Diploma in Engineering and Technology: 1220 Department of Mechanical Engineering (Tool & Die)

DIPLOMA IN ENGINEERING AND TECHNOLOGY
1220 DEPARTMENT OF
MECHANICAL ENGINEERING (TOOL & DIE)
SEMESTER PATTERN
N – SCHEME
IMPLEMENTED FROM 2020 - 2021
CURRICULUM DEVELOPMENT CENTRE
DIRECTORATE OF TECHNICAL EDUCATION

CHENNAI-600 025, TAMIL NADU
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STATE BOARD OF TECHNICAL EDUCATION & TRAINING, TAMILNADU
DIPLOMA IN ENGINEERING / TECHNOLOGY SYLLABUS
N SCHEME
(Implemented from the Academic Year 2020 -2021 onwards)
Chairperson
Tmt G.LAXMI PRIYA I.A.S.

Director
Directorate of Technical Education, Guindy, Chennai.
Co-ordinator
Thiru R.KANAGARAJ Principal
Government Polytechnic College, Purasaiwakam, Chennai.
1220 DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

Convener
Dr. S.SELVARAJ
HOD( I/C)
Dept. of Tool & Die Making
Murugappa Polytechnic College
S.M Nagar, Chennai- 600 062
Members
Thiru A.N. Rajendiran, Dr. R. Rajendran,
Managing Director, Professor,
Nutech CNC Pvt Limited, Department of Automobile Engineering,
Athipet, Chennai- 600 058 SRM Institute of Science & Technology,
Kattankulathur- 603 203
Thiru G.Nallaiya, Thiru G.Athi Pragash,
Lecturer, Dept. of Tool & Die Making, Asst. Engineer (Industries),
Murugappa Polytechnic College Department of Industries & Commerce,
Chennai- 600 062 Guindy, Chennai- 600 032
Thiru R.Ramachandran,
Head of the Department,
Mechanical Engg(Tool & Die),
Er. Perumal Manimekalai Polytechnic College,
Hosur-635 117
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DIPLOMA COURSES IN ENGINEERING/TECHNOLOGY
(SEMESTER SYSTEM)
(To be implemented for the students admitted from the year 2020 – 21 onwards)
N – SCHEME
R E G U L A T I O N S*
*Applicable to the Diploma Courses other than Diploma in Hotel Management & Catering
Technology.
1. Description of the Course:

a. Full Time (3 years)
The Course for the Full Time Diploma in Engineering shall extend over a period of three
academic years, consisting of 6 semesters* and the First Year is common to all
Engineering Branches.
b. Sandwich (3½ years)

The Course for the Sandwich Diploma in Engineering shall extend over a period of three
and half academic years, consisting of 7 semesters* and the First Year is common to all
Engineering Branches. The subjects of three years full time diploma course being
regrouped for academic convenience.
During 4th and/or during 7th semester the students undergo industrial training for six
months / one year. Industrial training examination will be conducted after completion of
every 6 months of industrial training.
c. Part Time (4 years)
The course for the Part Time Diploma in Engineering shall extend over a period of 4
academic years containing of 8 semesters*, the subjects of 3-year full time diploma
courses being regrouped for academic convenience.
* Each Semester will have 16 weeks duration of study with 35 hrs. / Week for Regular
Diploma Courses and 18 hrs. / Week for Part-Time Diploma Courses.
i
The Curriculum for all the 6 Semesters of Diploma courses (Engineering &
Special Diploma Courses Viz. Textile Technology, Leather Technology, Printing
Technology, Chemical Technology etc.) have been revised and revised
curriculum is applicable for the candidates admitted from 2020 – 2021
academic year onwards.
2. Condition for Admission:

Condition for admission to the Diploma courses shall be required to have
passed in the S.S.L.C Examination of the Board of Secondary Education, Tamil
Nadu.
(Or)
The Anglo-Indian High School Examination with eligibility for Higher Secondary
Course in Tamil Nadu.
(Or)
The Matriculation Examination of Tamil Nadu.
(Or)
Any other Examinations recognized as equivalent to the above by the Board of
Secondary Education, Tamil Nadu.
Note: In addition, at the time of admission the candidate will have to satisfy certain
minimum requirements, which may be prescribed from time to time.
3. Admission to Second year (Lateral Entry):

A pass in HSC (academic) or (vocational) courses mentioned in the Higher
Secondary Schools in Tamil Nadu affiliated to the Tamil Nadu Higher
Secondary Board with eligibility for University Courses of study or equivalent
examination & Should have studied the following subjects.
A pass in 2 Years ITI with appropriate Trade or Equivalent examination.
ii
H.Sc Academic H.Sc Vocational Industrial
Sl. Subjects Studied Training
Courses
No Subjects Studied Vocational Institutes
Related subjects
subjects Courses
1. All the Physics and Maths / Physics / Related 2 years
Regular and Chemistry as Chemistry Vocational course to be
Sandwich compulsory along Subjects passed with
Diploma with Mathematics Theory& appropriate
Courses / Biology Practical Trade
2. Diploma English & English & Accountancy & -
Course in Accountancy Accountancy, Auditing,
Commercial
Practice English & English & Banking,
Elements of Elements of Business
Economics Economics, Management,
English & English & Co-operative

Elements of Management Management,
Commerce Principles International
& Techniques, Trade,
English & Marketing &

Typewriting Salesmanship,
Insurance &
Material
Management,
Office
Secretary ship.
For the Diploma Courses related with Engineering/Technology, the related /
equivalent subjects prescribed along with Practical’s may also be taken for
arriving the eligibility.
Branch will be allotted according to merit through counseling by the respective
Principal as per communal reservation.
For admission to the Textile Technology, Leather Technology, Printing
Technology, Chemical Technology and Commercial Practice Diploma courses
the candidates studied the related subjects will be given first preference.
Candidates who have studied Commerce Subjects are not eligible for
Engineering Diploma Courses.
4. Age Limit: No Age limit.
5. Medium of Instruction: English
iii
6. Eligibility for the Award of Diploma:
No candidate shall be eligible for the Diploma unless he/she has
undergone the prescribed course of study for a period of not less than 3
academic years in any institution affiliated to the State Board of Technical
Education and Training,Tamil Nadu, when joined in First Year and two
years if joined under Lateral Entry scheme in the second year and passed
the prescribed examination.
The minimum and maximum period for completion of Diploma Courses is

as given below:
Minimum Maximum
Diploma Course
Period Period
Full Time 3 Years 6 Years
Full Time 2 Years 5 Years
(Lateral Entry)
Sandwich 3½ Years 6½ Years
Part Time 4 Years 7 Years
This will come into effect from N Scheme onwards i.e., from the academic year
2020-2021.
7. Subjects of Study and Curriculum outline:
The subjects of study shall be in accordance with the syllabus prescribed from
time to time, both in theory and practical subjects.
The curriculum outline is given in Annexure – I.
8. Examinations:
Board Examinations in all subjects of all the semesters under the scheme of
examinations will be conducted at the end of each semester.
The internal assessment marks for all the subjects will be awarded on the basis
of continuous internal assessment earned during the semester concerned. For
each subject 25 marks are allotted for internal assessment. Board
Examinations are conducted for 100 marks and reduced to 75.
The total marks for result are 75 + 25 = 100 Marks.
iv
9. Continuous Internal Assessment:
A. For Theory Subjects:

The Internal Assessment marks for a total of 25 marks, which are to be
distributed as follows:
i) Subject Attendance 5 Marks
(Award of marks for subject attendance to each subject Theory/Practical will be
as per the range given below)
80% - 83% 1 Mark
84% - 87% 2 Marks
88% - 91% 3 Marks
92% - 95% 4 Marks
96% - 100% 5 Marks
ii) Test # 10 Marks
2 Tests each of 2 hours duration for a total of
50 marks are to be conducted. Average of
these two test marks will be taken and the 05 Marks
marks to be reduced to:
The Test – III is to be the Model Examination
covering all the five units and the marks
05 Marks
obtained will be reduced to:
WHEN TO
TEST UNITS MARKS DURATION
CONDUCT
End of 6th
Test I Unit – I & II 50 2 Hrs
week
End of 12th
Test II Unit – III & IV 50 2 Hrs
week
Model
Examination:
Covering all the
End of 16th
Test III 5 Units. 100 3 Hrs
(Board week
Examinations-
question paper-
pattern).
# From the Academic Year 2020 – 2021 onwards.
v
Question Paper Pattern for the Test - I and Test – II is as follows. The tests
should be conducted by proper schedule. Retest marks should not be
considered for internal assessment.
Without Choice:
Part A Type questions: 6 Questions × 1 mark 06 marks
Part B Type questions: 7 Questions × 2 marks 14 marks
Part C Type questions: 2 Questions × 15 marks 30 marks
Total 50 marks
iii) Assignment 5 Marks

For each subject Three Assignments are to be given each for 20 marks and the
average marks scored should be reduced for 5 marks.
iv) Seminar Presentation 5 Marks

The students have to select the topics either from their subjects or general subjects
which will help to improve their grasping capacity as well as their capacity to
express the subject in hand. The students will be allowed to prepare the material
for the given topic using the library hour and they will be permitted to present
seminar (For First and Second Year, the students will be permitted to present the
seminar as a group not exceeding six members and each member of the group
should participate in the presentation. For the Third Year, the students should
present the seminar individually.) The seminar presentation is mandatory for all
theory subjects and carries 5 marks for each theory subject. The respective subject
faculty may suggest topics to the students and will evaluate the submitted materials
and seminar presentation. (2 ½ marks for the material submitted in writing and 2 ½
marks for the seminar presentation). For each subject minimum of two seminars
are to be given and the average marks scored should be reduced to 5 marks.
All Test Papers, Assignment Papers / Notebooks and the seminar
presentation written material after getting the signature with date from the
students must be kept in safe custody in the department for verification and
audit. It should be preserved for one semester after publication of Board Exam
results and produced to the flying squad and the inspection team at the time of
inspection/verification.
vi
B. For Practical Subjects:
The Internal Assessment mark for a total of 25 marks which are to be
distributed as follows: -
a) Attendance : 5 Marks
(Award of marks same as theory subjects)
b) Procedure/ observation and tabulation/
Other Practical related Work : 10 Marks
c) Record writing : 10 Marks
TOTAL : 25 Marks
All the Experiments/Exercises indicated in the syllabus should be completed
and the same to be given for final Board examinations.
The observation note book / manual should be maintained for 10 marks.
The observation note book / manual with sketches, circuits, programme,
reading and calculation written by the students manually depends upon
the practical subject during practical classes should be evaluated properly
during the practical class hours with date.
The Record work for every completed exercise should be submitted in the
subsequent practical classes and marks should be awarded for 10 marks
for each exercise as per the above allocation.
At the end of the Semester, the average marks of all the exercises should
be calculated for 20 marks (including Observation and Record writing) and
the marks awarded for attendance is to be added to arrive at the internal
assessment mark for Practical. (20+5=25 marks)
Only regular students, appearing first time have to submit the duly signed
bonafide record note book/file during the Practical Board Examinations.
All the marks awarded for Assignments, Tests, Seminar presentation and
Attendance should be entered periodically in the Personal Theory Log Book of the
staff, who is handling the theory subject.
The marks awarded for Observation, Record work and Attendance should be
entered periodically in the Personal Practical Log Book of the staff, who is handling
the practical subject.
vii
10. Communication Skill Practical, Computer Application Practical and
Physical
Education:
The Communication Skill Practical and Computer Application Practical
with more emphasis are being introduced in First Year. Much Stress is
given to increase the Communication skill and ICT skill of students.
As per the recommendation of MHRD and under Fit India scheme, the Physical
education is introduced to encourage students to remain healthy and fit by
including physical activities and sports.
11. Project Work and Internship:

The students of all the Diploma Courses have to do a Project Work as part
of the Curriculum and in partial fulfillment for the award of Diploma by the
State Board of Technical Education and Training, Tamil Nadu. In order to
encourage students to do worthwhile and innovative projects, every year
prizes are awarded for the best three projects i.e. institution wise, region
wise and state wise. The Project work must be reviewed twice in the same
semester. The project work is approved during the V semester by the
properly constituted committee with guidelines.
a) Internal assessment mark for Project Work & Internship:

Project Review I … 10 marks
Project Review II … 10 marks
Attendance … 05 marks (Award of marks same as
theory subject pattern)
Total … 25 marks
Proper record should be maintained for the two Project Reviews and preserved
for one semester after the publication of Board Exams results. It should be
produced to the flying squad and the inspection team at the time of
inspection/verification.
b) Allocation of Marks for Project Work & Internship in Board Examinations:
Demonstration/Presentation 25 marks
Report 25 marks
Viva Voce 30 marks
Internship Report 20 marks
Total 100* marks
*Examination will be conducted for 100 marks and will be converted to 75
marks.
viii
c) Internship Report:
The internship training for a period of two weeks shall be undergone by every
candidate at the end of IV / V semester during vacation. The certificate shall be
produced along with the internship report for evaluation. The evaluation of
internship training shall be done along with final year “Project Work &
Internship” for 20 marks. The internship shall be undertaken in any industry /
Government or Private certified agencies which are in social sector / Govt. Skill
Centres / Institutions / Schemes.
A neatly prepared PROJECT REPORT as per the format has to be

submitted by individual student during the Project Work & Internship
Board examination.
12. Scheme of Examinations:

The Scheme of examinations for subjects is given in Annexure - II.
13. Criteria for Pass:

1. No candidate shall be eligible for the award of Diploma unless he/she has
undergone the prescribed course of study successfully in an institution
approved by AICTE and affiliated to the State Board of Technical Education &
Training, Tamil Nadu and pass all the subjects prescribed in the curriculum.
2. A candidate shall be declared to have passed the examination in a subject if

he/she secures not less than 40% in theory subjects and 50% in practical
subjects out of the total prescribed maximum marks including both the Internal
Assessment and the Board Examinations marks put together, subject to the
condition that he/she secures at least a minimum of 40 marks out of 100 marks
in the Board Theory Examinations and a minimum of 50 marks out of 100
marks in the Board Practical Examinations.
14. Classification of successful candidates:

Classification of candidates who will pass out the final examinations from April
2023 onwards (Joined first year in 2020 -2021) will be done as specified below.
ix
First Class with Superlative Distinction:
A candidate will be declared to have passed in First Class with Superlative
Distinction if he/she secures not less than 75% of the marks in all the subjects
and passes all the semesters in the first appearance itself and passes all
subjects within the stipulated period of study 2 / 3 / 3½ / 4 years [Full time
(lateral entry)/Full Time/Sandwich/Part Time] without any break in study.
First Class with Distinction:
A candidate will be declared to have passed in First Class with Distinction if
he/she secures not less than 75% of the aggregate marks in all the semesters
put together and passes all the semesters except the I and II semester in the
first appearance itself and passes all subjects within the stipulated period of
study 2 / 3 / 3½ / 4 years [Full time(lateral entry)/Full Time/Sandwich/Part Time]
without any break in study.
First Class:
A candidate will be declared to have passed in First Class if he/she secures
not less than 60% of the aggregate marks in all the semesters put together and
passes all the subjects within the stipulated period of study 2 / 3 / 3½ / 4 years
[Full time (lateral entry)/Full Time/Sandwich/Part Time] without any break in
study.
Second Class:
All other successful candidates will be declared to have passed in Second
Class.
The above classifications are also applicable for the Sandwich / Part-Time
students who pass out Final Examination from October 2023 /April 2024
onwards (both joined First Year in 2020 -2021)
15. Duration of a period in the Class Time Table:

The duration of each period of instruction is 1 hour and the total period of
instruction hours excluding interval and lunch break in a day should be
uniformly maintained as 7 hours corresponding to 7 periods of instruction
(Theory & Practical).
******
x
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xi
ANNEXURE – I
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE) SYLLABUS
N SCHEME
CURRICULUM OUTLINE
THIRD SEMESTER
Col. HOURS PER WEEK
No. Subject
SUBJECT Theory Tutorial / Practical Total
Code
Hours Drawing hours Hours
1 4020310 Strength of Materials @@ 5 - - 5
2 4022320 Manufacturing Technology 5 - - 5
3 4022330 Engineering Metrology 5 - - 5
4 4022340 Computer Aided Machine and Tool
1 3 4
Drawing
5 4022350 Engineering Metrology Practical - - 4 4
6 4022360 Manufacturing Technology
- - 5 5
Practical
7 4022370 Basic Engineering Practical - - 4 4
TOTAL 15 1 16 32
Extra / Co- Physical Education - - - 2
curricular Library
activities - - - 1
GRAND TOTAL 35
FOURTH SEMESTER
Col. HOURS PER WEEK
No. Subject
Code
1 4022410 Engineering Materials and
5 - - 5
Metallurgy
2 4022420 Fluid Power and Thermal
5 - - 5
Engineering
3 4022430 Tool Room Special Machines 5 - - 5
4 4022440 Forging dies, Die casting Dies and
5 - - 5
Die Maintenance
5 4022450 Mechanical Material Testing
- - 4 4
Practical
6 4022460 Hydraulics and Pneumatics
- - 4 4
Practical
7 4022470 Tool Room Special Machines
- - 4 4
Practical
TOTAL 20 - 12 32
curricular Library
activities - - - 1
GRAND TOTAL 35
1
CURRICULUM OUTLINE (N SCHEME)
FIFTH SEMESTER
Col. HOURS PER WEEK

No. Subject
Code
1 4022510 Jigs, Fixtures and Gauges 5 - - 5
2 4022520 Press Tools 5 - - 5
3 - Elective I Theory 5 - - 5
4 - Elective I Practical - - 4 4
5 4022550 Jigs and Fixtures Practical - - 4 4
6 4022560 Press Tools Practical - - 5 5
7 4020570 Entrepreneurship and Start up - - 4 4
TOTAL 15 - 17 32
curricular Library
- - - 1
activities
GRAND TOTAL 35
SIXTH SEMESTER
Col. HOURS PER WEEK

No. Subject
Code
1 4022610 Tool Design and Drawing 5 - - 5
2 4022620 Plastic Moulding Technology 5 - - 5
3 - Elective II Theory 5 - - 5
4 - Elective II Practical - - 5 5
5 4022650 Plastic Moulds Practical - - 6 6
6 4022660 Project Work and Internship - - 6 6
TOTAL 15 - 17 32
curricular Library
- - - 1
activities
GRAND TOTAL 35
@@ - Common subject with Mechanical Engineering

$$ - Common subject to all Department
2
LIST OF ELECTIVE SUBJECTS
Note: Select one Elective I Theory subject and one Related Elective I Practical subject
from the below table
FIFTH SEMESTER
Elective I Theory
@@
4020531 Computer Integrated Manufacturing 5 - - 5
4020533 Mechatronics@@ 5 - - 5
@@
4020440 Process Planning and Quality Control 5 - - 5
Elective I Practical
4020561 Computer Integrated Manufacturing
- - 4 4
Practical @@
@@
4020563 Mechatronics Practical - - 4 4
@@
4020540 Process Automation Practical - - 4 4
Note: Select one Elective II Theory subject and one Related Elective II Practical subject
from the below table
VI SEMESTER
Elective II Theory
@@
4020610 Industrial Engineering & Management 5 - - 5
4020631 Industrial Robotics and 3D Printing@@ 5 - - 5
4020620 E Vehicle Technology & Policy @@ 5 5
Elective II Practical
4020640 Solid Modelling Practical @@ - - 5 5
4020651 Industrial Robotics and 3D Printing
- 5 5
Practical @@
4020550 Thermal Engineering Practical @@ - - 5 5
@@ - Common subject with Mechanical Engineering

$$ - Common subject to all Department
3
ANNEXURE – II
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE) SYLLABUS
N SCHEME
SCHEME OF THE EXAMINATION
THIRD SEMESTER
Examination Marks
Minimum
Duration
for pass
of Exam
Hours
Subject Internal * Board
SUBJECT Total
Code assessment Exam.
Mark
Marks Marks
4020310 Strength of Materials@@ 25 100 100 40 3
4022320 Manufacturing Technology 25 100 100 40 3
4022330 Engineering Metrology 25 100 100 40 3
Computer aided Machine and
4022340 25 100 100 40 3
Tool Drawing
Engineering Metrology
4022350 25 100 100 50 3
Practical
Manufacturing Technology
4022360 25 100 100 50 3
Practical
4022370 Basic Engineering Practical 25 100 100 50 3
175 700 700
FOURTH SEMESTER
Examination Marks
Minimum
Duration
for pass
of Exam
Hours
Subject Internal * Board
SUBJECT Total
Mark
Marks Marks
Engineering Materials and
4022410 25 100 100 40 3
Metallurgy
Fluid Power and Thermal
4022420 25 100 100 40 3
Engineering
4022430 Tool Room Special Machines 25 100 100 40 3
Forging Dies, Die casting
4022440 25 100 100 40 3
Dies & Die Maintenance
Mechanical Material Testing
4022450 25 100 100 50 3
Practical
Hydraulics and Pneumatics
4022460 25 100 100 50 3
Practical
Tool Room Special Machines
4022470 25 100 100 50 3
Practical
TOTAL 175 700 700
* Examinations will be conducted for 100 Marks and will be converted 75 Marks
4
SCHEME OF THE EXAMINATION
FIFTH SEMESTER
Examination Marks
Duration of
Minimum
for pass
Hours
Subject
Exam
Internal * Board Total
SUBJECT
Mark
Marks Marks
4022510 Jigs, Fixtures and Gauges 25 100 100 40 3
4022520 Press Tools 25 100 100 40 3
- Elective I Theory 25 100 100 40 3
- Elective I Practical 25 100 100 50 3
4022550 Jigs and Fixtures Practical 25 100 100 50 16
4022560 Press Tools Practical 25 100 100 50 16
4020570 Entrepreneurship and Start up 25 100 100 50 3
175 700 700
SIXTH SEMESTER
Examination Marks
Duration of
Minimum
for pass
Hours
Exam
Subject Internal * Board Total
SUBJECT
Mark
Marks Marks
4022610 Tool Design and Drawing 25 100 100 40 3
4022620 Plastic Moulding Technology 25 100 100 40 3
- Elective II Theory 25 100 100 40 3
- Elective II Practical 25 100 100 50 3
4022650 Plastic Moulds Practical 25 100 100 50 16
4022660 Project Work and Internship 25 100 100 50 3
150 600 600
* Examinations will be conducted for 100 Marks and will be converted 75 Marks
@@ - Papers Common with Diploma in Mechanical Engineering Branch

$$- Papers common with other branches of Engineering
5
Diploma in Mechanical Engineering (Tool & Die)
List of Equivalent Subjects for M & N-Scheme subjects

III SEMESTER
M-SCHEME N-SCHEME
Subject Subject
S.No Code Name of the Subject Code Name of the Subject
1 32031 Strength of Materials @@ 4020310 Strength of Materials@@
2 32232 Manufacturing Technology Not Equivalent
3 32233 Engineering Metrology 4022330 Engineering Metrology

