V-Sem DTDM

GOVT.
TOOL ROOM & TRAINING CENTRE
SEMESTER: FIFTH
Course: DIPLOMA IN TOOL & DIE MAKING
Syllabus -Theory and practical Subjects
SL. Contact Contact Hours/

CODE SUBJECTS
NO Hours/Week Semester
1 DTDM-VS501 Press Tool Theory-II 3 64

2 DTDM-VS502 Mould Theory-I 3 64
3 DTDM-VS503 Mechatronics 3 64
Practical’s
4 DTDM-VS504 Press Tool Design-I 4 94
5 DTDM-VS505 Mould Design-I 4 94
6 DTDM-VS506 Material Testing Lab 3 64
7 DTDM-VS507 CAD Lab-III 3 64
8 DTDM-VS508 Work Shop – V 17 292
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
SUBJECT CODE: DTDM-VS501
Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64
Learning goals Press Tool Theory- II:
Learning goals for Press Tool Theory:

On completion of this subject, the trainees will be able to:
 Explain different types of non-cutting operations

 Explain the behaviour of material during deformation
 Specifying proper stock materials for non-cutting operations
 Understand the significance of fine blanking operation
 Select proper materials for punch and die and recommend suitable heat treatment
operations
 Understand the importance of a combination tool
 Understand the theory of bending and calculate all the required parameters
 Understand the theory of drawing and calculate all the required parameters
 Understand the application of each element in a bending and drawing tool
 Select proper lubricants
 Select a proper press machine for a required operation
PRESS TOOL THEORY – II
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. INTRODUCTION TO NON-CUTTING OPERATIONS

- Introduction
- Purpose and applications
- Advantages
- Types of non-cutting operations
- Types of non-cutting press tools
- Behaviour of material during deformation
- Stock material for non-cutting operations
2. FINE BLANKING
- Introduction
- Construction
- Functions
- Operational sequences
- Applications and advantages
- Press selection for fine blanking
3. PUNCH AND DIE

- Materials for punch and die
- Heat treatment of punch and die
- Methods of manufacturing punch and die
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
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:
1. Tool and die maker by Mahajan

2. Design fundamentals by Pacquin
3. Tool design by Donaldson
4. Basic die design by Osterguard
5. Advanced die design by Osterguard
WEEKLY PLAN FOR PRESS TOOL THEORY-2
Week Chapt Topics to be covered Learning Goals

ers
1 - Introduction Review
- Purpose and applications Necessity Explain operations – Embossing,
Introduction to Non Cutting
Advantages Coining, Curling, Flanging, Bulging

Lowering Etc & Demonstrate
- Types of non-cutting operations
Operations
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
4 - Introduction Explain Purpose, Necessity &

FINE BLANKING
- Construction Advantages & Disadvantage over

- Functions Conventional blanking. Impinger,
Cut band, Edge, Radius, Burr. Cost of
5 - Operational sequences tool
- Applications and advantages
- Press selection for fine blanking
6 HCHCR, OHNS. Secondary Heat
PUNCH AND
- Materials for punch and die

- Heat treatment of punch and die treatment, Quench cracks.
- Methods of manufacturing punch and die Conventional & Non conventional
DIE
machining
7 - Introduction Explain Construction Purpose,
COMBINATION
- Construction Rigidity.
- Functions
DIE
- Advantages and disadvantages

- Manufacturing methods
8 - Theory of bending Explain Tension and Compression

- Bend elements Bend angle, Radius, Area, Line.
- Neutral axis and its importance Explain construction, Purpose,
Necessity & Advantages of wiping
dies, Air bend & Bottoming dies
- Blank development calculation
BENDING
9 - Calculation of bend allowance Solve problems
- V-bending procedure and force calculation

- U-bending theory and force calculation
10 - Wiping Procedure and force calculation
-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
- Purpose of lubricants Mineral oil, Chemicals, Soluble oil,

Lubrica
- Types of lubricants Solvents , Animal fats

tion
12
13 - Introduction Pressure pad & Solid Forming.

