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V-Sem DTDM
V-Sem DTDM
SEMESTER: FIFTH
Scheme of Examination
Course: DIPLOMA IN TOOL & DIE MAKING
Scheme of Examination
Subjects Contact Internal
Exam Total
SI. Sub. Hours Exam Assessment
Marks
No Code per Duration Min marks
Max Min Max Min
Theory Week for passing
Marks Marks Marks Marks
DTDM-
1 Press Tool Theory-II 3 3 100 50 20 10 120 60
VS501
DTDM-
2 Mould Theory-I 3 3 100 50 20 10 120 60
VS502
DTDM-
3 Mechatronics 3 4 100 50 20 10 120 60
VS503
Practical’s
DTDM-
4 Press Tool Design-I 4 8 100 50 20 10 120 60
VS504
DTDM-
5 Mould Design-I 4 8 100 50 20 10 120 60
VS505
DTDM-
6 Material Testing Lab 3 3 100 50 20 10 120 60
VS506
DTDM-
7 CAD Lab-III 3 3 100 50 20 10 120 60
VS507
DTDM-
8 Work Shop – V 17 10 900 540 100 60 1000 600
VS508
Total 40 1600 890 260 130 1840 1020
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 1
PRESS TOOL THEORY – II
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 2
PRESS TOOL THEORY – II
2. FINE BLANKING
- Introduction
- Construction
- Functions
- Operational sequences
- Applications and advantages
- Press selection for fine blanking
4. COMBINATION DIE
- Introduction
- Construction
- Functions
- Advantages and disadvantages
- Manufacturing methods
5. BENDING
- Theory of bending
- Bend elements
- Neutral axis and its importance
- Blank development calculation
- V-bending procedure and force calculation
- U-bending theory and force calculation
- Calculation of bend allowance
- Bending pressure
- Spring back
- Methods of avoiding spring back in U and V bending
- Bending tool – constructional features
- Defects and remedies of bent component and bending tool
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 3
6. LUBRICATION
- Purpose of lubricants
- Types of lubricants
7. FORMING OPERATIONS
- Introduction
- Theory of forming
- Types of forming dies
- Purpose and application
8. DRAWING
- Introduction
- Metal flow during drawing
- Calculations – flat blank diameter, draw reductions, number of draws required, draw force
- Variables that affect metal flow during drawing
- Types of draw dies
9. PRESS MACHINE
- Introduction
- Specification
- Classification
- Types of presses
- Power source
- Attachments for presses
- Selection of a press
- Feeding system – purpose, types, advantages
REFERENCE BOOKS:
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 4
WEEKLY PLAN FOR PRESS TOOL THEORY-2
different Components
2 - Types of non-cutting press tools
Explain Parallel and Perpendicular
-Behaviour of material during
Grain direction, Ductility,
3 deformation
Compression Elongation and
- Stock material for non-cutting
operations. Strength Spring Back
machining
7 - Introduction Explain Construction Purpose,
COMBINATION
- Construction Rigidity.
- Functions
DIE
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 5
-Bending Tool Construction Radius, Bend Angle & Sheet Thickness.
-Spring Back
Corner setting, Ironing, Squeezing & Over
-Methods of avoiding spring back
11 bending
-V bending , U bending & wiping Dies
12
- Theory of forming
ng
action.
- Attachments for presses
- Selection of a press
18 - Feeding system – purpose, types, advantages Roll feed, Hitch feed, De-Coiler. Push &
Pull feed
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 6
MOULD THEORY-I
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 7
MOULD THEORY-I
1. EINLEITUNG
- Definition of mould
2. TYPES
3. INJECTION MOULD
- Introduction
- Definition of injection mould
- Advantages & Disadvantages of injection mould
5. MOULD CONSTRUCTION
- Introduction
- The various Parts Associated with working of injection mould
- Function of injection mould
- Classification of injection mould
- Construction of various parts of injection moul
6. FEED SYSTEM
- Types of Runners (Full round, half round, Square, Trapezoidal, Modified Trapezoidal)
- Typical Applications
- Type and classification of Gates
- Manually trimmed gates (Edge, Ring, Tab, Direct Sprue, Spoke, Disk,)
- Automatically trimmed gates (Pin point and Submarine)
- Typical Applications
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 8
7. EJE CTION
- Importance of Ejection
- Types (Pin, Stepped pin, ‘D’ shape, Blade, Stripper plate, Sleeve, Air)
- Typical Applications
9. PARTING SURFACE
- Introduction
- Classification (Flat, Non-flat, Stepped, Local stepped, Angled, Complex)
- Balancing of mould surface
- Typical Applications
- Importance and applications of Air Vents
10. SHRINKAGE
- Introduction
- Why does shrinkage occur?
