CURRICULUM DOCUMENET FOR ADVANCE CERTIFICATE COURSE IN CNC MACHINING TRADE

Transcription

1 2015 MSME TOOL ROOM INDO-GERMAN TOOL ROOM AURANGABAD- (MAHARASHTRA STATE) GOVT. OF INDIA CURRICULUM DOCUMENET FOR ADVANCE CERTIFICATE COURSE IN CNC MACHINING TRADE

2 INDEX PART PARTICULARS PAGE NO. General Information 2 Course information: Certificate 3 Course in CNC Machining I Curriculum Philosophy 4 II Course Structure 09 III First Semester: Course Details 12 IV Second Semester: Course Details 26 V Comparison of curriculum: DGET 31 and Advance Certificate Course in CNC Machining 1 P a g e o f 3 1

3 GENERAL INFORMATION 1. Name of the Trade : ADVANCE CERTIFICATE COURSE IN CNC MACHINING 2. NCO Code No. : 3. Duration of Craftsmen Training : One year (Two semesters each of six Months duration) 4. Power Norms : 3.7 Kw. 5. Space Norms : 69 Sq. Mtrs [ 100 Sq. M. in actual] 6. Entry Qualification : Passed ITI (Machinist,Turner,Fitter,Tool & Die Maker or its equivalent 7.Trainees per unit : 20(Max. Supernumeraries seats :5) 8a. Qualification for Instructor : Degree in Mechanical Engineering from Recognized university with one year Post qualification experience in the Relevant field. OR Diploma in Mechanical Engineering from a recognized board of technical education with two year post qualification experience in the relevant field. OR NTC/NAC passed in the Draftsman Mechanical trade with 3 years post qualification experience. Mechanical Trade. Note: (i) Out of two Instructors required for the unit of 2(1+1), one must have Degree/Diploma and other must have NTC/NAC qualifications. (ii) Instructor qualification for WCS and E.D, as per the training manual. Distribution of training on Hourly basis: Total hours /week Trade practical Trade theory Work shop Cal. &Sc. Employability skills Extra curricular activity 40 Hours 28Hours 6 Hours 2 Hours 2 Hours 2 Hours 2 P a g e o f 3 1

4 COURSE INFORMATION 1. Introduction: This course is meant for the candidates who aspire to become a professional CNC Operator. 2. Terminal Competency/Deliverables: After successful completion of this course the trainee shall be able to perform the following skills with proper sequence. 1. Trainees will work as a CNC Operator in industry 2. Prepare tool planning, process planning, material planning 3. Knowledge of CNC Programming, post processing 4. Manufacturing of part production 5. Knowledge of command application, inspection. 6. Knowledge of Technical English terms used in industry. 3. Employment opportunities: On successful completion of this course, the candidates shall be gainfully employed in the following industries: 1. Production & Manufacturing industries. 2. Structural Fabrication like bridges, Roof structures, Building & construction. 3. Automobile and allied industries 4. Service industries like road transportation and Railways. 5. Ship building and repair 6. Infrastructure and defense organizations 7. In public sector industries like BHEL, BEML, NTPC, etc and private industries in India & abroad. 8. Self-employment 4. Further learning pathways: On successful completion of the course trainees can pursue Apprenticeship training in the reputed Industries / Organizations. On successful completion of the course trainees can opt for Diploma course. On successful completion of the course trainees can opt for CITS course. 3 P a g e o f 3 1

5 CURRICULUM PHILOSOPHY The Indo German Tool Room, Aurangabad has been introduced the rational process of curriculum development. This rationale for the curriculum development is based on the following basics: 1. The scientific principles embodied in Theories of Learning, Educational Technology, curriculum development. 2. Social Surveys to identify the job description of a diploma holder in the Tool and Die Making / using industry. 3. The contents design of the entire curriculum. 4. Resource requirement for implementing the curriculum. While developing the curriculum, the following factors also taken into consideration to the maximum extent possible. - The vast experience obtained from Centre Tool Room, Ludhiana Indo-German Tool Rooms, Ahmedabad, Indore & Aurangabad. - The expectations of Industries. The overview of design of curriculum process followed is given below: - Aims & objectives of course have been derived from the job description. - The curriculum areas are identified on the basis of aims and objectives of the course. - On identifying the curriculum areas, these are classified into discipline & nondiscipline subjects. - Graphical structure of the contents of entire subjects is derived from the subjects objectives and identifies its concepts, principles, procedures and problems to be dealt with by the subject and its organisation designed to achieve subject objective. - Identified units & chapters from the graphical structure and the subject is divided semester wise. - The detail contents of each chapter derived linking to the subject objective. Accordingly the trainer Guide 1 (Curriculum documents for subject level) has been designed for all the subject areas. In this syllabus, only the overall structure of the course with objectives, Horizontal & Vertical organisation of subjects with time and the unit & chapter level of each subject are given. The evolving approach to student s evaluation is also derived. 4 P a g e o f 3 1

6 THEORY AND PRACTICAL HOURS TOTAL NO. OF HRS IN 2 SEMESTERS = 1920 Hrs TOTAL NO. OF HRS THEORY = 160 Hrs TOTAL NO. OF HRS PRACTICE & LABS = 1760 Hrs 5 P a g e o f 3 1