Oper
Formi
- Theory of forming
ng
- Types of forming dies

- Purpose and application
14 - Introduction Shallow & Deep ,Reverse draw, Single
- Metal flow during drawing action ,Double action, Push through
- Variables that affect metal flow during drawing
DRAWING
- Types of draw dies

Punch Radius, Die Radius & Blank Holder
- Calculations – flat blank diameter, draw reductions, (Rigid, Spring) Draw beads
15 number of draws required, draw force & Cup Solve problems
height
16 Wrinkling, Puckering And Earing.
- Defects in Drawing operation Demonstrate different Components
17 - Introduction Tons, Manual, Fly, Bull, Mechanical,
- Specification Hydraulic. ” H”,”C” frame. Drives Crank,
- Classification Eccentric, Cam, Knuckle, Toggle, Screw,
- Types of presses
Rack & Pinion. Single, Double & Triple
- Power source, Frame, Driving mechanism, Slides
PRESS MACHINES
action.
- Attachments for presses
- Selection of a press
18 - Feeding system – purpose, types, advantages Roll feed, Hitch feed, De-Coiler. Push &
Pull feed
MOULD THEORY-I
Learning goals for Mould Theory-I

 Know how to differentiate Thermoplastic and Thermo set moulding methods.
 Identify the working process of Blow moulding and applications.
 Identify Extrusion moulding working process and applications.
 Identify Rotational moulding, working process and applications.
 Identify working process of Thermo forming, types, and applications.
 Identify Calendaring working process and applications.
 List out the material of Core & Cavity, effects of alloying elements &
treatment.
 Know the definition of an injection mould. Advantages & Disadvantages of
injection mould.
 Know the function of an injection mould and their classification.
 Know the construction of various elements of an injection mould.
 Know the importance of feed system and balancing the same.
 Know the classifications of Runners, Gates with their typical applications.
 Know the importance and type of Ejector elements.

 Know the functions and applications of Pin, Stepped pin, ‘D’ shape, Blade,
Stripper plate, Sleeve and Air ejectors.
 Factors influencing as well as considerations in cooling.
 Classification and typical applications of different cooling methods.
 Importance of Flat, Non-flat, stepped, local stepped, Angled, Complex
surface.
 Balancing of mould surface.
 The importance of providing vents in an injection mould.
 The importance of providing Shrinkages in an injection mould.
MOULD THEORY-I
Contact Hours /Week: 3 Contact Hours / Semester: 64
1. EINLEITUNG
- Definition of mould
2. TYPES
- Construction, Working process of Thermoplastic and Thermo set moulding methods

- Thermoplastic moulding methods
- Injection moulding
- Blow moulding
- Extrusion moulding
- Thermo forming
- Rotational moulding
- Calendaring
3. INJECTION MOULD
- Introduction
- Definition of injection mould
- Advantages & Disadvantages of injection mould
4. TYPES OF INJECTION MOULD
- Two Plate Mould

- Three Plate Mould
- Hot Runner Mould
- Insulated Runner Mould
- Stacked 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)
7. EJE CTION
- Importance of Ejection
- Types (Pin, Stepped pin, ‘D’ shape, Blade, Stripper plate, Sleeve, Air)
8. TEMPERTURE CONTROL SYSTEM
- Factors influencing the cooling

- Cooling considerations
- Types (Parallel, ‘U’ type, Baffle, Stepped, Angle hole, Thermal pin, Bubbler, Annular)
9. PARTING SURFACE
- Introduction
- Classification (Flat, Non-flat, Stepped, Local stepped, Angled, Complex)
- Balancing of mould surface
- Importance and applications of Air Vents
10. SHRINKAGE
- Introduction
- Why does shrinkage occur?
- Problems caused by the shrinkage
- Cavity dimension calculations
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
- Thermo Plastics, Definition of Injection Mould, Moulding Machine,

