GOVT.TOOL ROOM & TRAINING CENTRE … Term...Explain about Injection moulding machine. Explain the...

Govt. Tool Room & Training Centre Bangalore – 10 V- SEMESTER D.T.D.M COURSE P a g e | 1

GOVT.TOOL ROOM & TRAINING CENTRE

SEMESTER: FIFTH

Course: DIPLOMA IN TOOL & DIE MAKING

Syllabus -Theory and practical Subjects

SL.

CODE SUBJECTS Contact

Hours/Week Contact Hours/

Semester NO

1 TDM501 Mould Theory-II 3 60

2 TDM502 Press Tool Design-I 4 80

3 TDM503 Mould Design -I 4 80

4 TDM504 Hydraulics & Pneumatics (Theory) 3 60

5 TDM505 CNC Technology 3 60

Practical’s

6 TDM506 Work Shop – V 27.5 550

7 TDM507 Hydraulics & Pneumatics -Lab 3 60

Scheme of Examination

Course: DIPLOMA IN TOOL & DIE MAKING

SI. No

Sub. Code

Subjects Contact Hours

per Week

Exam Duration

Scheme of Examination Total

Marks

Min marks

for passing

Exam Internal

Assessment

Theory Max Min Max Min

Marks Marks Marks Marks

1 TDM501 Mould Theory-II 3 3 100 50 20 10 120 60

2 TDM502 Press Tool Design-I 4 3 100 50 20 10 120 60

3 TDM503 Mould Design -I 4 4 100 50 20 10 120 60

4 TDM504 Hydraulics & Pneumatics (Theory)

3 3 100 50 20 10 120 60

5 TDM505 CNC Technology 3 3 100 50 20 10 120 60

Practical’s

6 TDM506 Work Shop – V 27.5 10 900 540 100 60 1000 600

7 TDM507 Hydraulics & Pneumatics Lab

3 3 100 50 20 10 120 60

Total 47.5

1500 840 220 120 1720 960


MOULD THEORY-II

SUBJECT CODE: TDM 501

Learning goals for Mould Theory-II

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

Define injection mould & explain briefly

Explain Advantages & disadvantages of injection mould.

Explain different types of injection moulds.

Explain how to construct an injection mould.

Explain the parts of injection mould and their functions

Define a bolster and explain different types.

Define a Feed System & explain briefly on principle

Define Runner & Explain Runner System and their types.

Define gate and explain different types.

Define parting surface and explain their types.

Explain the importance of venting.

Define cooling and their importance in moulding

Explain different types of cooling systems.

Give introduction to ejection system and explain their types.

Explain about splits, side cores and their types.

Explain about working of Finger cam and Dogleg cams.

Explain about split cores & there Types

Define three plate mould, parts & working cycle of three plate moulds.

List out the advantages & disadvantages of Three Plate mould.

Explain about operating system of three plate mould.

Explain About Hot Runner System & There Working Process.

Explain Advantages & disadvantages of Hot Runner System.

Explain about Injection moulding machine.

Explain the Types of injection moulding machines: Hand, Piston, Reciprocating screw.

Explain about the mould polishing & its need, types of material used in polishing.

Define Shrinkage & Explain briefly, calculations on core & cavity.

Explain the defects & remedies of Injection mould.


MOULD THEORY-II

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

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. Introduction

- Definition of injection mould

- Advantages & Disadvantages of injection mould.