7 EDUCATIONAL OBJECTIVES I. To manufacture parts of Press Tools, Plastic Moulds, Die Casting Dies, Jigs Fixtures & Gauges etc. independently by using CNC Technologies. II. To work as competent employee in industry and business III. To set up an own enterprise IV. The apply knowledge, skills & attitudes (core) through the relevant Theoretical subjects needed to perform the above task effectively & efficiently. V. The individual development with sspecial emphasis on cultural values & personality development. 6 P a g e o f 3 1

8 NO. OF HRS CATEGORY WISE FOR ADVANCE CERTIFICATE COURSE IN CNC MACHINING INDO GERMAN TOOL ROOM, AURANGABAD 7 P a g e o f 3 1

9 SYSTEMS APPROACH CHART STRUCTURING OF BROAD CATEGORIES OF SUBJECTS DERIVED FROM CURRICULUM OBJECTIVES BASIC PHY.SC. ENGINEERING SCIENCE. CORE TECHNOLOGY TECHNOLOGY Machine Tool Technology CNC Technology Cutting Tool Technology Engg. Metrology CNC Programming & Machining Inplant Training (Live Projects) Communication skill Independent study technique Sociology Entrepreneurship CURRICULUM OBJECTIVES. Primarily (social/person context) Independent operation of machines Supervision of production Production Planning Also Design of Tools Orientation towards system up gradation Capable on the job learning Later Overall supervision of Tool Room -Career development: Higher Qualification Start own Business Move to Medium & large industries Move within the organization SKILLS Liaison Designing Estimating Production Planning Independent skill in operation of machines Independent skills Formative Evaluation Summative Evaluation Maintenance Entrepreneurial Social Skill Personal Development VALUES System Orientation Customer Needs Productivity Employee welfare Precise Communication Quality Safety Environmental protection Inquisitiveness Initiative Innovativeness Society needs Personal development 8 P a g e o f 3 1

10 COURSE STRUCTURE ADVANCE CERTIFICATE COURSE IN CNC MACHINING I ST Semester Teaching Scheme/ No. of Hours Examination Scheme Sr. No. Subject code Subject Name Theory Practice Sessional Max. Marks Theory Min to pass Semester Exam Max. Marks Min to pass Sessional Max. Marks Practice Min to pass Semester Exam Max. Marks Min to pass Total Marks ENGINEERING METROLOGY (TH&PR) MACHINE TOOL TECHNOLOGY CUTTING TOOL TECHNOLOGY CNC TECHNOLOGY CNC PROGRAMMING CNC MACHINING- TURNING CNC MACHINING- MILLING CNC MACHINING- WEDM CNC MACHINING- EDM P a g e o f 3 1

11 ADVANCE CERTIFICATE COURSE IN CNC MACHINING II ND Semester Teaching Scheme/ No. of Hours Examination Scheme Sr. No. Subject code Subject Name Theory Practice Sessional Max. Marks Theory Min to pass Semester Exam Max. Marks Min to pass Sessional Max. Marks Practice Min to pass Semester Exam Max. Marks Min to pass Total Marks 1 INPLANT TRAINING(LIVE PROJECTS) P a g e o f 3 1

12 MSME INDO-GERMAN TOOL ROOM FIRST SEMESTER: COURSE DETAILS ADVANCE CERTIFICATE COURSE IN CNC MACHINING TRADE 11 P a g e o f 3 1

13 Syllabus for the Trade of ACCCM First Semester Duration: Six Month Engineering Metrology Week No. Trade Practical Trade Theory 1. Visit of IGTR & giving information about all measuring instruments used in industries Introduction To Engineering Metrology Scope & Need Of Metrology. Objectives Of Metrology. General Care Of Equipment. 2. Demo on international system of units used for measuring instruments Terminology Used In Metrology. Measuring Range. International System Of Units. 3. Showing different measuring instruments for repeatability & sensitivity Readability. Sensitivity. Repeatability. 4. Demo & practice on Steel Rule Accuracy. Precision. Uncertinity Of Measurement: Calibration. Steel Rule 5. Demo & practice on Types Of Calipers. Concept: Application & Procedure. Calipers 6 Demo & practice on Vernier Caliper Description Application & Procedure. Vernier Caliper Reading The Vernier Scale. 7 Demo & practice on Reading The Vernier Scale. Least Count. Errors Observed In Vernier Precautions In The Case Of V.C. & Procedure. 8 Demo & practice on Vernier Height Gauge. Reading Height Gauge Precautions In The Case Of V.C. & Procedure. Description Of Parts & Requirements. Precautions In The Use Of Height Gauge. 9 Demo & practice on outside Micrometer. Test For Accuracy & Procedure. Micrometer. Description Of Parts, Reading Of Micrometer. 10 Demo & practice on inside Micrometer. Ratchet Stop Mechanism, Possible Errors. 12 P a g e o f 3 1