5-6 Working Process.
- Definition, Working Cycle: Variables – Mould, Machine, Design,
Material
- Advantages & Dis-Advantages of an Injection Mould
Definition of an injection
mould
- Advantages & Disadvantages

of an injection mould.
7-8 - Types of an injection mould
- Two Plate Mould
- Three Plate Mould
- Hot Runner Mould
- Insulated Runner Mould
Stacked Mould
- Types of Runners (Full round, half round,
Square, Trapezoidal, Modified Trapezoidal)
- Manually trimmed gates (Edge, Ring, Tab,
-Feed system Direct Sprue, Spoke, Disk,)
9-10 - Different types of Runners - Automatically trimmed gates
and gates (Pin point and Submarine)
11 Unit Test - 1
- Importance of Ejection
- Types (Pin, Stepped pin, ‘D’ shape, Blade,
12-13 Ejection Stripper plate, Sleeve, Air)
- Factors influencing the cooling

- Cooling considerations
14-15 Temperature control system - Types (Parallel, ‘U’ type, Baffle, Stepped,
Angle hole, Thermal pin, Bubbler, Annular)
- Introduction
- How to select
- Classification (Flat, Non-flat, Stepped,
16-17 Parting surface
Local stepped, Angled, Complex)
- Balancing of mould surface
- 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
PRESS TOOL DESIGN - I
Learning goals for Press Tool Design-1
 Prepare a strip lay-out & calculate material utilization
 Calculate centre of pressure graphically
 Calculate thickness of die plate.
 Calculations tool elements size & thickness.
 Design of Die lay-out with ‘0’ line dimensions
 Design a blanking tool assembly, part list & detail drawings
 Design progressive blanking tool assembly & calculations of
tool elements size & thickness.
 Design progressive tool with Fixed type & Floating type
strippers
 Design progressive tool with Cut off & Part off operations
 Design compound tool assembly in three views
PRESS TOOL DESIGN -I
1. INTRODUCTION TO PRESS TOOL DESIGN & ANALYSES CONCEPT
- 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
2. STRIP LAY OUT
- Structure of Strip Layout

- Blank Layout [ Single Row, Multi Rows, Single Pass,
- Double Pass]
- Utilization of sheet material Calculation
- Required tonnage Calculation
3. DIE LAY OUT
- Top view, Sectioned Front view, Sectioned Side

- View, Partial Enlarged Views.
- Die openings & Holes Projections.
- Die block Length, width & Thickness Calculations.
- Dimensioning [ Co-ordinate, Centralized ]
- Geometrical Symbols
- Sub Title Block
- Centre of pressure (COP) Graphically & Algebraic
- Calculation
- Calculations of Plate Thickness.
4. SINGLE STAGE, SINGLE ROW BLANKING TOOL ( OPEN TOOL CONSTRUCTION)
- Calculation of size of tool elements

- Blank Layout
- Assembly Side view
- Bill of Material
- Detail Part Drawings
5. SINGLE STAGE , SINGLE ROW ANGULAR LAYOUT BLANKING TOOL (WITH DIAGONAL PILLAR DIE
SET) FRONT FEEDING

- Blank Layout
- Bill of Material
6. SINGLE STAGE , DOUBLE ROW BLANKING TOOL (WITH REAR PILLAR DIE SET) SIDE FEEDING

- Blank Layout
- Bill of Material
7. SECONDARY OPERATIONAL TOOLS WITH DIE NESTING , PIERCING TOOL (WITH CENTRE PILLAR DIE
SET)

- Bill of Material
4. TWO STAGES PROGRESSIVE CUTTING TOOL WITH STAGE STOPPER (WITH REAR PILLAR DIE SET)

- Economical Strip Layout
- Bill of Material
5. THREE / FOUR STAGES PROGRESSIVE CUTTING TOOL WITH PITCH PUNCH & PILOTS ON A REAR
PILLAR DIE SET

- Bill of Material
6. PROGRESSIVE CUTTING TOOL WITH CUT-OFF ARRANGEMENT ON A FOUR PILLAR DIE SET

- Bill of Material
7. PROGRESSIVE CUTTING TOOL WITH PART-OFF ARRANGEMENT ON A DIAGONAL PILLAR DIE SET

- Bill of Material
8. PROGRESSIVE CUTTING TOOL WITH FLOATING STRIPPER ON A REAR PILLAR DIE SET

- Bill of Material
9. COMPOUND TOOL FOR WASHER

- Bill of Material
10. COMPOUND TOOL FOR NON CIRCULAR COMPONENTS

- Bill of Material
11. SINGLE STAGE BLANKING TOOL WITH REAR PILLAR DIE SET COMPOUND TOOL FIVE STAGES
PROGRESSIVE CUTTING TOOL WITH FLOATING STRIPPER & FOUR PILLAR DIE SET