- Problems caused by the shrinkage
- Cavity dimension calculations
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 9
WEEK WISE SYLLABUS FOR MOULD THEORY – I
Week
Chapter Learning Goals
No.
a. Introduction to -Thermoplastic & Thermosetting Plastics.
- Application Examples of Plastic components.
Moulding
1-2 - General Concept of Mould & Manufacturing
b. Mould Making Methods
- Moulding Process & Moulding Machines
methods
Thermoplastic processing
methods
a. Blow Moulding
- Definition, Construction, Working Process.
3-4 b. Extrusion Moulding - Types and Suitable Typical Applications.
c. Rotational Moulding
d. Calendaring
e. Thermoforming
Definition of an injection
mould
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 10
11 Unit Test - 1
- Importance of Ejection
- Types (Pin, Stepped pin, ‘D’ shape, Blade,
12-13 Ejection Stripper plate, Sleeve, Air)
- Typical Applications
- Introduction
- How to select
- Classification (Flat, Non-flat, Stepped,
16-17 Parting surface
Local stepped, Angled, Complex)
- Balancing of mould surface
- Typical Applications
- Importance and applications of Air Vents
-Introduction
-Why does shrinkage occur?
18 Shrinkage -Problems caused by the shrinkage
-Cavity dimension calculations
19 Unit Test - 2
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 11
PRESS TOOL DESIGN - I
strippers
Design progressive tool with Cut off & Part off operations
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 12
PRESS TOOL DESIGN -I
- Type of Material
- Component Application
- Types of Press operations
- Critical & General Dimension
- Production Quantity
- Type of Press Tool required
- Strip Layout
- Die Layout
- Tool Elements Layout
- Assembly Plan view
- Assembly Sectioned Front View
- Assembly Full/ Partial Side view
- Bill of Material & its contents
- Planning of GTTC Standard Layout on A1 Sheet
st
- 1 Angle Projection
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 13
PRESS TOOL DESIGN -I
5. SINGLE STAGE , SINGLE ROW ANGULAR LAYOUT BLANKING TOOL (WITH DIAGONAL PILLAR DIE
SET) FRONT FEEDING
6. SINGLE STAGE , DOUBLE ROW BLANKING TOOL (WITH REAR PILLAR DIE SET) SIDE FEEDING
7. SECONDARY OPERATIONAL TOOLS WITH DIE NESTING , PIERCING TOOL (WITH CENTRE PILLAR DIE
SET)
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 14
PRESS TOOL DESIGN -I
4. TWO STAGES PROGRESSIVE CUTTING TOOL WITH STAGE STOPPER (WITH REAR PILLAR DIE SET)
5. THREE / FOUR STAGES PROGRESSIVE CUTTING TOOL WITH PITCH PUNCH & PILOTS ON A REAR
PILLAR DIE SET
6. PROGRESSIVE CUTTING TOOL WITH CUT-OFF ARRANGEMENT ON A FOUR PILLAR DIE SET
7. PROGRESSIVE CUTTING TOOL WITH PART-OFF ARRANGEMENT ON A DIAGONAL PILLAR DIE SET
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 15
PRESS TOOL DESIGN -I
8. PROGRESSIVE CUTTING TOOL WITH FLOATING STRIPPER ON A REAR PILLAR DIE SET
11. SINGLE STAGE BLANKING TOOL WITH REAR PILLAR DIE SET COMPOUND TOOL FIVE STAGES
PROGRESSIVE CUTTING TOOL WITH FLOATING STRIPPER & FOUR PILLAR DIE SET
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 16
WEEKLY PLAN FOR PRESS TOOL DESIGN-I
WEEK
CHAPTER TOPICS ACTIVITY
No.
1. COMPONENT ANALYSES Ask students to get different
- Type of Material sheet metal Components
- Component Application before commencement of the
- Types of Press operations Design Classes.
- Critical & General Dimension
- Production Quantity Collect Single & Progressive
- Type of Press Tool required stage Punched Strips.
Introduction to Press Tool 2. DESIGN ANALYSES
1 Design & Analyses - Strip Layout
Concept - Die Layout
- Tool Elements Layout Display Single Stage,
- Assembly Plan view Progressive Stage &
- Assembly Sectioned Front View Compound Stage model Tools
- Assembly Full/ Partial Side view present in your centre.
- Bill of Material & its contents
- Planning of GTTC Standard Layout
on A1 Sheet
- 1st Angle Projection
- Structure of Strip Layout
- Blank Layout [ Single Row, Multi
- Rows, Single Pass, Double Pass] Design Strip Layouts for 10
2&3 Strip lay out
- Utilization of sheet material different Components
- Calculation
- Required tonnage Calculation
- Top view, Sectioned Front view,
Sectioned Side view, Partial Enlarged
Views.
- Die openings & Holes Projections.