Types of injection mould - Two Plate Mould - Three Plate Mould - Hot Runner Mould - Insulated Runner Mould - Stacked Mould

2. 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 mould

3. Feed System

- Working Principle - Runner System - Determining Sprue Dimension - Runner Balancing - Gates & its Types -

4. Parting Surface

- Introduction - Classification of parting Surfaces - Balancing of mould Surface - Relief of Parting Surface - Vents & venting

5. Temperature control system

- Introduction - Factors influencing the cooling - Cooling consideration - Types of cooling system

6. Ejection system

- Introduction - The basic ejection techniques - Ejection for fixed half - Sprue pullers - Ejection force calculations


MOULD THEORY-II

7. Splits and side cores

- Introduction The major forms of split tool are of the following categories: Types of actuating splits - Splits locking method

- Safety arrangement of splits - Summary of splits - Moulding internal undercuts - Form pin

8 Three plate mould

- Introduction - Arrangement of part in three plate mould - Under feeding system - Working cycle of 3-plate mould - Advantages & Disadvantages of 3 plate mould - Limitations - Operating system

9 Hot runner system

- Introduction - Runner less mould - Hot runner unit moulds - Design features of the hot runner mould - Applications of hot runner unit type moulds - Hot runner unit - The manifold block - Nozzle: - Advantages & Disadvantages of hot runner system

10 Injection moulding machines

- Introduction

- Types of injection moulding machines

- Hand Injection Moulding machine

- Piston type injection moulding machine

- Reciprocating screw type injection moulding machines

- Plasticizing Capacity:

- Injection Pressure:

- Factors that influence injection pressure requirements:

- Injection Rate:

- Injection capacity:

- Swept volume:

- Shot capacity:

- Machine operating sequence


MOULD THEORY-II

11 Mould polishing

- Introduction - Need of polishing - Factors which affect polish ability - Different surface conditions prior to polishing - Grinding and stoning of moulds (practical hints) - Polishing of moulds - Polishing sequences - Polishing Technique - Polishing problems - Material used for mould polishing - Lubricants used in Polishing - Hand tools used in polishing - Care of polished surface

12 Shrinkage

- Introduction - Why does shrinkage occur? - Problems caused by part shrinkage - Injection variables & Shrinkage - Caused of excessive part shrinkage - War page - Cavity dimension calculations - Important notes on shrinkage

13 Injection moulding troubles & its remedies

- Air traps - Black specks & black Streaks - Brittleness - Burn Marks - Delaminating - Dimensional Variation - Short shot - Fish Eyes - Flash - Flow marks - Sink marks


WEEKLY PLAN FOR

MOULD THEORY-II

WEEK NO

CHAPTER TITLE CONTENTS OF TOPICS

1-2

INTRODUCTION DEFINITION OF INJECTION MOULD

ADVANTAGES & DISADVANTAGES OF INJECTION MOULD.

Definition of injection mould Advantages & Disadvantages of injection mould.

Types of injection mould Two Plate Mould

Three Plate Mould Hot Runner Mould Insulated Runner Mould Stacked Mould

3 MOULD CONSTRUCTION

Introduced The various Parts Associated with working of Injection mould Function of injection mould Classification of injection mould Construction of various parts of injection mould

4-5 Feed System

Working Principle Runner System Determining Sprue Dimension Runner Balancing Gates & its Types

6 PARTING SURFACE

Introduction Classification of parting Surfaces Balancing of mould Surface Relief of Parting Surface Vents & venting

7 TEMPERATURE CONTROL SYSTEM

Introduction Factors influencing the cooling Cooling consideration Types of cooling system

8-9 EJECTION SYSTEM

Introduction The basic ejection techniques Ejection for fixed half Sprue pullers Ejection force calculations

10-11 SPLITS AND SIDE CORES

Introduction The major forms of split tool are of the following categories: Types of actuating splits Splits locking method Safety arrangement of splits Summary of splits Moulding internal undercuts Form pin

12-13 THREE PLATE MOULD

Introduction Arrangement of part in three plate mould Under feeding system Working cycle of 3-plate mould Advantages & Disadvantages of 3 plate mould Limitations Operating system


WEEKLY PLAN FOR

MOULD THEORY-II

WEEK

NO CHAPTER TITLE CONTENTS OF TOPICS

14 HOT RUNNER SYSTEM

Introduction Runner less mould Hot runner unit moulds Design features of the hot runner mould Applications of hot runner unit type moulds Hot runner unit The manifold block Nozzle: Advantages & Disadvantages of hot runner system