32234 Machine & Tool Drawing Not Equivalent
4
Engineering Metrology 4022350 Engineering Metrology
32235
5 Practical Practical
Manufacturing Technology Not Equivalent
32236
6 Practical
Computer Applications Not Equivalent
30001
7 Practical $$
IV SEMESTER
M-SCHEME N-SCHEME
Subject Subject
S.No Code Name of the Subject Code Name of the Subject
Engineering Materials and Engineering Materials and
1 32241 4022410
Metallurgy Metallurgy
Fluid Power and Thermal Not Equivalent
2 32242
Engineering
Tool Room Special Tool Room Special Machines
3 32243 4022430
Machines
Computer Aided Machine & Computer Aided Machine &
4 32244 4022340
Tool Drawing Practical Tool Drawing Practical
Mechanical Material Testing Mechanical Material Testing
5 32245 4022450
Practical Practical
Hydraulics and Pneumatics Hydraulics and Pneumatics
6 32246 4022460
Practical Practical
Tool Room Special Tool Room Special Machines
7 32247 4022470
Machines Practical Practical
6
V SEMESTER
M – SCHEME N - SCHEME
Subject Subject
S.N Code Name of the Subject Code Name of the Subject
1 32251 Jigs, Fixtures and Gauges 4022510 Jigs, Fixtures and Gauges
2 32252 Press Tools 4022520 Press Tools
Forging Dies, Die casting Not Equivalent
32253
3 Dies & Die Maintenance
4 32254 Tool Design and Drawing 4022610 Tool Design and Drawing
5 32255 Press Tools - I Practical Not Equivalent
6 32256 Jigs and Fixtures Practical 4022550 Jigs and Fixtures Practical
Life and Employability skill
7 30002 Not Equivalent
$$
Practical
VI SEMESTER
M – SCHEME N -SCHEME
Subject Subject
S.N Code Name of the Subject Code Name of the Subject
Industrial Engineering &
32061 4020610 Tool Design and Drawing
1 Management @@
Computer Aided Design and Computer Integrated
32062 4020531
2 Manufacturing @@ Manufacturing @@
3 32263 Plastic Moulding Technology 4022620 Plastic Moulding Technology
Computer Aided Design and Computer Integrated
32064 4020561
@@ @@
4 Manufacturing Practical Manufacturing Practical
5 32265 Press tools – II Practical Not Equivalent
6 32266 Plastic Moulds Practical 4022650 Plastic Moulds Practical
7 32067 Project Work @@ Not Equivalent
@@
- Papers Common with Diploma in Mechanical Engineering Branch
7
Board Examination-Question Paper Pattern (Theory)
(Common to all Theory subjects except 4020610 Tool Design & Drawing)
Time: 3 Hrs. Max.Marks:100
PART - A Five questions will be asked covering all units. All questions are to be answered.
Each question carries 1 mark.
PART- B Fifteen questions will be asked covering all the units. Three questions from each
unit. Answer any ten questions. Each question carries 2 marks.
PART-C Five questions will be asked either or type. One question from every unit. Answer
either A or B. Each question carries 15 marks. A and B have subdivisions. (7 + 8)
The questions are to be numbered from 1 to 25. All the units are to be covered with
equal weightage.
PART A
Definitions and Statements. 5 X 1 = 5 Marks
Question Number 1 to 5
PART B
Short answer type questions 10 X 2 = 20 Marks
Question Number 6 to 20
PART C
Descriptive answer type questions
5 X15 = 75 Marks
(Either A or B)
Question number 21 to 25
TOTAL 100 Marks
Note: Board Examinations will be conducted for 100 Marks and converted to 75 Marks.
8
DIPLOMA IN MECHANICAL ENGINEERING

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4020310 –STRENGTH OF MATERIALS
9
STATE BOARD OF TECHNICAL EDUCATION &TRAINING, TAMILNADU
N-SCHEME
(Implemented from the Academic year 2020 - 2021 onwards)
Course Name : 1220: DIPLOMA IN MECHANICAL ENGINEERING (TOOL&DIE)

Subject Code : 4020310
Semester : III
Subject Title : STRENGTH OF MATERIALS
TEACHING AND SCHEME OF EXAMINATION

No of weeks per semester: 16 weeks
Instructions Examination
Marks
Subject Hours / Hours /
Internal Board Duration
Week Semester Total
Assessment Examinations
STRENGTH OF
5 80 25 100* 100 3 hrs.
MATERIALS
* Examinations will be conducted for 100 marks and it will be reduced to 75 marks for result.
Topics and Allocation of Hours

Unit No Topics Hours
I Engineering Materials 15
II Deformation of Metals 15
III Geometrical Properties of Sections and Thin Shells 15
IV Theory of Torsion and Springs 14
V SFand BM Diagrams of Beams and Theory of Bending 14
Test & Model Examinations 7
Total 80
10
RATIONALE:
Day by day, engineering and technology experience tremendous growth. Design plays a major
role in developing engineering and technology. Strength of material is backbone for design.
The strength of material deals generally with the behaviour of objects, when they are subject to
actions of forces. Evaluations derived from these basic fields provide the tools for investigation
of mechanical structure.
OBJECTIVES
Acquire knowledge about materials properties.
Calculate the deformation of materials, which are subjected to axial load and shear.
Determine the moment of Inertia of various sections used in industries.
Estimate the stresses induced in thin shells.
Draw the shear force and bending moment diagram of the beam for different load.
DETAILED SYLLABUS
4020310 STRENGTH OF MATERIALS
Contents: Theory
Unit Name of the Topics Hours
I ENGINEERING MATERIALS
Chapter: 1.1: Engineering materials: Classification - definition of 7
Mechanical properties - ferrous metals - cast iron - uses - advantages -
types of cast iron - properties and applications - effect of impurities on
cast iron. steel - classification - alloying elements - purpose of alloying -
effect of alloying elements on steel - uses of steels - properties of mild
steel - defects in steel - applications - properties of hard steel - market
forms of steels – nonferrous metals - properties and uses.
Chapter: 1.2: Mechanical testing of materials:
Compression test - bend test - hardness test - Brinell hardness test, 6
Vickers hardness test, Rockwell hardness test - impact test - fatigue test
- creep test. Tensile test of mild steel in UTM - stress strain diagram -
limit of proportionality - elastic limit - yield stress - breaking stress -
ultimate stress - percentage of an elongation and percentage reduction in
area - problems.
Chapter: 1.3: Friction
Introduction - definition - force of friction - limiting friction - static friction - 2
dynamic friction - angle of friction - coefficient of friction - laws of static
and dynamic friction. Description only.
11
II DEFORMATION OF METALS
Chapter: 2.1: Simple stresses and strains 4
Definition - load, stress and strain - classification of force systems:
tensile, compressive and shear force systems. Hooke’s law - definition
Young’s modulus - working stress, factor of safety, load factor, shear
stress and shear strain - modulus of rigidity. Linear strain - deformation
due to tension and compressive forces - simple problems in tension,
compression and shear forces.
Chapter: 2.2:Elastic constants 7
Definition - lateral strain – poison’s ratio - volumetric strain - bulk
modulus - volumetric strain of rectangular and circular bars - problems
connecting linear, lateral and volumetric deformations - elastic constants
and their relationship - problems on elastic constants. Composite bar -
definition - problems in composite bars subjected to tension and
compression. Temperature stresses and strains - simple problems.
Chapter: 2.3 Strain Energy 4
Definition – proof resilience – modulus of resilience – the expression for
strain energy stored in a bar due to axial load – instatntaneous stresses
due to gradual, sudden, impact and shock loads – problems computing
instantaneous stress and deformation in gradual, sudden, impact and
shock loadings.
III GEOMETRICAL PROPERTIES OF SECTIONS AND THIN SHELLS
Chapter: 3.1: Properties of sections 8
Definition – center of gravity and centroid - position of centroids of plane
geometrical figures such as rectangle, triangle, circle and trapezium-
problems to determine the centroid of angle, channel, T and I sections
only – Definition - centroidal axis - Axis of symmetry. Moment of Inertia –
parallel axis theorem and perpendicular axis theorem (statement only).
Moment of Inertia of lamina of rectangle, circle, triangle, I and channel
sections – Definition - Polar moment of Inertia - radius of gyration –
Problems computing moment of inertia and radius of gyration for angle,
T, Channel and I sections.
Chapter: 3.2:Thin Shells 7
Definition – Thin and thick cylindrical shell – Failure of thin cylindrical
shell subjected to internal pressure – Derivation of Hoop and longitudinal
stress causes in a thin cylindrical shell subjected to internal pressure –
simple problems – change in dimensions of a thin cylindrical shell
12
subjected to internal pressure – problems – Derivation of tensile stress
induced in a thin spherical shell subjected to internal pressure – simple
problems – change in diameter and volume of a thin spherical shell due
to internal pressure – problems.
IV THEORY OF TORSION AND SPRINGS
Chapter: 4.1: Theory of Torsion 7
Assumptions – torsion equation - Strength of solid and