14 Precaution, Use Of Micrometer & Procedure. Description Of Parts, Reading Of Micrometer 11 Demo & Practice On Surface Plate Surface Plate Matl. Cast Iron & Graphite. Sizes & Accurancy. Care,Use Of S.P. & Procedure. 12 Demo & Practice On Surface Plate Care,Use Of S.P. & Procedure. Sizes & Accurancy. Application, Care,Use Of Angle Plate. V' Block. 13 Demo & Practice On Try Square/Engg. Straight Edge. Radius Gauge. Try Square/Engg. Straight Edge. Radius Gauge. Feeler Gauge. Feeler Gauge. 14 Demo & Practice On Pitch Screw Gauge. Bevel Protractor Pitch Screw Gauge. Bevel Protractor Description Of Parts. Application. 15 Demo & Practice On Combination Set. Combination Set. Application Care & Procedure. 16 Demo & Practice On different types of errors in measuring instruments Introduction To Errors. Types Of Errors: Controllable Errors, Static Errors, Random Errors. Concept Of Precision & Accuracy. Definition & Symbols. 17 Practice Of Gd & T Symbols Straightness,Flatness,Parralism,Circularity, Cylindricity, Concentricity,.Co- Axiality,Ovality, Lobbing,Angularity,Roundess. Introduction To Limits & Fits. Interchangability. Limit Of Size(Min. & Max.). Types Of Fit Clearance Fit,Transitoin Fit, Interference Fit. 18 Practice On Limits Fits & Tolerances Terminology For Limits & Fits. 13 P a g e o f 3 1

15 Shaft, Hole, Basic Nominal Size, Actual Size. Deviation: Lower Deviation, Upper Deviation. Fundamental Deviation. Basic Shaft, Basic Hole, Tolerance Zone. 19 Practice On Limits Fits & Tolerances Hole Basis System Shaft Basis System Introduction To Gauges Definitation. 20 Practice On Limits Fits & Tolerances Classification Of Gauges. According To Type, According To Purposes, According To Form Of Tested Surfaces, According To Design. Advantages Of Gauges. 21 Revision 22 & 23 SESSIONAL THEORY: 40; END-TERM (TH): 60; Examination 14 P a g e o f 3 1

16 Machine Tool Technology Week No. Trade Practical Trade Theory 1. Operations Demo & practicals on Various Types Of Operations Facing, Turning, Angular turning, Threading, Grooving, Drilling & Lathe Machine Introduction To Lathe Operation& Machine Construction & Description Of The Machine & Its Parts Boring. Machine Setting (Straight, Parallel, Angular) Job Setting (Support, Clamping, References) Machine Parameters & Calculations (Speed, Feed, Depth Of Cut, Angular Setting 2. Demo and practice on different types of Lathe machines Introduction to Lathe machine Types Of The Machine Working Of The Machine 3. Operations Demo & practicals on various Types Of Operations Face milling, Angular milling, Drilling, reaming, gear cutting & Boring. Milling Machine Introduction To Milling Operation& Machine Construction & Description Of The Machine & Its Parts Machine Setting (Straight, Parallel, Angular) Job Setting (Support, Clamping, References) Machine Parameters & Calculations (Speed, Feed, Depth Of Cut, Angular Setting 4. Demo and practice on different types of Milling machines Introduction to Milling machine Types Of The Machine Working Of The Machine 5. Operations Demo & practicals on various Types Of Operations surface grinding, cylindrical grinding, profile grinding, angular grinding Machine Setting (Straight, Parallel, Angular) Grinding Machine Introduction To grinding Operation& Machine Construction & Description Of The Machine & Its Parts Job Setting (support, Clamping, References) Machine Parameters & Calculations (Speed, Feed, Depth Of Cut, Angular Setting 6. Demo and practice on cylindrical grinding & Introduction to grinding machine 15 P a g e o f 3 1

17 surface grinding 7. Operations Demo & practicals on Various Types Of Operations boring, jig boring Machine Setting (Straight, Parallel, Angular) Job Setting (Support,Clamping, Refrences) Machine Parameters & Calculations (Speed, Feed, Depth Of Cut, Angular Setting Types Of The Machine Working Of The Machine Boring Machine Introduction To boring Operation& Machine Construction & Description Of The Machine & Its Parts 8. Demo and practice on boring machine Introduction to boring machine Types Of The Machine: Horizontal & vertical Working Of The Machine 9. Demo & practicals on various Work Holding Device Work Holding Devices Description & Construction Of The Work Holding Device Working Principle Types Of Devices Handling & Safety Measures 10. Demo & practicals on various Types Of Cutting Tool Holders Cutting Tools Nomenclature & Description Of Cutting Tools (Single & Multi Point) Used On Jig Boring Selection & Their Use Handling & Safety Measures Cutting Tool Holders Types Of Cutting Tool Holders Functions & Working Of Tool Holders Selecton & Their Use Handling & Safety Measures 11. Demo on Machine & practice of different letters using standard template Pentograph Machine Introduction To pentograph Operation& Machine Construction & Description Of The Machine & Its Parts 16 P a g e o f 3 1