15-16 INJECTION MOULDING MACHINES

Introduction Types of injection moulding machines Hand Injection Moulding machine Piston type injection moulding machine Reciprocating screw type injection moulding machines Plasticizing Capacity: Injection Pressure Factors that influence injection pressure requirements: Injection Rate: Injection capacity: Swept volume: Shot capacity: Machine operating sequence

17-18 MOULD POLISHING

Introduction Need of polishing Factors which affect polish ability Different surface conditions prior to polishing Grinding and stoning of moulds (practical hints) Polishing of moulds Polishing sequence Polishing Technique Polishing problems Material used for mould polishing Lubricants used in Polishing Hand tools used in polishing Care of polished surface

19 SHRINKAGE

Introduction Why does shrinkage occur? Problems caused by part shrinkage Injection variables & Shrinkage Caused of excessive part shrinkage War page Cavity dimension calculations Important notes on shrinkage

20 INJECTION MOULDING TROUBLES &

ITS REMEDIES

Air traps Black specks & black Streak Brittleness Burn Marks Delaminating Dimensional Variation Short shot Fish Eyes Flash Flow marks Sink marks


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

- 1st

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




8. TWO STAGES PROGRESSIVE CUTTING TOOL WITH STAGE STOPPER (WITH REAR PILLAR DIE SET)


- Economical Strip Layout




- Bill of Material


9. THREE / FOUR STAGES PROGRESSIVE CUTTING TOOL WITH PITCH PUNCH & PILOTS ON A REAR

PILLAR DIE SET






- Bill of Material


10. PROGRESSIVE CUTTING TOOL WITH CUT-OFF ARRANGEMENT ON A FOUR PILLAR DIE SET






- Bill of Material


11. PROGRESSIVE CUTTING TOOL WITH PART-OFF ARRANGEMENT ON A DIAGONAL PILLAR DIE SET






- Bill of Material




12. PROGRESSIVE CUTTING TOOL WITH FLOATING STRIPPER ON A REAR PILLAR DIE SET






- Bill of Material


13. COMPOUND TOOL FOR WASHER





- Bill of Material


14. COMPOUND TOOL FOR NON CIRCULAR COMPONENTS





- Bill of Material


15. 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 No.

CHAPTER TOPICS ACTIVITY

1

Introduction to Press Tool

Design & Analyses

Concept

1. COMPONENT ANALYSES - Type of Material - Component Application - Types of Press operations - Critical & General Dimension - Production Quantity - Type of Press Tool required

2. DESIGN ANALYSES - 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 - 1st Angle Projection

Ask students to get different sheet metal Components before commencement of the Design Classes.

Collect Single & Progressive stage Punched Strips.

Display Single Stage, Progressive Stage & Compound Stage model Tools present in your centre.

2 & 3 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

Design Strip Layouts for 10 different Components

4 & 5 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.

Design Strip Layouts & Die Layouts for 06 different Components

6

Single Stage, Single Row

Blanking Tool (Open Tool

Construction)

- Calculation of size of tool elements - Blank Layout - Assembly Plan view - Assembly Sectioned Front View

- Assembly Side view - Bill of Material - Detail Part Drawings

Create the Importance & Awareness about Punch; Fixed

Stripper & Die block alignments.

2 Components

7

Single Stage , Single

Row Angular Layout

Blanking Tool (With

Diagonal Pillar Die Set)

Front Feeding



Create the Importance & Awareness about Economical Strip Utilization during angular

layouts, Positions of Punch with reference to Die opening

& Importance of Die Set 2 Components

8

Single Stage , Double

Row Blanking Tool

(With Rear Pillar Die Set)

Side Feeding



Create the Importance & Awareness of Strip Utilization factor & Need for Double Row in Small Components & Huge

requirements 2 Components

9

Secondary Operational

Tools with Die Nesting,

Piercing Tool (With

Centre Pillar Die Set)

- Calculation of size of tool elements - Assembly Plan view - Assembly Sectioned Front View