- Bill of Material
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.
- 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
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
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
Side Feeding requirements
- Bill of Material
2 Components
Secondary Operational Create the Importance &
Tools with Die Nesting, Awareness of Secondary
9 Operational Tools & Nesting
Piercing Tool (With - Assembly Side view
Concept ( Plate type, Pin type)
Centre Pillar Die Set) - Bill of Material
2 Components
WEEKLY PLAN FOR PRESS TOOL DESIGN-I
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
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
Progressive Cutting Tool Create the Importance &
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
Progressive Cutting Tool - Economical Strip Layout
with Part-off Arrangement - Assembly Plan view
Awareness Part-off design &
14 & 15 - Assembly Sectioned Front View
on a diagonal Pillar Die its construction.
Set 2 Components
- Bill of Material
Progressive Cutting Tool Awareness Floating Stripper &
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
Compound Tool for Awareness of Compound Tool
17 & highlight types of
Washer - Assembly Side view
Components produced in this
- Bill of Material
Tool
Compound Tool - Assembly Plan view
for Non Circular - Assembly Sectioned Front View
18 ----
Components - Bill of Material
DESIGN HANDS ON SOFTWARE
1. Single Stage Blanking
tool with Rear Pillar Die
Set ( 4 hrs) - Calculation of size of tool elements
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
Stripper & four Pillar Die
set (8 hrs)
MOULD DESIGN-I
Learning goals for Mould Design-1
 Designing of concept an Assembly Two Plate Mould as per GTTC Standards.
 Designing methods for simple thermo plastic Components.
 Shrinkage calculation and their importance for core cavity dimensioning.
 Core and cavity Design concept for simple components.
 Design concept for simple two plate injection mould.
 Understands the importance of Core & cavity alignment/ manufacturing concept.
 Understands the placement of multiple impressions in an injection mould.
 Understands how to select/ extract suitable mould base within GTTC standards.
 Understands the significance of designing a single cavity mould. (Direct sprue gate)
 Understands the importance of adopting different ejection methods.
 Select various cooling methods for individual moulds.
 Choose/ select different parting surfaces.
 Importance of Providing Shrinkage Allowance
MOULD DESIGN-I
SYLLABUS FOR MOULD DESIGN – I
WEEK
DESIGN CONCEPT OBJECTIVES
No.
a. Parting Line Selection

Design of a Single Cavity Hand b. Alignment of Core & Cavity
Mould with Edge Gate, & Round c. Ejection
1&2
runner & Plate Ejection. d. All Parts Drawing with suitable dimensioning method
e. Dimensioning Core &Cavity with Shrinkage Values
a. List out parts of a Two Plate Mould

Design of a Standard Two Plate b. Draw to 1:1 scale, individual parts with respect to Dimensions
Mould PARTS as per GTTC for Mould Set No. 1
3 &4
Standards for Mould Set No1 c. Dimensioning Methods Selection
d. Fits & Tolerances
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
a. Introduction – Direct Sprue, Spoke Gate, Stripper Ejection –

Size, location.
b. Parting surface selection, Design of Core & Cavity,
Dimensioning with Shrinkage, Fits & Tolerances
c. Mould Size selection
Design of an Assembly Two Plate d. Annular Cooling for Cavity, Baffle Cooling for Core, ‘O’ Rings
Mould as per GTTC Standards e. Top View / Plan View
6 with Stripper Plate Ejection for f. Selection of Section Plane
Mould Set No-1. g. Sectional Front View as per Section Plane
h. Side view - Missing Views, Partial Sectioning.
i. Dimensioning Top View & Front View, plate Thickness,
Pitches and Shut Height ….
j. Ballooning & Parts Numbering
k. Part List to Standard Practice
a. Introduction – Direct Sprue Gate, Stripper Ejection – Length