hollow shafts – power transmitted – Definition – Polar modulus –
Torsional rigidity – strength and stiffness of shafts – comparison of
hollow and solid shafts in weight and strength considerations –
Advantages of hollow shafts over solid shafts – Problems.
Chapter: 4.2:Springs 7
Types of springs – Laminated and coiled springs and applications ––
Difference between open and closely coiled helical springs – closely
coiled helical spring subjected to an axial load – problems to determine
shear stress, deflection, stiffness and resilience of closed coiled helical
springs.
V SF AND BM DIAGRAMS OF BEAMS AND THEORY OF BENDING
Chapter: 5.1: SF and BM diagrams 7
Classification of beams – Definition – shear force and Bending moment –
sign conventions for shear force and bending moment – types of
loadings – Relationship between load, force and bending moment at a
section – shear force diagram and bending moment diagram of cantilever
and simply supported beam subjected to point load and uniformly
distributed load (UDL) – Determination of Maximum bending moment in
cantilever beam and simply supported beam when they are subjected to
point load and uniformly distributed load.
Chapter: 5.2:Theory of bending 7
Theory of simple bending – Assumptions – Neutral axis – bending stress
distribution – moment of resistance – bending equation – M/I=f/y=E/R –
Definition – section modulus - rectangular and circular sections –
strength of beam – simple problems involving flexural formula for
cantilever and simply supported beam.
13
Reference Books:
1. Strength of Materials, R. S. Khurmi, S.Chand & Co., Ram Nagar, New Delhi.
2. Strength of Materials, S. Ramamrutham, 15 th Edition 2004, DhanpatRai Pub. Co., New
Delhi.
3. Strength of Materials, R.K. Bansal, Laxmi Publications Pvt. Ltd., New Delhi, 3 rd Edition,
2010.
4. Strength of materials, S.S.Rattan, Tata Mcgraw hill, New Delhi,2008, ISBN
9780070668959,
5. Strength of Materials, B K Sarkar, I Edition, 2003Tata Mcgraw hill, New Delhi.
6. Engineering mechanics, R.K. Bansal, Laxmi Publications Pvt. Ltd., New Delhi, 2 nd
Edition, 2007.
14

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022320 – MANUFACTURING TECHNOLOGY
15
N-SCHEME
Course Name : 1220: DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

Semester : III
Subject Title : MANUFACTURING TECHNOLOGY

Marks
Week Semester Total
MANUFACTURING
5 80 25 100* 100 3 hrs.
TECHNOLOGY
* Examinations will be conducted for 100 marks and it will be reduced to 75 marks.

UNIT Topic Hrs.
I Casting Processes 15
II Metal Joining Processes 15
III Centre Lathe, Semi-Automatic and Automatic Lathe 15
IV Drilling, Grinding and Broaching Machines 14
V Planner, Shaper, Slotter Machines 14
Total 80
16
RATIONALE:
To be a mechanical engineer, it is necessary to understand the various recent
technologies that are being used in the process of conversion of raw materials into end
products. So, it is very essential to learn the basics of various recent technologies and
processes that are available and predominantly used in the industries.
OBJECTIVES:
Acquire knowledge about types of patterns, types of moulding and casting processes
Acquire knowledge about various metal joining processes
Appreciate the safety practices used in welding
Explain the lathe working principles and its various operations
Explain the Semi-Automatic and Automatic lathe working principles
Explain the drilling and drilling machine principles and its various operations
Explain the grinding machine and types of grinding wheels
Explain the vertical and Horizontal broaching machines
Describe the working of planer, shaper and slotter
17
DETAILED SYLLABUS
Contents: Theory
Unit Name of the Topics Hrs
Casting Processes
Chapter: 1.1: Patterns: Definition-Pattern materials-factors for selecting
pattern materials-single piece solid, split patterns-pattern allowances-core
prints-color coding patterns. Moulding-definition-moulding boxes, moulding
8
sand-ingredients-silica-clay-moisture and miscellaneous materials-properties of
moulding sand-sand additives-moulding sand preparation-mixing-tempering
and conditioning-types of moulding-greensand-dry sand-machine moulding-top
and bottom squeezer machines-jolting machines-sand slinger-CO2 process
core making-types of core-core boxes
Chapter: 1.2:Casting : Definition-sand casting using green sand and dry
I sand-gravity die casting-pressure die casting :hot and cold chamber
processes-centrifugal casting-continuous casting-chilled casting-malleable 7
casting-melting of cast iron-cupola furnace-melting of nonferrous metals-
crucible furnace melting of steel-arc furnaces-induction furnaces-instrument for
measuring temperature-optical pyrometer-thermo electric pyrometer-cleaning
of casting-tumbling trimming sand and shot blasting-defects in casting causes
and their remedies-safety practices in foundry.
Metal Joining Processes
Chapter: 2.1: Arc Welding: Definition-Arc welding equipment-arc welding
methods-carbon arc, metal arc, Metal Inert Gas (MIG), Tungsten Inert Gas 4
(TIG), Atomic hydrogen, Plasma arc, Submerged arc and Electro slag welding
II Chapter: 2.2: Gas welding: Definition-Gas welding equipment-Oxy and
2
acetylene welding-Three types of flame.
Chapter: 2.3: Resistance welding: Classification of resistance welding-butt-
spot-seam-projection welding-welding related processes-oxy and acetylene 5
cutting-arc cutting-hand facing bronze welding-soldering and brazing-special
welding processes: cast iron welding- thermit welding-solid state welding,
ultrasonic, diffusion and explosive welding-explosive cladding.
Chapter: 2.4: Modern welding: Electron beam and laser beam welding-types
of welded joints-inspection and testing of welded joints-destructive and 4
nondestructive types of tests-safety practices in welding
Centre Lathe, Semi-Automatic and Automatic Lathe

Chapter: 3.1:Centre Lathe: Theory of Lathes-specifications-simple sketches-
principal parts and its functions-tumbler gear mechanism-quick change gear
18
box-apron mechanism-carriage cross slide-automatic, longitudinal and cross 8
feed mechanism-work holding devices : face plate, three jaw chuck, four jaw
chuck, catch plate and carrier-types of centres-machining operations done on
lathe: facing, plain turning, step turning, taper turning, knurling, thread cutting,
boring, chamfering-major machining parameters.
III Chapter: 3.2: Semi-Automatic Lathe: Types of Semi-Automatic Lathe –
3
Capstan and turret lathes – difference between turret and capstan – tools and
work holding devices – self-opening die head –collapsible tapes
Chapter: 3.3: Automatic Lathe: Classification of single spindle automatic 4
lathe – principle of automatic lathe – automatic screw cutting machine – multi
spindle automatic lathes
Drilling, Grinding and Broaching Machine
Chapter: 4.1: Drilling Machines: Drills: Flat drills, twist drills-nomenclature-
types of drilling machines: bench type, floor type, radial type, gang drill, multi 7
spindle type- principle of operations in drilling-drilling parameters of various

materials-methods of holding drill bit: drill chucks, socket and sleeve-drilling
operation: drilling, boring, reaming, counter sinking, counter boring, spot facing,
tapping, deep hole drilling
Chapter:4.2: Grinding Machine: Types and Classification-specifications-
principles of operations-grinding wheels abrasives: natural and artificial-types 5
IV of bonds-grit, grade and structure of wheels-wheel shapes and sizes-BIS
marking systems of grinding wheels-selection of grinding wheels-dressing and
truing of wheels-balancing of grinding wheels.
Chapter: 4.3: Broaching: Broaching Machine – Basic Process – Vertical
broaching Machine – Horizontal Broaching machine – Double cut broaching – 2
Key way Broaching