18 12. Demo and practice on pantograph machine Introduction to pantograph machine Classification Of The Machine Working Of The Machine 13. Machine Construction & Description Of The Machine & Its Parts Single lip Grinder Introduction To single lip grinding Operation& Machine Construction & Description Of The Machine & Its Parts 14. Demo and practice on single lip grinding machine Introduction To single lip grinding Classification Of The Machine Working Of The Machine 15. Working Principle & Process Applications Electric discharge Machining Introduction Working Principle Process 16. Demo and practice on Electric discharge Machining machine Introduction to Electric discharge Machining Classification Of The Machine Working of the Machine 17. Demo and practice on Ram type Electric discharge Machining machine Introduction to Ram type EDM Machine Working of machine 18. Working Principle & Process Applications Wire Electric discharge Machining Introduction Working Principle Process 19. Demo and practice on Electric discharge Machining machine 20. Demo and practice of simultaneous four axis wire Electric discharge Machining machine Introduction to Wire Electric discharge Machining Classification Of The Machine Working of the Machine Introduction to simultaneous for axis WEDM machine 21. Revision 22. Examination SESSIONAL THEORY: 40; END-TERM (TH): P a g e o f 3 1

19 Cutting Tool Technology Week Trade Practical No. 1. Introduction to basic geometry of Commonly used cutting tool Introduction. Trade Theory Definition of cutting tool Different types of cutting tool 2. Practice on scriber grinding Practice on Center punch grinding Introduction to Scriber Centre punch 3. Practice on file Practice on chisel Practice on Hack-saw Introduction to File Chisel Hack-saw 4. Practice on various angles of single point cutting tool geometry Grinding Practice of various angles of single Introduction to single point cutting tool Nomenclature of single point cutting tool, Tool signature point cutting tool on pedestal grinder 5. Introduction to multi point cutting tool. Multi point cutting tool. Nomenclature of multi point cutting tool - Reamer. 6. Practice on drilling of various diameters by using different cutting parameters. Introduction to Multi point cutting tool. Introduction to drill Types of drill Applications of drills 7. Practice on tapping of various sizes by using different cutting parameters. Introduction to tap Types of taps Applications of taps 8. Practice on threading of various sizes by using different dies. Introduction to die Types of dies Applications of dies 9. Practice on reamer of various sizes by using different reamer. Introduction to Reamer Types of reamer Applications of reamers 10. Introduction to multi point cutting tool. Multi point cutting tool Nomenclature of multi point cutting tool 11. Practice on milling machine of various types Introduction to milling cutters 18 P a g e o f 3 1

20 of milling cutters by using different cutting parameters. Types of milling cutter Applications of milling cutter 12. Practice on hob of various sizes by using different cutting parameters. 13. Practice on broaching of various sizes by using different broach. 14. Practice on grinding machine of various specifications. 15. Practice of doing orthogonal cutting on machine by using cutting tools. Introduction to hob Types of hob cutters Applications of hob cutters Introduction to broach Types of broach cutters Applications of broach cutters Introduction to Grinding wheel. Specification of grinding wheel. Applications of grinding wheel. Introduction Methods of metal cutting Orthogonal cutting 16. Practice of doing oblique cutting on machine by using cutting tools. Introduction Methods of metal cutting Oblique cutting 17. Practice on different types of chip breakers Mechanics of metal cutting Chip formation Chip breakers 18. Practice on different types of metal cutting parameters using different metals. Introduction Metal cutting parameters Cutting forces 19. Practice on merchant s circle Introduction to merchant circle. Applications of marchant s circle Marchant's circle diagrame of forces 20. Practice of Re-sharpening of all cutting tools using different methods. Procedure for Re-sharpening 19 P a g e o f 3 1

21 Tools used for Re-sharpening Re-sharpening of cutting tool 21. Revision 22. Examination SESSIONAL THEORY: 40; END-TERM (TH): P a g e o f 3 1

22 CNC Programming-MTS Week Trade Practical Trade Theory 1. Determine Shape Dimensions & Material Of Introduction & Review Of Previous The Electrodes Pre-Machine Electrode To Knowledge Specifications Fine Finish Electrode By Introduction & Objective Of Syllabus Polishing & Machine Operations To Given / Planned Quality Criteria. Apply In Process Inspection & Testing Procedures Check Electric Media. Set Machine Data Clamp Electrode Align Component And Electrode Operate Machine Cycles & Observe Operations. Apply In-Process Inspection & Testing Procedure. Correction Of Tasks/Task Elements Not Conforming To The Specifications & Quality Criteria. Practice Programming (Of Start Point, Straight Line, and Cycles) Edit Programme & Set Machine Parameters/ Cutting Path. Setting Of Machine Condition & Simulate Programme. Optimize Machine Parameter Setting. Check Electric Media. Prepare Pare For Wire Cutting, Position & Clamp Part Position & Check Wire For Condition Final Check Of Machine Set Up. Handling Of Data Input & Output Devices Check Electric Media. Prepare Pare For Wire Cutting, Position & Clamp Part Position & Check Wire For Condition Final Check Of Machine Set Up. Handling Of Data Input & Output Devices Operate Machine Cycles & Observe Introduction To - CNC Programming & Machining General Study And Discussion On Production Processes Use Of Conventional & Non-Conventional Machines Various Controls On CNC Machines. Historical Development Of CNC Technology Conventional Vs CNC Machine Tool Characteristics Of Modern CNC Machine Tools Workshop & Demo On CNC Lathe & Milling Simulator Co-Ordinate System On CNC Machine Tools Nc Mathematics Zero & Reference Points On CNC Machine Tools Numeric Controls On CNC Machine Tools. 21 P a g e o f 3 1