Create the Importance & Awareness of Secondary

Operational Tools & Nesting Concept ( Plate type, Pin type)

2 Components


WEEKLY PLAN FOR PRESS TOOL DESIGN-I

10

Two Stages Progressive

Cutting Tool with Stage

Stopper (With Rear Pillar

Die Set)

- Calculation of size of tool elements - Economical Strip Layout - Assembly Plan view - Assembly Sectioned Front View


Create the Importance & Awareness of Pitch, & Opening Alignments of Punch Holder, Stripper plate & Die Block to the students. 2 Components

11

Three / Four Stages

Progressive Cutting Tool

with Pitch Punch & Pilots

on a Rear Pillar Die Set



Create Awareness of Pitch Punch ( Notching Group,

Heeled construction) and Pilots Shape Size & Application

2 Components

12 & 13


with Cut-off Arrangement

on a Four Pillar Die Set



Create the Importance & Awareness Cut-off design & its

construction. 2 Components

14 & 15


with Part-off Arrangement

on a diagonal Pillar Die

Set



Create the Importance & Awareness Part-off design &

its construction. 2 Components

16


with Floating Stripper on

a Rear Pillar Die Set



Create the Importance & Awareness Floating Stripper &

its purpose. ( Clamping type & Non

Clamping type) 2 Components

17 Compound Tool for

Washer



Create the Importance & Awareness of Compound Tool

& highlight types of Components produced in this

Tool

18

Compound Tool

for Non Circular

Components



----

DESIGN HANDS ON SOFTWARE

19 to 22

1. Single Stage Blanking

tool with Rear Pillar Die

Set ( 4 hrs)

2. Compound Tool

( 4 hrs)

3.Five Stages Progressive

Cutting Tool With Floating

Stripper & four Pillar Die

set (8 hrs)



Designing to be done using Software’s


MOULD DESIGN-I



Learning goals for Mould Design-1


Manufacturing methods for thermo set plastic Components.

Manufacturing methods for simple thermo plastic Components.

Shrinkage calculation and there importance for core cavity dimension.

Core and cavity Design concept for simple components.

Design concept for blow moulded Component.

Design concept for rotational moulded Component.

Design concept for thermoforming and calendaring.

Calculation of bulk factor, loading well, shrinkage and flash allowance in

compression mould.

Design concept for simple hand operated compression mould.

Design concept for semi automatic compression mould.

Design concept for fully automatic compression mould.

Calculation of shrinkage in transfer mould.

Design concept for pot type transfer mould.

Design concept for plunger type transfer mould.

Design concept for simple two plate injection mould.


MOULD DESIGN-I



1. INTRODUCTION TO DIFFERENT TYPES PLASTIC MATERIALS, AND MOULDING METHODS

Component application. Type of materials. Type of moulding methods.

2. CORE CAVITY DESIGN AND IMPORTANCE OF SHRINKAGE

- Component application. - Type of materials. - Type of moulding methods. - Core cavity concept. - Core cavity design. - Cooling methods - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage.

3. DESIGN: - BLOW MOULD

- Component application. - Type of materials. - Type of moulding method - Core cavity concept. - Core cavity design. - Basic Attachments for blow mould - Cooling methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.

4. DESIGN: - ROTATIONAL MOULD

- Component application. - Type of materials. - Type of moulding methods - Core cavity concept. - Core cavity design. - Basic Attachments for rotation mould. - Cooling methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.


MOULD DESIGN-I

5. DESIGN: - THERMOFORMING AND CALENDARING

- Component application. - Type of materials. - Type of moulding methods - Core cavity concept. - Core cavity design. - Basic Attachments for thermo forming and calendaring mould. - Cooling methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage.

- Bill of material.

6. DESIGN: - HAND COMPRESSION MOULD

- Component application. - Type of materials. - Type of moulding methods. - Pre forms. - Calculation of bulk factor, loading well, shrinkage and flash allowance. - Advantages & Limitations. - Design of hand compression mould - Core cavity concept. - Core cavity design. - Ejection method. - Heating methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage.

