H GRANT
Hand Book of Jigs and Fixtures design-BOYES
Hand Book of Fixture Design-FRANK W WILSON
Jigs and Fixture and Gauges for Limited production
Jig and Fixture- JOSHI.

PRESS TOOLS
INTRUUCTION:
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,
plug/point/centre of pressure.

bridge

size,

calculation

of

PRESS TOOL OPERATIONS:

Piercing, blanking, slitting, cropping, trimming, shaving, lunching,
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, forming tools, bending on
press brake, bending force calculation.

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.

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.

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

TOOL ROOM MANAGEMENT

MANAGEMENT SCIENCE:
Definition, Theory and Practice, Tools of Management Science,
Function 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, Concepts of optimization,
Operation Research, Present Scenario.

PLANNING AND CONTROLLING:

Nature and Purpose of planning, Objectives, Strategies, Decision
making, Process Planning, Flow process char, 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,
communication.

Job

Evaluation,

Motivation,

leadership,

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.
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TOOL ROOMPRACTICE:
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 method EDM, WEDM, Electrode
manufacturing process.

ESTIMATION AND COSTING:

Estimation, Manufacturing cost, Processing cost, Material cost,
Material cost, Estimation of Tool cost for Drill Jig, Press tool,
Injection moulding tool and Die casting tool.

REFERENCE BOOKS:
1. Essentials of Management- Harold Koontz
Heinz Weihrich.
2.
3.
4.
5.

Production and Operation Management- S N Chary

Industrial Engineering and Management- O P Khanna
Estimating and costing- J S Charya & G S Narang
Mechanical Estimating and Costing-D Kannappan, A G Augustine
&
D Paranthaman
6. Industrial Organization and Engg. Economics- Bang and Sharma

PLASTIC MOULDS
1. INJECTION MOULD:
Introduction to injection moulding process, Injection moulding
materials and their properties, Injection moulding machines,
Injection mould- initial design consideration, part of Two Plate
mould, parting line and flash face selection.
Design Manufacture, material and heat treatment of core and
cavity, feed systems, ejection methods, cooling arrangements,
shrinkage allowance, design of Three plate mould, mould design
for threaded components.
Common defects in moulded parts and the remedies.

2. COMPRESSION MOULDS:
Principles and techniques, Material and their properties, moulds
and machines.

3. TRANSFER MOULDS:
Principles and techniques, Material and their properties, mould
and machines.

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 mould.

REFERENCE BOOKS:
1.
2.
3.
4.
5.

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Injection mould design R G W PYE.

Injection mould design fundamentals-GRANVILL & DENTON
Hand book on plastic from C I P E T
Plastic tooling- WILLIAM P.BENJAMIN
Plastic technology- WILLIAM J PATTON

DIE- CASTING
INTRUDUCTION:
Classification of castings, Sand casting, metal 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 system furnaces, lading or metals in
to hot chamber.

FEED SYSTEM:
Gates, Runners, Taper tangent runner system, Impression layout,
Spreader, shot sleeve, shot weight calculation etc.

DIE CONSTRUCTION:
Core cooling, Cavity cooling, cooling shot sleeve, cooling of
spreader, baffles,
Cooling calculation.
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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.

DIES WITH SIDE CORES:

Construction, actuation of side cores.

DIE CASTINGS DEFECTS AND REMEDIES:

DESIGN EXERCISES:
Cold runner dies, Hot runner dies, Single cavity dies, Multi cavity
dies, Dies with side cores etc.
REFERENCE BOOKS:
1. Die casting buhler
2. Die casting die design Burton S
3. SMED

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