23 Operations. Apply In-Process Inspection & Testing Procedure. Correction Of Tasks/Task Elements Not Conforming To The Specifications & Quality Criteria. Determine Shape Dimensions & Material Of The Electrodes Pre-Machine Electrode To Specifications Fine Finish Electrode By Polishing & Machine Operations To Given / Planned Quality Criteria. Apply In Process Inspection & Testing Procedures. Check Electric Media. Set Machine Data Clamp Electrode Align Component And Electrode Operate Machine Cycles & Observe Operations. Apply In-Process Inspection & Testing Procedure. Correction Of Tasks/Task Elements Not Conforming To The Specifications & Quality Criteria. Practice Programming (Of Start Point, Straight Line, Cycles) Edit Programme & Set Machine Parameters/ Cutting Path. Setting Of Machine Condition & Simulate Programme. Optimize Machine Parameter Setting. Check Electric Media. Prepare Pare For Wire Cutting, Position & Clamp Part Position & Check Wire For Condition Final Check Of Machine Set Up. Handling Of Data Input & Output Devices Check Electric Media. Prepare Pare For Wire Cutting, Position & Clamp Part Position & Check Wire For Condition Final Check Of Machine Set Up. Handling Of Data Input & Tool Compensation Values For CNC Machining. Path Measuring Systems Workshop & Demo On CNC Lathe & Milling Simulator CNC Tool System For Turning & Milling Structure & Application Of Lathe Tools For CNC Machining Structure & Application Of Milling Tools For CNC Machining Calculation Of Technological Data For CNC Machining CNC Clamping Systems Workshop & Demo On CNC Lathe & Milling Simulator Codes & Cycles For CNC Lathe Programming Preparatory Commands (G - Codes) Miscellaneous Commands (M Codes) Cycles Used In CNC Lathe Programming Codes & Cycles For CNC Milling Programming Preparatory Commands (G - Codes) Miscellaneous Commands (M Codes) 22 P a g e o f 3 1

24 Output Devices Simulation & execution of program by using G70,G71 & G72 cycle Simulation & execution of program by using G73,G74 & G75 cycle Simulation & execution of program by using G76,boring cycle Simulation & execution of program by using facing cycle on milling Simulation & execution of program by using spotting & drilling cycle on milling Simulation & execution of program by using boring cycle on milling Simulation & execution of program by using deep drilling cycle on milling Cycles Used In CNC Lathe Programming Workshop & Demo On CNC Lathe & Milling Simulator Cycles Used In CNC Lathe Programming Workshop & Demo On CNC Lathe & Milling Simulator Introduction Into Manual NC Programming. NC Programming Workshop & Demo On CNC Lathe & Milling Simulator Cycles Used In CNC Lathe Programming Workshop & Demo On CNC Lathe & Milling Simulator Cycles Used In CNC Lathe Programming Workshop & Demo On CNC Lathe & Milling Simulator Cycles Used In CNC Lathe Programming Workshop & Demo On CNC Lathe & Milling Simulator Exercises Programming And Machining On CNC Lathe & Milling For Any One Exercise From Programmed One 21 Revision 22 Examination SESSIONAL THEORY: 40; END-TERM (TH): P a g e o f 3 1

25 CNC MACHINING-LATHE Week Trade Practical Trade Theory 1. Introduction & Review Of Previous Knowledge Introduction & Objective Of Syllabus Demo on CNC lathe machine for their different parts Introduction to different parts of CNC lathe machine Writing CNC program for turning to specifications Demo and practice of simulation of program on control panel Practice on making program on different controls & making work plan for the product Demo & practice on clamping & declamping on CNC lathe machine Simulating & optimizing the program on the control Generating work plan for machine operations to given quality criteria. Types of clamping Tool clamping on turret 5. Demo & practice of zero setting & offset on machine Setting job in the machine chuck. Setting Tool parameters on the machine control 6 Practice of offsetting on CNC lathe machine Optimizing the cutting & geometrical parameters of the available tools 7 Demo & practice of setting tools using different tool holders. Checking and confirming the tool & tool holders condition. 8 Giving the demo and introduction about safety precautions while working on CNC machines Actuating the protection zones of machine. 24 P a g e o f 3 1

26 9 Demo & practice on simulation & execution of part programming Checking the optimized program with simulation. Recording the variations after final tool setup. 10 Demo & practice of zero setting of the workpiece Setting zero point displacement and offset parameters of each tool 11 Demo & practice of simulating program & tool setting on turret Checking the optimized program with simulation Tool setting on turret 12 Demo and practice of job clamping in chuck Setting job in the machine chuck. Optimizing the cutting & geometrical parameters of the available tools 13 Demo & practice of Execution of facing & turning cycle on CNC lathe Introduction about facing cycle 14 Demo & practice of Execution of G72 cycle on CNC lathe Introduction about G72 cycle Demo & practice of Execution of G73 cycle on CNC lathe Demo & practice of Execution of G74 cycle on CNC lathe Demo & practice of Execution of G75 cycle on CNC lathe Demo & practice of Execution of G76 cycle on CNC lathe Introduction about G73 cycle Introduction about G74 cycle Introduction about G75 cycle Introduction about G76 cycle 25 P a g e o f 3 1