Planner, Shaper and Slotter Machine
Chapter: 5.1: Planner: Types of Planner-specifications-principles of operation-
quick return mechanism-feed mechanism-work holding devices-types of 5
planner operation
Chapter: 5.2: Shaper: Types of Shaper-specifications-principle of operations-
V 5
quick return mechanism-crank and slotted link mechanism-feed mechanism-
work holding devices-types of shaper operations
Chapter: 5.3: Slotter: Types of slotter-specifications-principle of operation-
4
Whitworth quick return mechanism-feed mechanism-work holding devices
TEST & MODEL EXAMINATIONS 07
19
Text Books
1. Hajra Chowdry & Bhattacharaya, Elements of workshop Technology Volume I & II,
Media Promoters & Publishers Pvt. Ltd., Noshir Bharucha Marg, Mumbai
2. WAJ Chapman, Workshop Technology, Volume I, II, & III, Vima Books Pvt. Ltd., ND
Reference Books:
1. Raghuwanshi, Workshop Technology, Khanna Publishers. Jain & Gupta, Production
Technology, Edn. XII, Khanna Publishers, 2-B, North Market, NAI Sarak, New Delhi
2. P. C. SHARMA, Production Technology, Edn. X, S.Chand & Co. Ltd.,
3. HMT, Production Technology, Edn. 18, published by Tata McGraw Hill publishing Co.
Ltd., 7 West Patel Nagar, New Delhi 110 008.
20

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022330 – ENGINEERING METROLOGY

DRA 32233 - ENGINEERING METROLOGY
WING
21
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)
N-SCHEME
(Implemented from the academic year 2020-2021 onwards)
Course Name : 1220:DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

Semester : III
Subject Title : ENGINEERING METROLOGY
TEACHING AND SCHEME OF EXAMINATION:

Marks
Week Semester Total
ENGINEERING
5 80 25 100* 100 3 hrs.
METROLOGY
TOPICS AND TIME ALLOCATION

UNIT TOPIC TIME (Hrs)
I Introduction to Metrology and Linear Measurement 15
II Angular Measurement, Measurement of Gears and Threads 15
III Measurement of Geometric Parameters and Surface Finish 15
IV Comparators and Measurement by Light Wave Interference 14
V Measuring Machines and Recent Trends in Metrology 14
Total 80
22
Rationale: -
The modern industries demand wide knowledge in the understanding and use of
conventional and advanced digital measuring instruments that are being used in the process of
manufacture of goods. Hence it is essential to have better understanding of the various
measuring techniques and the technology that are being used in the various measuring
instruments. The fundamentals of various measuring technique needs to be known to
understand the modern measuring equipment’s that are being used in Industries.
OBJECTIVES
The objective of this course is to make the Student:
To understand the Needs & Objectives of metrology.
To understand about the various linear & angular measuring Instruments.
To Study about the various Measurement Techniques.
To Calibrate an Instrument.
To know about various geometric parameters.
To use Light rays in Measuring an Object.
To Measure Force, Torque and temperature.
To know about the measuring machines.
To acquire Knowledge about Recent Trends in Metrology.
23
DETAILED SYLLABUS
4022330 - ENGINEERING METROLOGY
Contents: Theory
Unit
No. Name of the Topics Hours
Introduction to Metrology and Linear Measurement:
I 1.1 Introduction: Metrology, objectives of metrology, Precision vs 3
Accuracy. Repeatability, calibration, sensitivity and readability,
classification of methods of measurement, general care of equipments.
1.2 Non precision Linear Measurements: Surface plates, Tool maker’s
flats and high precision surface plates, Angle plates, bench centers, v- 5
blocks, straight edges, Toolmaker’s straight edges, using a straight edge,
sprit levels, combination set, universal surface gauge, Engineer’s square,
Engineer’s parallel, Radius gauge, feeler gauge, screw pitch gauge,
Engineer’s taper, wire and thickness gauge.
1.3 Precision Linear Measurements: Characteristics and principles of
precision measuring instruments. Vernier instruments, types of vernier 7
calipers, errors in calipers, Vernier height gauge, Vernier depth gauge,
digital readout height gauge. Micrometers – Internal micrometers,
micrometer depth gauge, thread micrometer, v-anvil micrometer, dial
micrometers, digital micrometers, groove micrometer. Telescope internal
gauge, Measuring dia of deep holes, cylinder gauges, Keilpart gauge, slip
gauges.
Angular Measurement, Measurement of Gears and Threads:
II 2.1 Angular Measurement: Instruments for angular measurement-
optical bevel protractor, universal bevel protractor, acute angle attachment, 3
optical dividing head, Sine bars, Sine center, angle gauges, clinometers.
2.2 Optical instruments for angular measurement: - Autocollimator –
principle of the autocollimator, micro-optic autocollimator, measurement of 5
straightness and flatness. Angle dekkor – working principle, use of angle
dekkor in combination with angle gauges. Optical square.
2.3 Measurement of Gears: Gear tooth terminology, Gear tooth vernier 2
caliper.
2.4 Thread Measurements: Screw thread projection, Tool Maker’s 5
Microscope, Measurement of Effective Diameter, one wire, Two wire and
Three wire Methods using floating carriage micrometer.
24
Measurement of Geometric Parameters and Surface Finish:
III 3.1 Straightness, Flatness, Parallelism and squareness: - Definition of
straightness, straight edge and its uses, test for straightness by using spirit 7
level and Autocollimator, Flatness definition, flatness testing, procedure for
determining flatness, laser equipment for alignment testing. Parallelism
definition, various cases of parallelism of lines and planes, measurement
of equidistance, checking of coincidence or alignment. Squareness
definition, measurement of squareness of lines and planes, checking the
perpendicularity of motion, squareness testing methods – indicator
method, Engineer’s square tester, optical tests for squareness.
3.2 Circularity and Rotation: - Circularity definition, measurement of
circularity, Different types of irregularities of a circular part – ovality,
lobbing, irregularities of non-specific form. Roundness and circularity. 6
Devices for measuring circularity error – V block, precision measuring
instruments. Tests for checking Rotation – Run out, measurement of run
out, Periodical axial slip, camming.
3.3 Surface Finish: - Surface roughness – definition, terminologies as per
BIS, Methods of measuring Surface finish, surface finish parameters – 2
Surface inspection by comparison methods, Direct measurement methods.
Analysis of surface traces.
Comparators and Measurement By Light Wave Interference:
IV 4.1 Comparators: Characteristics and uses of comparators, Working 6
principle, advantages and disadvantages of various types of comparators–
Mechanical comparators, optical comparators, Electrical comparators,
pneumatic comparators, Fluid displacement comparators, optical
Projectors.
4.2 Measurement by light wave interference: Interferometry,
interference of two rays, light source for interferometry, interferometry 4
applied to flatness testing, Interferometers.
4.3 Testing and Calibration of Gauges: - Calibration of linear and
angular measuring instruments – General metrological instrument, optical 4
measuring instruments, Measurement of limit gauges.
Measuring Machines and Recent Trends In Metrology:
V 5.1 Measuring Machines: Optical profile projector – working principle, 7
use, precaution in use. Coordinate Measuring Machine – Types, uses,
advantages, possible source of error in CMM. Electronic Inspection and
measuring machines.
25
5.2 Trends in Metrology: Laser Telemetric system, Feeler microscope,
Isometric viewing of surface defects. optoelectronic dimensional gauging, 7
computers in metrology, Computer Aided dimensional analysis and
reporting system, In process probing, contact less 3D measurements by
Laser based system.
Text Books:
1. R.K.Jain., Engineering Metrology, Khanna Publishers, Eleventh edition
2. R.Jenkins, Fundamentals of Mechanical Inspection, McGraw Hill Book company.
Reference books:
1. ASTME, Hand book of Industrial Metrology, Prentice Hall
2. A.J.T Scarr, Metrology and Precision Engineering, McGraw Hill Book company.
3. J.Johnson, Precision Measurement, Pitman publishers
4. R.L.Murty, Precision Engineering in Manufacturing, New Age International Publishers (P)
26