- Bill of material.

7. DESIGN: - SEMI AUTOMATIC COMPRESSION MOULD

- Component application. - Type of materials. - Type of moulding methods. - Pre forms. - Calculation of bulk factor, loading well, shrinkage and flash allowance. - Advantages & Limitations. - Design of semi automatic compression mould. - Core cavity concept. - Core cavity design. - Ejection method. - Heating methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage.

- Bill of material.


MOULD DESIGN-I

8. DESIGN: - FULLY AUTOMATIC COMPRESSION MOULD

- Component application. - Type of materials. - Type of moulding methods. - Pre forms. - Calculation of bulk factor, loading well, shrinkage and flash allowance. - Advantages & Limitations. - Design of fully automatic compression mould. - Core cavity concept. - Core cavity design. - Ejection method. - Heating methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage.

- Bill of material.

9. DESIGN: - POT TYPE TRANSFER MOULD

- Component application. - Type of materials. - Type of moulding methods. - Calculation of shrinkage. - Advantages & Limitations. - Design of pot type transfer mould. - Core cavity concept. - Core cavity design. - Ejection method. - Heating methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.

10. DESIGN: - PLUNGER TYPE TRANSFER MOULD.

- Component application. - Type of materials. - Type of moulding methods. - Calculation of shrinkage. - Advantages & Limitations. - Design of plunger type transfer mould. - Core cavity concept. - Core cavity design. - Ejection method. - Heating methods. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material


MOULD DESIGN-I

11. DESIGN: - SIMPLE HAND INJECTION MOULD

- Component application. - Type of materials. - Type of moulding methods. - Advantages & Limitations. - Design of hand injection mould. - Core cavity concept. - Core cavity design. - Ejection method. - Detail drawing of core and cavity. - Dimensioning of core cavity with shrinkage. - Bill of material.

-

12. BLOW MOULD. ROTATION MOULD. THERMO FORMING. COMPRESSION MOULD. TRANSFER

MOULD HAND INJECTION MOULD

- Basic rules. - Component design. - Core cavity design - Tool design. - Detail drawings. - Electrode design. - Dimensioning with shrinkage. - Bill of material


WEEKLY PLAN FOR MOULD DESIGN -I

WEEK No.


1

Introduction to

different types plastic

materials, and

moulding methods.

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods.

Ask students to get different plastic materials before commencement of the design class.

Ask the application to student their collected components.

Segregate the components like heat, wear resistance, toughness, aesthetic look, commonly used household components etc.

2 & 3 Core cavity design and importance of shrinkage

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods.

2. DESIGN ANALYSES. Core cavity concept. Core cavity design. Cooling methods Detail drawing of core and cavity. Dimensioning of core cavity with

shrinkage.

Ask the student to identify the placement of component.

Ask the students to identify core cavity surface.

Core cavity Design for 05 different types of components.

Example/assignment: 05 components.

4 Design:- Blow mould

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods

2. DESIGN ANALYSES. Core cavity concept. Core cavity design. Basic Attachments for blow

mould. Cooling methods. Detail drawing of core and cavity. Dimensioning of core cavity with

shrinkage. Bill of material.

Ask students to get different blow mould plastic components before commencement of the design class.

5 Design :- Rotational

mould

1. COMPONENT ANALYSES Component application. Type of materials. Type of moulding methods

2. DESIGN ANALYSES. Core cavity concept. Core cavity design. Basic Attachments for rotation

mould. Cooling methods. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different rotational mould plastic components before commencement of the design class.

Ask the students to identify the applications of the components.



6

Design :-

Thermoforming and

calendaring

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods

2. DESIGN ANALYSES. Core cavity concept. Core cavity design. Basic Attachments for thermo

forming and calendaring mould. Cooling methods. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different thermo forming and calendaring mould plastic components before commencement of the design class.