- Die block Length, width & Thickness
Calculations. Design Strip Layouts & Die
4&5 Die lay out - Dimensioning [ Co-ordinate, Layouts for 06
Centralized ] different Components
- Geometrical Symbols
- Sub Title Block
- Centre of pressure (COP) Graphically
& Algebraic Calculation
- Calculations of Plate Thickness.
- Calculation of size of tool elements
- Blank Layout Create the Importance &
Single Stage, Single Row - Assembly Plan view Awareness about Punch; Fixed
6 Blanking Tool (Open Tool - Assembly Sectioned Front View Stripper & Die block
Construction) - Assembly Side view alignments.
- Bill of Material 2 Components
- Detail Part Drawings
Single Stage , Single - Calculation of size of tool elements Create the Importance &
- Blank Layout Awareness about Economical
Row Angular Layout - Assembly Plan view Strip Utilization during angular
7 Blanking Tool (With - Assembly Sectioned Front View layouts, Positions of Punch
Diagonal Pillar Die Set) - Assembly Side view with reference to Die opening
Front Feeding - Bill of Material & Importance of Die Set
- Detail Part Drawings 2 Components
- Calculation of size of tool elements
Create the Importance &
Single Stage , Double - Blank Layout
Awareness of Strip Utilization
Row Blanking Tool - Assembly Plan view
factor & Need for Double Row
8 - Assembly Sectioned Front View
(With Rear Pillar Die Set) in Small Components & Huge
- Assembly Side view
Side Feeding requirements
- Bill of Material
2 Components
- Detail Part Drawings
- Calculation of size of tool elements
Secondary Operational Create the Importance &
- Assembly Plan view
Tools with Die Nesting, Awareness of Secondary
- Assembly Sectioned Front View
9 Operational Tools & Nesting
Piercing Tool (With - Assembly Side view
Concept ( Plate type, Pin type)
Centre Pillar Die Set) - Bill of Material
2 Components
- Detail Part Drawings
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 17
WEEKLY PLAN FOR PRESS TOOL DESIGN-I
- Calculation of size of tool elements
Two Stages Progressive - Economical Strip Layout Create the Importance &
Cutting Tool with Stage - Assembly Plan view Awareness of Pitch, & Opening
10 - Assembly Sectioned Front View Alignments of Punch Holder,
Stopper (With Rear Pillar
- Assembly Side view Stripper plate & Die Block to
Die Set) - Bill of Material the students. 2 Components
- Detail Part Drawings
- Calculation of size of tool elements
Three / Four Stages - Economical Strip Layout Create Awareness of Pitch
Progressive Cutting Tool - Assembly Plan view Punch ( Notching Group,
11 - Assembly Sectioned Front View Heeled construction) and Pilots
with Pitch Punch & Pilots
- Assembly Side view Shape Size & Application
on a Rear Pillar Die Set - Bill of Material 2 Components
- Detail Part Drawings
- Calculation of size of tool elements
- Economical Strip Layout
Progressive Cutting Tool Create the Importance &
- Assembly Plan view
with Cut-off Arrangement Awareness Cut-off design & its
12 & 13 - Assembly Sectioned Front View
construction.
on a Four Pillar Die Set - Assembly Side view
2 Components
- Bill of Material
- Detail Part Drawings
- Calculation of size of tool elements
Progressive Cutting Tool - Economical Strip Layout
Create the Importance &
with Part-off Arrangement - Assembly Plan view
Awareness Part-off design &
14 & 15 - Assembly Sectioned Front View
on a diagonal Pillar Die its construction.
- Assembly Side view
Set 2 Components
- Bill of Material
- Detail Part Drawings
- Calculation of size of tool elements
Create the Importance &
- Economical Strip Layout
Progressive Cutting Tool Awareness Floating Stripper &
- Assembly Plan view
with Floating Stripper on its purpose.
16 - Assembly Sectioned Front View
( Clamping type & Non
a Rear Pillar Die Set - Assembly Side view
Clamping type)
- Bill of Material
2 Components
- Detail Part Drawings
- Calculation of size of tool elements
Create the Importance &
- Assembly Plan view
Compound Tool for Awareness of Compound Tool
- Assembly Sectioned Front View
17 & highlight types of
Washer - Assembly Side view
Components produced in this
- Bill of Material
Tool
- Detail Part Drawings
- Calculation of size of tool elements
Compound Tool - Assembly Plan view
for Non Circular - Assembly Sectioned Front View
18 ----
- Assembly Side view
Components - Bill of Material
- Detail Part Drawings
DESIGN HANDS ON SOFTWARE
1. Single Stage Blanking
tool with Rear Pillar Die
Set ( 4 hrs) - Calculation of size of tool elements
- Economical Strip Layout
2. Compound Tool - Assembly Plan view
( 4 hrs) Designing to be done using
19 to 22 - Assembly Sectioned Front View
Software’s
3.Five Stages Progressive - Assembly Side view
Cutting Tool With Floating - Bill of Material
- Detail Part Drawings
Stripper & four Pillar Die
set (8 hrs)
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 18
MOULD DESIGN-I
SUBJECT CODE: DTDM-VS505
Understands how to select/ extract suitable mould base within GTTC standards.