27 19 20 Demo & practice of Execution of combination cycle on CNC lathe Demo & practice of Execution of combination cycle on CNC lathe Introduction about how to make the combination of all the cycles Introduction about how to make the combination of all the cycles 21 Revision 22 Examination SESSIONAL PR :160 END TREM PR: 240 MARKS 26 P a g e o f 3 1

28 CNC MACHINING-Milling Week Trade Practical Trade Theory 1. Introduction & Review Of Previous Knowledge Introduction & Objective Of Syllabus Demo on CNC milling machine for their different parts Introduction to different parts of CNC milling machine Writing CNC program for milling to specifications Demo and practice of simulation of program on control panel Practice on making program on different controls & making work plan for the product Demo & practice on clamping & declamping on CNC milling machine Simulating & optimizing the program on the control Generating work plan for machine operations to given quality criteria. Types of clamping Tool clamping on turret 5. Demo & practice of zero setting & offset on machine Setting job in the machine chuck. Setting Tool parameters on the machine control 6 Practice of offsetting on CNC milling machine Optimizing the cutting & geometrical parameters of the available tools 7 Demo & practice of setting tools using different tool holders. Checking and confirming the tool & tool holders condition. 8 Giving the demo and introduction about safety precautions while working on CNC machines Actuating the protection zones of machine. 27 P a g e o f 3 1

29 9 Demo & practice on simulation & execution of part programming Checking the optimized program with simulation. Recording the variations after final tool setup. 10 Demo & practice of zero setting of the workpiece Setting zero point displacement and offset parameters of each tool 11 Demo & practice of simulating program & tool setting on turret Checking the optimized program with simulation Tool setting on turret 12 Demo and practice of job clamping in different work holding devices Setting job in the machine chuck. Optimizing the cutting & geometrical parameters of the available tools 13 Demo & practice of Execution of facing cycle on CNC milling Introduction about facing cycle 14 Demo & practice of Execution of making cores of different profiles using cycles on CNC milling machine Introduction about different types of cutters used for core profile machining Demo & practice of Execution of making cavity of different profiles using cycles on CNC milling machine Demo & practice of Execution of making spotting & drilling using cycles on CNC milling machine Demo & practice of Execution of making deep drilling using cycles on CNC milling Introduction about different types of cutters used for cavity profile machining Introduction about different types of center drills used & drills used on CNC milling machine Introduction about different types of long drills used on CNC milling machine 28 P a g e o f 3 1

30 machine 18 Introduction about boring cycle Demo & practice of Execution of making boring using cycles on CNC milling Introduction about parameters used in cycles 19 Introduction about tapping cycle 20 Demo & practice of Execution of making tapping using cycles on CNC milling Demo & practice of Execution of making external threading using cycles on CNC milling Introduction about parameters used in cycles Introduction about threading cycle Introduction about parameters used in cycles 21 Revision 22 Examination SESSIONAL PR :160 END TREM PR: 240 MARKS 29 P a g e o f 3 1

31 CNC MACHINING-WEDM Week Trade Practical Trade Theory 1. Introduction & Review Of Previous Knowledge Introduction & Objective Of Syllabus Demo on CNC WEDM machine for their different parts Introduction to different parts of CNC WEDM machine Writing CNC program for WEDM to specifications Demo and practice of simulation of program on control panel Practice on making program on different controls & making work plan for the product Demo & practice on clamping & declamping on CNC WEDM machine Simulating & optimizing the program on the control Generating work plan for machine operations to given quality criteria. Types of clamping Tool clamping on tool holding devices 5. Demo & practice of zero setting & offset on machine Setting job in the machine chuck. Setting Tool parameters on the machine control 6 Practice of offsetting on CNC WEDM machine Optimizing the cutting & geometrical parameters of the available tools 7 Demo & practice of setting tools using different tool holders. Checking and confirming the tool & tool holders condition. 8 Giving the demo and introduction about safety precautions while working on CNC machines Actuating the protection zones of machine. 30 P a g e o f 3 1

32 9 Demo & practice on simulation & execution of part programming Checking the optimized program with simulation. Recording the variations after final tool setup. 10 Demo & practice of zero setting of the workpiece Setting zero point displacement and offset parameters of each tool Demo & practice of simulating program & tool setting on turret Demo and practice of job clamping in different work holding devices Checking the optimized program with simulation Tool setting Introduction about types of wires Setting job in the work holding devices. Optimizing the cutting & geometrical parameters of the available tools 13 Demo & practice of making simple circular cavities using different parameters Introduction about spark gap 14 Demo & practice of making simple rectangular cavities using different parameters Introduction about different parametes like voltage, current-on,t-off etc Demo & practice of complex cavities using different profiles Demo & practice of complex cores using different profiles Demo & practice of complex cores & cavities using different profiles Introduction about ionized water used for machining Introduction about different types of wire cut machines used for production 31 P a g e o f 3 1

33 Demo & practice of complex cores & cavities using different profiles Demo & practice of complex cores & cavities using different profiles Demo & practice of complex cores & cavities using different profiles Introduction about different types of wire cut machines used for production Introduction about different types of wire cut machines used for production Introduction about different types of wire cut machines used for production 21 Revision 22 Examination SESSIONAL PR :160 END TREM PR: 240 MARKS 32 P a g e o f 3 1