Ask the students to identify

the applications of the components

7 & 8 Design :- Hand

compression mould

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods. Pre forms. Calculation of bulk factor, loading

well, shrinkage and flash allowance.

Advantages & Limitations. 2. DESIGN ANALYSES.

Design of hand compression mould

Core cavity concept. Core cavity design. Ejection method. Heating methods. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different compression (heat, wear resistance, toughness) mould plastic components before commencement of the design class.


9 & 10

Design:- Semi

automatic compression

mould




Design of semi automatic compression mould.







11 & 12

Design :- Fully

automatic compression

mould




Design of fully automatic compression mould.





13 & 14 Design: - Pot type

transfer mould.

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods. Calculation of shrinkage. Advantages & Limitations.

2. DESIGN ANALYSES. Design of pot type transfer

mould. Core cavity concept. Core cavity design. Ejection method. Heating methods. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different (heat, wear resistance, toughness) plastic components before commencement of the design class.


15 & 16 Design: - Plunger type

transfer mould.

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods. Calculation of shrinkage. Advantages & Limitations.

2. DESIGN ANALYSES. Design of plunger type transfer

mould. Core cavity concept. Core cavity design. Ejection method. Heating methods. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different (heat, wear resistance, toughness) plastic components before commencement of the design class.



WEEKLY PLAN FOR MOULD DESIGN –I

17 Design:- Simple hand

injection mould

1. COMPONENT ANALYSES. Component application. Type of materials. Type of moulding methods. Advantages & Limitations.

2. DESIGN ANALYSES. Design of hand injection mould. Core cavity concept. Core cavity design. Ejection method. Detail drawing of core and cavity. Dimensioning of core cavity with


Ask students to get different (other than heat, wear resistance, toughness) plastic components before commencement of the design class.


DESIGN HANDS ON SOFTWARE

WEEK No.


18 to 22

1. Blow mould.

2. Rotation mould.

3. Thermo forming.

4. Compression mould.

5. Transfer mould

6. Hand injection

mould

Basic rules. Component design. Core cavity design. Tool design. Detail drawings. Electrode design. Dimensioning with shrinkage. Bill of material.

Designing to be done using Software’s

Solid works/Pro-e/UG/Catia


HYDRAULICS AND PNEUMATICS (THEORY)


Learning Goals of Hydraulics & Pneumatics

Understand basics of Hydraulics and its application

Know the components of Hydraulic Power

Understand Motor and Pumps

Understand the types of Hydraulic Valves

Understand Hydraulic oil

Understand about sealing and its Materials

Understand about Hydraulic and Pneumatic symbol

Understand about basics of Pneumatic

Understand different types of Pneumatic Valves with examples.

Understand accumulators

To know about compressor

Understand the circuit diagram





1. Introduction to Hydraulics

- Fluid Power

- Basic Law- Pascal’s law, continuity equation

- Introduction to conversion of units

- Application and advantages of fluid power

2. Hydraulic fluids and properties

- Types of fluids

- Properties of fluids - Problems caused by gases in fluids

3. Pumps

- Introduction to pumps - -

- External Gear Pumps - -

- Internal Gear Pumps

- -

- Unbalanced vane pump - -

- Pressure compensated variable delivery pump

4. Introduction to actuators

- Gear type Hydraulic Motors -

- Vane motors

-

- Piston motors

-

- Semi Rotary Actuator -

- Vane Type Actuator

-

- Rack and pinion semi rotary actuator

- Lever arm semi rotary actuator -

- Chain and sprocket semi rotary actuator

- Helical screw semi rotary Actuator

- Hydraulic cylinder

-

- Single, and double acting cylinder

5. Seals and Filters

- Introduction

- Static Seals

- Dynamic Seals

- Materials for seals

- Strainer

- Filters

- Types of filters

- Accumulators, types


HYDRAULICS AND PNEUMATICS( THEORY)