Bolt Actuation. Size, location.
b. Mould Size selection
Design of an SINGLE Cavity Two c. Annular Cooling for Cavity, Baffle Cooling for Core, ‘O’ Rings
Plate Length Bolt Actuation, d. Top View / Plan View
Stripper Ejection Mould as per e. Selection of Section Plane
7 &8 GTTC Standards for Mould Set f. Sectional Front View as per Section Plane
No. 2. g. Side view - Missing Views, Partial Sectioning.
h. Dimensioning Top View & Front View, plate Thickness,
SAME COMPONENT AS ABOVE Pitches and Shut Height
i. Ballooning & Parts Numbering
j. Part List to Standard Practice
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
a. Introduction - Edge Gate, Round Runner, Pin Ejection – Size,

location.
b. Local Stepped Parting surface selection, Design of Core &
Cavity, Dimensioning with Shrinkage, Fits & Tolerances
d. Annular Cooling for Cavity, Baffle Cooling for Core, ‘O’ Rings
Design of a Two Cavity, Two e. Top View / Plan View
11&12 Plate, Injection Mould as per f. Selection of Section Plane
GTTC Standards g. Sectional Front View as per Section Plane
13 TEST - I
a. Introduction – Fan Gate, Round Runner, Pin Ejection – Size,

location.
Design of a Two Cavity, Two d. Annular Cooling for Cavity, Baffle Cooling for Core, ‘O’ Rings
Plate, Injection Mould as per e. Top View / Plan View
14&15 GTTC Standards f. Selection of Section Plane
g. Sectional Front View as per Section Plane
a. Introduction – Submarine Gate, Round Runner, Sleeve

Ejection – Size, location.
d. Annular Cooling for Cavity, Bubbler Cooling for Core, ‘O’
Rings
Design of a Two Cavity, Two
e. Top View / Plan View
16&17 Plate, Injection Mould as per
f. Selection of Section Plane
GTTC Standards
18 TEST - II
a. Introduction – Submarine Gate, Round Runner, Blade
Ejection – Size, location.
b. Stepped Parting surface selection, Design of Core & Cavity,
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
h. Sectional Side view.
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,
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.
Part List to Standard Practice
SUITABLE SELECTION OF PARTING SURFACE,

COMPONENT SELECTION BY COOLING & EJECTION TECHNIQUES
23
TRAINEE
24 SEMESTER EXAMINATION
MECHATRONICS
Learning goals for MECHATRONICS

 Scope of Mechatronics
 Sensors & Transducers
 Electrical actuation systems

 Microprocessor systems and its applications
 Advanced Manufacturing systems

 Programmable Logic Controllers
 Overview of robots
MECHATRONICS
SPECIFIC INSTRUCTIONAL OBJECTIVES
1. INTRODUCTION
- What is Mechatronics?
- Scope of Mechatronics
- Key Issues
- Systems
- Measurement systems
- Control Systems
- Microprocessor based controller
- Response of a system
- Mechatronics approach
2. SENSORS & TRANSDUCERS

- Sensors & Transducers
- Performance terminology
- Displacement, position, & Proximity
- Velocity and motion
- Force
- Fluid pressure
- Liquid flow
- Liquid levels
- Light sensors
- Selection of sensors
- Data i/p using switches
3. ELECTRICAL ACTUATION SYSTEMS

- Electrical systems: Relays
- Solid state switches
- Solenoid
4. MICROPROCESSORS
- Control
- Microprocessor systems
- Microcontrollers
- Applications
- Programming
MECHATRONICS
5. INTRODUCTION TO MODERN CNC MACHINE & MANUFACTURING

SYSTEMS
- Introduction
- Advantages of CNC Machines
- CNC Machining centre developments
- Turning centre developments
- Tool monitoring on CNC Machines
- Other CNC developments
- Advanced Manufacturing systems
- Benefits of FMS
- Trends in adoption of FMS
6. PROGRAMMABLE LOGIC CONTROLLERS

- Programmable Logic Controllers
- Basic structures
- I/O Processing
- Programming
7. Robots & Other Motion Control Systems