Understands the significance of designing a single cavity mould. (Direct sprue gate)
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 19
MOULD DESIGN-I
SUBJECT CODE: DTDM-VS505
WEEK
DESIGN CONCEPT OBJECTIVES
No.
a. Introduction
b. Fixed Half & Moving Half
c. Top View / Plan View
Design of an Assembly Two Plate d. Selection of Section Plane
Mould as per GTTC Standards for e. Sectional Front View as per Section Plane
5
Mould Set No1. f. Dimensioning Top View & Front View, plate Thickness,
Pitches and Shut Height.
g. Ballooning & Parts Numbering
h. Part List to Standard Practice
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 20
a. Parting Line Selection
b. Alignment of Core & Cavity
Design of a Single Cavity Injection c. Ejection
9 & 10 Mould with Sprue Gate for Pin d. All Parts Drawing with suitable dimensioning method
Ejection. e. Dimensioning of Core &Cavity with Shrinkage Values
13 TEST - I
18 TEST - II
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 21
a. Introduction – Submarine Gate, Round Runner, Blade
Ejection – Size, location.
b. Stepped Parting surface selection, Design of Core & Cavity,
Dimensioning with Shrinkage, Fits & Tolerances
c. Mould Size selection
Design of a Two Cavity, Two d. Parallel / ‘U’ Circuit Cooling for Cavity & Core, ‘O’ Rings
Plate, Injection Mould as per e. Top View / Plan View
19&20
GTTC Standards f. Selection of Section Plane
g. Sectional Front View as per Section Plane
h. Sectional Side view.
i. Dimensioning Top View & Front View, plate Thickness,
Pitches and Shut Height ….
j. Ballooning & Parts Numbering
Part List to Standard Practice
a. Introduction – Submarine Gate, Modified Trapezoidal Runner,
Blade Ejection – Size, location.
b. Stepped Parting surface selection, Design of Core & Cavity,
Dimensioning with Shrinkage, Fits & Tolerances
Design of a Four Cavity, Two c. Mould Size selection
Plate, Injection Mould as per d. Parallel / ‘U’ Circuit Cooling for Cavity & Core, ‘O’ Rings
GTTC Standards e. Top View / Plan View
21&22
f. Selection of Section Plane
COMPONENT SELECTION BY g. Sectional Front View as per Section Plane
TRAINEE h. Sectional Side view.
i. Dimensioning Top View & Front View, plate Thickness,
Pitches and Shut Height ….
j. Ballooning & Parts Numbering
Part List to Standard Practice
24 SEMESTER EXAMINATION
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 22
MECHATRONICS
SUBJECT CODE: DTDM-VS503
Scope of Mechatronics
Sensors & Transducers
Overview of robots
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 23
MECHATRONICS
SUBJECT CODE: DTDM-VS503
1. INTRODUCTION
- What is Mechatronics?
- Scope of Mechatronics
- Key Issues
- Systems
- Measurement systems
- Control Systems
- Microprocessor based controller
- Response of a system
- Mechatronics approach
4. MICROPROCESSORS
- Control
- Microprocessor systems
- Microcontrollers
- Applications
- Programming
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 24
MECHATRONICS
Text Books
1. MECHATRONICS, Bolton, Pearson Publication [LPE]
2. MECHATRONICS, HMT Ltd., TMH Publication
3. Industrial Electronics, Kissel
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 25
WEEKLY PLAN FOR
MECHATRONICS
WEEK
CHAPTER TITLE CONTENTS OF TOPICS
NO
What is Mechatronics?
Scope of Mechatronics
Key Issues
Systems
INTRODUCTION Measurement systems
1-2
Control Systems
Microprocessor based controller
Response of a system
Mechatronics approach
Sensors & Transducers
Performance terminology
Displacement, position, & Proximity
Control
Microprocessor systems
10-11 MICROPROCESSORS Microcontrollers
Applications
Programming
Introduction
Advantages of CNC Machines
INTRODUCTION TO CNC Machining centre developments
MODERN CNC
Turning centre developments
12-14 MACHINE &
Tool monitoring on CNC Machine
MANUFACTURING Other CNC developments
SYSTEMS Advanced Manufacturing systems
Benefits of FMS
Trends in adoption of FMS
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 26
PROGRAMMABLE Programmable Logic Controllers
LOGIC Basic structures
15-16
CONTROLLERS I/O Processing
Programming
Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 27