6. Industrial Hydraulic System

- Introduction

-

- Deceleration circuit

-

- Intensifier -

-

- Intensifier press circuit -

- Circuits for operation of machine tools

- Planning machine

-

- Vertical milling machine - Control of single and double acting hydraulic cylinders -

-

7. Pneumatics

- Introduction to pneumatic

- Comparison of Pneumatic system with hydraulic system

- Basic Pneumatic system

- Air Filter

- Pressure regulator

- Lubricator

- Mufflers

- Pneumatics valves, Direction control valves

- Symbolic representation of Pneumatics valves

- a) Two way b) Three way c) Four way d) Five way

- Time delay valve

- Air Motors

- Types

- Pneumatic circuit

- Basic Pneumatic circuit

8. Hydro pneumatic

- Introduction

- Air-oil Reservoir

- Air-Oil Cylinder

- Ait-Oil intensifier

9. Pneumatic logic controls

- Introduction

- Pneumatic Sensors

- Pneumatic limit valves

- Back Pressure sensors

- Proximity sensor

- Gap sensor

- Limit switch

- Pneumatic logic Circuit



10. Electric control of fluid power

- Introduction

- Components of electrical controls

- switches

- solenoids

- relays

- Timers

- Electro hydraulic pneumatic circuit

- Reciprocation of a cylinder using pressure switches

- Control of a cylinder using a single limit switch

11. Installation, maintenance, trouble shooting of fluid power systems

- Introduction

- Installation of pumps, cylinders, valves, compressors, driers, filters and lubricators

- Maintenance of hydraulic system

- Production of compressed air

- Trouble shooting of hydraulic system

12. Test and revisions


WEEKLY PLAN FOR


WEEK NO


1-2 Introduction to Hydraulics

- Fluid Power

- Basic Law- Pascal’s law, continuity equation

- Introduction to conversion of units

- Application and advantages of fluid power

3-4

Hydraulic fluids and properties

- Types of fluids

- Properties of fluids - Problems caused by gases in fluids

- Types of fluids

Pumps

- Introduction to pumps

- External Gear Pumps

- Internal Gear Pumps

- Unbalanced vane pump

5-6 Introduction to actuators

- Gear type Hydraulic Motors

- Vane motors

- Piston motors

- Semi Rotary Actuator

- Vane Type Actuator

- Rack and pinion semi rotary actuator

- Lever arm semi rotary actuator

- Chain and sprocket semi rotary actuator

- Helical screw semi rotary Actuator

- Hydraulic cylinder

- Single, and double acting cylinder

7-8 Seals and Filters

- Introduction

- Static Seals

- Dynamic Seals

- Materials for seals

- Strainer

- Filters

- Types of filters

- Accumulators, types

9-10 Industrial Hydraulic System

- Introduction

- Deceleration circuit

- Intensifier

- Intensifier press circuit

- Circuits for operation of machine tools

- Planning machine

- Vertical milling machine - Control of single and double acting

hydraulic cylinders


WEEKLY PLAN FOR


WEEK NO


11-15

Pneumatics

- Introduction to pneumatic

- Comparison of Pneumatic system with hydraulic system

- Basic Pneumatic system

- Air Filter

- Pressure regulator

- Lubricator

- Mufflers

- Pneumatics valves, Direction control valves

- Symbolic representation of Pneumatics valves

- a) Two way b) Three way c) Four way d) Five way

- Time delay valve

- Air Motors

- Types

- Pneumatic circuit

- Basic Pneumatic circuit

16 Hydro pneumatics

- Introduction

- Air-oil Reservoir

- Air-Oil Cylinder

- Ait-Oil intensifier

17-18 Pneumatic logic controls

- Introduction

- Pneumatic Sensors

- Pneumatic limit valves

- Back Pressure sensors

- Proximity sensor

- Gap sensor

- Limit switch

- Pneumatic logic Circuit

19 Electric control of fluid

power

- Introduction

- Components of electrical controls

- Switches

- Solenoids


WEEKLY PLAN FOR


20 Electric control of fluid

power

- relays

- Timers

- Electro hydraulic pneumatic circuit

- Reciprocation of a cylinder using pressure switches

- Control of a cylinder using a single limit switch

21-22

Installation,

maintenance, trouble

shooting of fluid power

systems

- Introduction

- Installation of pumps, cylinders, valves, compressors, driers, filters and lubricators