- Overview of robots
- Types of robots
- Types of robot controls
- Types of robot programs
- Basic parts of robot systems
- Other types of robot actuators
- I/O signals for robots
- I/O circuits for robot signals
- I/O modules
- Robots in typical work and manufacturing cells
Text Books
1. MECHATRONICS, Bolton, Pearson Publication [LPE]
2. MECHATRONICS, HMT Ltd., TMH Publication
3. Industrial Electronics, Kissel
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
Velocity and motion

SENSORS & Force
3-6 TRANSDUCERS Fluid Pressure
Liquid flow
Liquid levels
Light sensors
Selection of sensors
Data i/p using switches
ELECTRICAL Electrical systems: Relays
ACTUATION Solid state switches
7-8
SYSTEMS Solenoid
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
PROGRAMMABLE Programmable Logic Controllers
LOGIC Basic structures
15-16
CONTROLLERS I/O Processing
Programming
WEEKLY PLAN FOR

MECHATRONICS
WEEK
CHAPTER TITLE CONTENTS OF TOPICS
NO
Overview of robots
Types of robots
Types of robot controls
Types of robot programs
ROBOTS & OTHER
Basic parts of robot systems
MOTION CONTROL Other types of robot actuators
17-20 SYSTEMS
I/O signals for robots
I/O circuits for robot signals
I/O modules
Robots in typical work and manufacturing
cells

V-Sem DTDM

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GOVT.

TOOL ROOM & TRAINING CENTRE

Course: DIPLOMA IN TOOL & DIE MAKING

Syllabus -Theory and practical Subjects

SL. Contact Contact Hours/

1 DTDM-VS501 Press Tool Theory-II 3 64

SUBJECT CODE: DTDM-VS501

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 64

Learning goals Press Tool Theory- II:

Learning goals for Press Tool Theory:

 Explain different types of non-cutting operations

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. INTRODUCTION TO NON-CUTTING OPERATIONS

3. PUNCH AND DIE

1. Tool and die maker by Mahajan

Week Chapt Topics to be covered Learning Goals

Advantages Coining, Curling, Flanging, Bulging

4 - Introduction Explain Purpose, Necessity &

- Construction Advantages & Disadvantage over

- Materials for punch and die

- Advantages and disadvantages

8 - Theory of bending Explain Tension and Compression

9 - Calculation of bend allowance Solve problems

- V-bending procedure and force calculation

- Purpose of lubricants Mineral oil, Chemicals, Soluble oil,

- Types of lubricants Solvents , Animal fats

13 - Introduction Pressure pad & Solid Forming.

- Types of forming dies

- Types of draw dies

SUBJECT CODE: DTDM-VS502

Learning goals for Mould Theory-I

On completion of this subject, the trainees will be able to:

 Know the importance and type of Ejector elements.

 The importance of providing vents in an injection mould.

 The importance of providing Shrinkages in an injection mould.

Contact Hours /Week: 3 Contact Hours / Semester: 64

SPECIFIC INSTRUCTIONAL OBJECTIVES:

- Construction, Working process of Thermoplastic and Thermo set moulding methods

4. TYPES OF INJECTION MOULD

- Two Plate Mould

8. TEMPERTURE CONTROL SYSTEM

- Factors influencing the cooling

- Thermo Plastics, Definition of Injection Mould, Moulding Machine,

- Advantages & Disadvantages

- Factors influencing the cooling

SUBJECT CODE: DTDM-VS504

Learning goals for Press Tool Design-1

On completion of this subject, the trainees will be able to:

 Prepare a strip lay-out & calculate material utilization

 Calculate centre of pressure graphically

 Calculate thickness of die plate.

 Calculations tool elements size & thickness.

 Design of Die lay-out with ‘0’ line dimensions

 Design a blanking tool assembly, part list & detail drawings

 Design progressive blanking tool assembly & calculations of

tool elements size & thickness.

 Design progressive tool with Fixed type & Floating type

 Design compound tool assembly in three views

Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. INTRODUCTION TO PRESS TOOL DESIGN & ANALYSES CONCEPT