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022340 – COMPUTER AIDED MACHINE &

TOOL DRAWING
27
N-SCHEME

Semester : III
Subject Title : COMPUTER AIDED MACHINE & TOOL DRAWING
TEACHING AND SCHEME OF EXAMINATIONS:

No. of Weeks per Semester: 16 Weeks
Marks
Week Semester Total
COMPUTER AIDED
MACHINE & TOOL 5 80 25 100* 100 3 hrs.
DRAWING
Topics and Allocation of Hours:
Unit
Topics Hours
No
I Introduction to CAD software 2
II Drawing aids and editing commands 4
III Basic dimensioning, hatching, blocks and views 5
IV Isometric drawing, printing and plotting 4
Cad Drawing Practice
Detailed drawings of following machine parts are given to students to
assemble and draw the sectional or plain elevations / plans / and side views
V with dimensioning and bill of materials using cad software – 10 Exercises: 65
Sleeve & Cotter Joint, Screw Jack, Foot Step Bearing, Universal Coupling,
Plummer Block, Machine Vice, Drill Jig, Welding Fixture, Blanking Tool,
Injection Moulding Tool.
TOTAL 80
28
RATIONALE:
The contemporary progressing world is fast with the latest production systems. The
advanced manufacturing of products is developed instantly using CAD Software. Even a small-
scale industry is now using a CAD software as it has become the heart of the Design
department. So, CAD has now become inevitable in industries. Accuracy and Precision are the
two important things that decide the quality of a product to survive its competitors in the market.
Using CAD software design, the uniform accuracy, multiples of copies and storing in a small
space for long time are assured.
The CAD software considerably improves the creativity and flexibility of a designer. The
syllabus here enables a candidate to draw an industrial drawing within the optimum reach of a
diploma cadre.
OBJECTIVES:
Appreciate the need of sectional view and types of sections.
Draw sectional views using different types of sections.
Explain the use of threaded fasteners and the types of threads.
Compare hole basis system with shaft basis system.
Select different types of fits and tolerance for various types of mating parts.
Practice on CAD commands in making 2D Drawings.
Draw assembled drawings of different types of joints and couplings using CAD.
Draw assembled drawings of various types of machine elements and Tool assembly
using CAD.
29
DETAILED SYLLABUS
4022340 - COMPUTER AIDED MACHINE AND TOOL DRAWING PRACTICAL
Contents: Theory
Unit Name of the Topic Hours
I INTRODUCTION TO CAD SOFTWARE 2
Introduction – History of CAD – Applications – Advantages over manual
drafting – Hardware requirements – Software requirements – Windows
desktop – CAD screen interface – menus – Tool bars – How to start CAD –
How to execute command – types of co-ordinate systems – Absolute –
Relative – Polar.
II DRAWING AIDS AND EDITING COMMANDS 4
Creating objects (2D) – Using draw commands – Line, Arc, Circle, Ellipse,
Donut, Polygon, Point, Pline, Sketch, Trace – Creating 2D Solid. Creating text
– Dtext, Mtext, Text styles – Mline, spline – Drawing with precision – O-snap
options – drafting settings –limits – Units – drawing aids – Fill, Snap, Grid,
Ortho lines – Function keys - Editing and modify commands – Object
selection methods – Erasing object – Oops - Cancelling and undoing a
command – Copy – Move – Array – Offset – Scale – Rotate – Mirror – Break
– Trim – Extend – Explode. Divide – Measure – stretch – Lengthen –
Changing properties – Color – line types –LT scale – Matching properties –
Editing with grips – Pedit – Ddedit – Mledit.
III BASIC DIMENSIONING, HATCHING, BLOCKS AND VIEWS 5
Basic dimensioning – Editing dimensions – Dimension styles – Dimension
system variables. Machine drawing with CAD. Creation of blocks – Wblock –
inserting a block – Block attributes – Hatching –Pattern types – Boundary
hatch – working with layers - Controlling the drawing display – Blipmode –
View group commands – Zoom, redraw, regen, regenauto, pan, viewres –
Real time zoom. Inquiry groups – calculating area – Distance – Time – Status
of drawing – Using calculator.
IV ISOMETRIC DRAWING, PRINTING AND PLOTTING 4
Isometric drawing – Isometric projection – drawing iso circles – Dimensioning
isometric objects. File commands – File Import and export – plotting drawing
– external references – 3D fundamentals – 2D to 3D Conversion
3D Drawing: 3D Primitives-Extrude – Revolve-Slice-Section, Surface 3D
Mesh-3D - Surface-3D Operation-Solid Editing
V CAD DRAWING PRACTICE 65
Detailed drawings of following machine parts are given to students to
30
assemble and draw the sectional or plain elevations / plans / and side views
with dimensioning and bill of materials using CAD Software
MACHINE DRAWING TOOL DRAWING
1. Sleeve & Cotter joint 7. Drill jig
2. Screw Jack 8. Welding fixture
3. Foot step bearing 9. Press tool assembly- Blanking
4. Universal Coupling tool
5. Plummer Block 10. Plastic moulding tool assembly-
6. Machine Vice Injection moulding tool
Reference Books:
1) Inside AutoCAD - D. Raker and H. Rice - BPB Publications, NewDelhi
2) Engineering Drawing and Graphics + AutoCAD – K.Venugopal, - New Age
International Publications
3) CAD/CAM/CIM - P. Radhakrishnan, S. Subramaniyan and V.Raju - New Age
International Publications.
4) AutoCAD 2002 with Applications - Sham Tickoo - Tata Mcgraw Hill.
5) Computer Graphics, Prentice – Donald Hearn, M. Pauline Baker - Hall of India
Pvt. Limited, New Delhi.
List Of Equipment’s (for a batch of 30 students)
1. Personal computer (With latest processor to suit Auto CAD) – 30 No’s
2. MS Windows OS – 30 No’s
3. AutoCAD software (release 2000 or above) – 30 Users
31
MACHINE DRAWING
Exercise – 1 Sleeve & Cotter Joint
PART & ASSEMBLY DRAWING
32
Exercise – 2 Knuckle Joint
PART DRAWING
33
ASSEMBLY DRAWING
34
Exercise – 3 FOOT STEP BEARING
PART DRAWING
35
ASSEMBLY DRAWING
36
Exercise – 4 PLUMMER BLOCK
PART DRAWING
37
ASSEMBLY DRAWING
38
Exercise – 5 Universal Coupling
PART DRAWING
39
ASSEMBLY DRAWING
40
Exercise – 6 Machine Vice
PART DRAWING
41
ASSEMBLY DRAWING
42
Tool Drawing
Exercise – 7 Drill Jig(Template Jig)
43
44
45
Exercise –8 Welding Fixture
46
47
48
Exercise- 9 Blanking Tool – Drop through type
49
50
51
52
53
54
55
56
Exercise –10 Single Cavity Injection Mould
57
58
59
60
Board of Examination
Part A (I to IV units)
Answer any 10 two mark questions (10 x 2) = 20 Marks
Part B – V Unit
1. Assembled view of a given drawing (2 Views only) = 60(30+30) Marks
a) Question from Machine drawing
(or)
b) Question from Tool Drawing
2. Bill of Materials, Dimensioning, Notes = 10 Marks
Viva voce = 10 Marks
Total = 100 Marks