- Maintenance of hydraulic system

- Production of compressed air

- Trouble shooting of hydraulic system

Test and revisions

- Test and revisions


CNC TECHNOLOGY (THEORY)




1.0 Introduction to CNC

- Definition of CNC - Function of CNC - Comparison between NC and CNC - Direct numerical control - Advantages of CNC - Disadvantages of CNC - Application of CNC - Parts suitable for CNC Machines

2.0 Components of numerical control system

- Introduction - Basic components of numerical control system - Functions of machine control unit (MCU) - Programming Instruction - NC Coding - Machine Tool

3.0 Classification of numerical control machine

- Introduction - Classifications Based on feedback control

- Open loop control - Closed loop control

- Classification based on control system features

- Point to Point control system - Straight line control system - Contouring control system


- Classification based on coordinate systems

- Cartesian coordinate system - Cylindrical coordinate system


4.0 Tooling for CNC Machines

- Introduction - Cutting Tools - Index able inserts - Tool holders - Work holding devices in CNC

5.0 Tool changing and Pallet changing

- Tool changes - Automatic tool changers - Tool storage - Tool length - Tool length offset - Automatic Pallet changers

6.0 Part Programming for Turning

- Introduction - Programming coordinates

- Mixing Absolute and Incremental Positioning - Metric coordinates

- Two axis programming - Turning Programs - Step turning Programs - Taper turning Programs - Knurling and Program - Canned programs


7.0 Part Programming for Milling

- Two axis programming - Rectangular milling Programs - Circular milling Programs

- Contour milling Programs - Drilling examples-Incremental Positioning

- Milling examples-Absolute Positioning - Milling examples-Incremental Positioning - Linear and circular interpolation - Cutter diameter compensation - Tool offset and sub programs - Canned Programs

REFERENCE BOOKS

1. CNC Machine – B S Pabla, M Adithan

2. Computer numerical control concepts & programming 4th Edition – Warren S. Seames

3. Programming of CNC Machines – Ken Evans

4. CNC Machines – K Adinarayana

5. Computer numerical control machines – P Radhakrishnan


WEEKLY PLAN FOR


WEEK NO


1-3 Introduction to CNC

Definition of CNC Function of CNC Comparison between NC and CNC Direct numerical control Advantages of CNC Disadvantages of CNC Application of CNC Parts suitable for CNC Machines

4-7

Components of numerical control system

Introduction Basic components of numerical control system Functions of machine control (MCU) Programming Instruction NC Coding Machine Tool

Q54

Classification of numerical control machine

Introduction classifications Based on feedback control Open loop control Closed loop control

Classification based on control system features Point to Point control system Straight line control system

Contouring control Classification based on coordinate systems Cartesian coordinate system Cylindrical coordinate system

12-14 Tooling for CNC Machines

Introduction Cutting Tools Index able inserts Tool holders Work holding devices in CNC

15-16 Tool changing and Pallet changing

Tool changes Automatic tool changers Tool storage Tool length Tool length offset Automatic Pallet changers


WEEKLY PLAN FOR

CNC TECHNOLOGY( THEORY)

17-18 Part Programming for Turning

Introduction Programming coordinates Mixing Absolute and Incremental Positioning Metric coordinates Two axis programming Turning Programs Step turning Programs Taper turning Programs knurling and Program Canned programs

19-20 Part Programming for Milling

Programming for Milling Two axis programming Rectangular milling Programs Circular milling Programs Contour milling Programs Drilling examples- Incremental Positioning Milling examples-Absolute Positioning Milling examples- Incremental Positioning Linear and circular interpolation Cutter diameter compensation Tool offset and sub programs Canned Programs

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