34 CNC MACHINING-EDM Week Trade Practical Trade Theory 1. Introduction & Review Of Previous Knowledge Introduction & Objective Of Syllabus Demo on CNC EDM machine for their different parts Introduction to different parts of CNC EDM machine Writing CNC program for EDM to specifications Demo and practice of simulation of program on control panel Practice on making program on different controls & making work plan for the product Demo & practice on clamping & declamping on CNC EDM machine Simulating & optimizing the program on the control Generating work plan for machine operations to given quality criteria. Types of clamping Tool clamping on tool holding devices 5. Demo & practice of zero setting & offset on machine Setting job in the different tool holding devices used in EDM Setting Tool parameters on the machine control 6 Practice of offsetting on CNC EDM machine Optimizing the cutting & geometrical parameters of the available tools 7 Demo & practice of setting tools using different tool holders. Checking and confirming the tool & tool holders condition. 8 Giving the demo and introduction about safety precautions while working on CNC machines Actuating the protection zones of machine. 33 P a g e o f 3 1

35 9 Demo & practice on simulation & execution of part programming Checking the optimized program with simulation. Recording the variations after final tool setup. 10 Demo & practice of zero setting of the workpiece Setting zero point displacement and offset parameters of each tool Demo & practice of simulating program & tool setting on turret Demo and practice of job clamping in different work holding devices Checking the optimized program with simulation Tool setting Introduction about types of electrodes Setting job in the work holding devices. Optimizing the cutting & geometrical parameters of the available tools 13 Demo & practice of making simple circular cavities using different parameters Introduction about spark gap 14 Demo & practice of making simple rectangular cavities using different parameters Introduction about different parametes like voltage, current-on,t-off etc Demo & practice of complex cavities using different profiles Demo & practice of complex cores using different profiles Demo & practice of complex cores & cavities using different profiles Introduction about dielectric Introduction about different types of flushing 34 P a g e o f 3 1

36 Demo & practice of complex cores & cavities using different profiles Demo & practice of complex cores & cavities using different profiles Demo & practice of complex cores & cavities using different profiles Introduction about different types EDM machines used for production Introduction about different types of EDM machines used for production Introduction about different types of EDM machines used for production 21 Revision 22 Examination SESSIONAL PR :160 END TREM PR: 240 MARKS 35 P a g e o f 3 1

37 MSME INDO-GERMAN TOOL ROOM SECOND SEMESTER: COURSE DETAILS ADVANCE CERTIFICATE COURSE IN CNC MACHINING TRADE 36 P a g e o f 3 1

38 Syllabus for the Trade of ACCCM Second Semester Duration: Six Month In plant Training (Live Projects) Week No. Trade Practical Trade Theory 1. Produce Press Tool, Mould, Jigs & Fixture Parts To Specification on milling machine Introduction about setting of parts on milling machine. Zero setting of the workpiece 2. Prepare tool planning, process planning, material planning Introduction about how to do the tool planning for producing of parts within the prescribed time. Job loading & unloading on the machine Process planning of the parts. 3. Make CNC Programming on CNC Milling machine for simple jobs, post processing For complex shapes on different CAM software s. Introduction to different CAM software used for manufacturing of products. Applications of CAM software s for manufacturing of parts. 4. Practice on command application & inspection of all produced parts. Introduction to command application Applications of command applications Introduction to all measuring instruments required for inspection. Practical applications of measuring instruments 5. Plan Material & Parts. Plan & Optimize Resource Plans. Plan Material & Parts. Plan & Optimize Resource Plans. 6 Produce Press Tool, Mould, Jigs & Fixture Parts To Specification on EDM machine Introduction about setting of parts on EDM machine. Zero setting of the workpiece. 7 Prepare tool planning, process planning, material planning Introduction about how to do the tool planning for producing of parts within the prescribed time. Job loading & unloading on the EDM machine Process planning of the parts. 8 Make CNC Programming on CNC EDM & Electrode preparation for producing Types of electrodes Materials used for electrodes. 37 P a g e o f 3 1

39 different complex shapes. 9 Practice on command application & electrode design. 10 Plan Material & Parts. Plan & Optimize Resource Plans. 11 Produce Press Tool, Mould, Jigs & Fixture Parts To Specification on WEDM machine 12 Prepare tool planning, process planning, material planning 13 Make CNC Programming on CNC WEDM & wire preparation for producing different complex shapes. 14 Practice on command application & different software used for making a programs. 15 Plan Material & Parts. Plan & Optimize Resource Plans. 16 Produce Press Tool, Mould, Jigs & Fixture Parts To Specification on Jig Boring Machine. 17 Prepare tool planning, process planning, material planning 18 Make Programming on jig boring for precision holes. 19 Practice on different diameter precision holes as per the requirements Applications of all electrode materials. Procedure of electrode design Information about spark gap Plan Material & Parts. Plan & Optimize Resource Plans. Introduction about setting of parts on WEDM machine. Zero setting of the workpiece. Introduction about how to do the tool planning for producing of parts within the prescribed time. Job loading & unloading on the WEDM machine Process planning of the parts. Types of wires Types of flushings. Deionized water. Information about cutting parameters. Introduction to ELCAM software. Application of ELCAM software. Plan Material & Parts. Plan & Optimize Resource Plans. Introduction about setting of parts on Jig Boring Machine. Zero setting of the workpiece. Information about tools used in jig boring machine. Introduction about how to do the tool planning for producing of parts within the prescribed time. Job loading & unloading on the jig boring machine. Process planning of the parts. Information about coordinate system Selection of tools for different diameters. Types of drills Applications of drills. 38 P a g e o f 3 1

40 20 Plan Material & Parts. Plan & Optimize Resource Plans. Plan Material & Parts. Plan & Optimize Resource Plans. 21 Revision 22 Examination SESSIONAL PR :160 END TREM PR: 240 MARKS 39 P a g e o f 3 1

41 LIST OF MACHINES AND EQUIPMENTS Sr..No. NAME OF THE MACHINE TYPE OF MACHINE QTY Vertical Machining Centre (VMC) CNC Milling 10 CNC Turning Centre CNC Turning Wire cut Machines Wire Cut 8 04 EDM EDM Jig Boring Machine B3-DR JB 1 06 Vertical Milling Machine Conv. Milling Universal Milling Machine Conv. Milling 6 08 Horizontal Milling Machine Conv. Milling 6 09 Lathe Machine Conv Turning Cylindrical Grinding CG 5 11 Surface Grinding Machine SG Tool and Cutter Grinder (SAACKE) SG 1 13 Engraving Machine Kibra TG 1 14 Injection Mouldig Machine Inj Moulding 4 15 Mechanical Press (125T) Eccentric Press Press 2 16 Hydraulic Press (63T) Dunkes Press 1 17 St.Press Dunkes Press 1 18 HMT Make Radial Drilling Machine Drilling 3 19 Colum type drilling machine (Floatt) Drilling 3 20 Bench type drilling machine (Floatt and Other) Drilling Single Chamber Furnace (Nolzen) HT 2 Tempering Furnace(Nolzen) Electric Hot Air Furnace HT 1 23 Heat Treatment Furnance (Fluidtherm) HT 1 24 Tempering Furnace (Fluidtherm) HT 1 25 Vertical Band Saw Mossener Steel & Metal Saw Machine Saw 1 26 Power Hack saw (Beheringer & other) saw 2 27 Indo tech Double column semi-auto Saw 1 Bandsaw Machine 28 Flame Cuttinig Machine FC 1 29 CNC CMM(Hexagon) CMM 1 30 CNC CMM (Carl Zeiss) CMM 1 31 Pofile Projector Batty SM-20 PP 1 32 Tool Maker Micro Scope Large TMMS 1 33 Chamfering Machine Hkf 125 CM 1 Assfalg Jitamitra Make 34 Tool Presetor ( Elbo Controli) TP 1 40 P a g e o f 3 1

42 CURRICULUM COMAPRISON (DGET) And ADVANCE CERTIFICATE COURSE IN CNC MACHINING (IGTR) 41 P a g e o f 3 1

43 SR.NO. SUBJECT NAME COMPARISION OF SYLLABUS OF IGTR & CSTRAI TRADES IGTR TRADE CCMTR TURNE R FITTER MACHIN IST CSTRAI TRADES TOOL & DIE MAKER MACHIN IST GRINDE R DRAFTSMAN MECHANICA L DURATION 2 YEARS 1 COMMUNICATION SKILL X X X X X X 2 SOCIOLOGY X X X X X X 3 ENTERPRENEURSHIP DEVELOPMENT X X X X X 4 APPLIED MATHEMATICS 5 APPLIED PHYSICS 6 ENGINEERING DRAWING 7 APPLIED MECHANICS 8 STRENGTH OF MATERIAL X X X X X X 9 WORKSHOP PRACTICE X WORKSHOP 10 TECHNOLOGY X ADVANCED MACHINE 11 TOOL TECHNOLOGY X X X X X X TOOL ROOM MACHINE 12 MAINTENANCE X 13 CNC TECHNOLOGY X X X 14 CNC PROGRAMMING X X X 15 CNC MACHINING X X X 16 METROLOGY X HYDRAULICS & 17 PNEUMATICS X X X X X 18 CAD ( AUTOCAD ) X X X X X 19 CAD / CAM (DELCAM ) X X X X X X 20 TOOL & DIE MAKING X X 21 TOOL & DIE PARTS MANUFACTURING X X X X X 22 MATERIAL TECHNOLOGY X 23 HEAT TREATMENT FUNDAMENTALS OF TOOL 24 ENGG. X X X X X X OCCUPATIONAL HEALTH 25 AND SAFETY X X 26 BASIC ELECTRONICS X X X X X 27 BASIC ELECTRICAL X X X 28 DESIGN OF MOULDS X X X X X X 29 DESIGN OF PRESS TOOL X X X X X X 30 JIGS AND FIXTURES X X X X X X PERCENTAGES DETAILS OF CCMTR COURSE CONDUCTED BY IGTR, AURANGABAD FROM 1995 COURSE DURATION ENTRY QUALIFICATION ADMISSION PROCEDURE REQUEST FOR CCMTR - CERTIFICATE COURSE IN MACHINIST TOOL ROOM 02 YEARS (FOUR SEMESTERS) SSC PASS WITH MIN 60% MARKS ON ALL INDIA BASIS THROUGH ENTRANCE EXAM ONLY NCTVT APPROVAL 42 P a g e o f 3 1