Note to the examiner:
Part A
Answer any 10 questions out of 15 questions.
Fifteen questions should cover the complete syllabus (UNIT I to IV)
Part-B
Answer should be evaluated from the print out for the Part-B questions
Examiner should set the question paper to cover the complete syllabus of Unit-V.
Examiner has to ask the student to answer any one question from the lot of 10 drawings
with either or choice as detailed above.
Examiner has to set the no. of questions minimum 10 , even one batch of students
contains less than 10.
61

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022350 – ENGINEERING METROLOGY PRACTICAL
62
N-SCHEME

Semester : III
Subject Title : ENGINEERING METROLOGY PRACTICAL
TEACHING AND SCHEME OF EXAMINATIONS:

Marks
Subject Hours/ Hours/ Duration
Week Semester Internal Board
Total
Assessment Examination
ENGINEERING
METROLOGY 3 48 25 100* 100 3 hrs.
PRACTICAL
* Examinations will be conducted for 100 marks and it will be reduced to 75 marks .
OBJECTIVES
To practice linear and angular measurements
To Use vernier caliper, vernier height gauge and micrometer
To Use slip gauges to make standard dimensions
To Measure angle of surface using sine bar
To Use dial indicator to measure geometrical parameters
To Demonstrate parallelism, squareness and circularity
To Check the perpendicularity and squareness of a surface
To Calibrate vernier caliper and micrometer using slip gauges
63
Detailed Syllabus
4022350 - ENGINEERING METROLOGY PRACTICAL
I. LINEAR MEASUREMENT:
1(a). Vernier caliper – Measuring the overall dimensions of a Die plate to an accuracy of
0.02 mm.
1(b). Micrometer – Measuring diameter and thickness of die components to an accuracy of
one micron (0.001mm)
2(i). Vernier height gauge:- a) Measurement of height of the given work piece
b) Marking the given dimensions on the work piece.
c) Transferring measurements from one job to another.
2(ii). Vernier Depth gauge – Measuring the depth of blind holes in the give work piece.
3(a). Screw thread micrometer – Measuring the root dia of the given screw thread
3(b). Measurement of pitch of screw threads using screw pitch gauges.
3(c). Measurement of effective dia of screw thread using three wire method.
4. Measurement of Internal dia of the given die set bush using Inside Micrometer to an
accuracy of one micron.
5. Slip Gauges – Building up the given required dimensions and measuring or marking or
setting Go and No Go sizes in adjustable gap gauges, to an accuracy of 0.5 micron.
6. Measuring the chordal thickness of the gear teeth using the gear tooth vernier.
II. ANGULAR MEASUREMENT:
7. Measurement of angles using universal bevel protractor to an accuracy of 5’.
8. Using combination set i) Measure angle in the given component with protractor head
ii) Find or mark the center of the given cylindrical job using center head.
iii) Check and report the squareness of the given specimen using square head.
9. Measure the angle of the surface using Sine bar and Slip Gauges.
III. MEASUREMENT OF GEOMETRIC PARAMETERS AND CALIBRATION OF
INSTRUMENTS:
10.Straightness – Measurement of concavity / convexity in a surface using Toolmaker’s
straight edge and feeler gauge.
11. Checking the parallelism of two planes using dial indicator.
12. Testing circularity of die set pillars using v-block and dial indicators.
64
13. Measurement of Run-out on
i) External cylindrical surface
ii) External conical surface using dial gauge
iii) Checking of Perpendicularity of drill head guide
iv) Checking of squareness of clamping surface of table to its axis.
14. Measurement of axial slip using dial indicators.
15. Calibration and adjusting of micrometers/ Vernier caliper using slip gauges
SCHEME OF EXAMINATION:
Duration Max. Marks
I) Part – A
a) Linear Measurement
or 1 ½ Hrs. 45
b) Angular Measurement
II) Part – B
c) Measurement of Geometrical
Parameters & calibration. 1 ½ Hrs. 45
III) Viva – Voce 10
Total 100
SCHEME OF VALUATION:
Observation / Reading - 20 marks

Tabulation / Formula - 10 marks
Calculation & Result - 15 marks
65
Details of The Equipment’s (for a batch of 30 students)
NAME OF THE BRANCH / MECHANICAL ENGINEERING
COURSE (TOOL & DIE)
YEAR SECOND
SEMESTER III
NAME OF THE LABORATORY 4022350 ENGINEERING METROLOGY
PRACTICAL
QUANTITY
S.NO LIST OF THE EQUIPMENTS
REQUIRED
1 Vernier caliper 0-150mm 6
2 Micrometer 0-25mm 6
3 Vernier height gauge 0-300mm 2
4 Vernier depth gauge 150mm 2
5 Screw thread micrometer 1
6 Inside micrometer 25-50 mm 6
7 Slip gauges 2
8 Gear tooth vernier 2
9 Universal bevel protractor 3
10 Combination set 1
11 Sine bar 200mm 1
12 Tool makers straight edge 2
13 Feeler gauge 2
14 Dial test indicator with magnetic stand 3
15 V-block 1
16 Surface plate 1
17 Spirit level 2
18 Go & No Go gauges set 1
66

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022360 – MANUFACTURING TECHNOLOGY PRACTICAL
67
N-SCHEME

Semester : III
Subject Title : MANUFACTURING TECHNOLOGY PRACTICAL

SUBJECT Instructions Examination
Hours/ Hours/ Marks
Week Semester
Internal Board Total Duration
MANUFACTURING
TECHNOLOGY 5 80 25 100* 100 3hrs
PRACTICAL
OBJECTIVES:
• Identify the parts of a centre lathe & Drilling machine
• Identify the work holding devices
• Set the tools for various operations
• Operate the lathe and Machine a component using lathe
• Operate the Drilling machine and produce different sizes of holes.
DETAILED SYLLABUS
Contents: Practical
Name of the Topics:
1. Lathe
Syllabus
1. Introduction of safety in operation machines.
2. Introduction to lathe and its parts.
3. Introduction to work holding devices and tool holding devices used in Lathe
4. Types of tools used in lathe work
5. Types of measuring instruments and their uses.
6. Setting of work and tools.
7. Operation done in lathe
8. Practice on a lathe
9. Introduction of work holding and tool holding devices used in drilling machine
10. Drilling, Tapping, Counter Boring, Countersinking and Reaming
68
Exercises :
1. Plain turning
2. Step turning
3. Taper turning
4. Thread cutting
5. Knurling
6. Bushing
7. Eccentric Turning
8. Drilling
9. Tapping
10. Counter Boring
11. Countersinking
12. Reaming
Lathe Works
Manufacture and estimate the cost of the following exercises by assuming the suitable
raw material for the final size of the components.
BOARD EXAMINATION
Note of the Faculty : Last job of the raw material(MS Rod Ǿ32x77mm and MS Rod
Ǿ25x77mm ) to be retained in student wise or batch wise (Maximum Two Students per
batch).This may be verifiable at the time of Board Practical Examination by the external
examiner
Board Examination-Question Paper Pattern

1. Two questions should be asked in such way that one from Lathe and one from drilling
2. Dimensions can be altered with the consent of External Examiner
69
MODEL QUESTION PAPER
1. Machine the component as per the given sketch 60 Marks
Any one of the exercises in Lathe
2. Make the component as per the given sketch 30 Marks
Any one of the exercises in Drilling
DETAILED ALLOCATION OF MARKS

Lathe Work - 60 Marks
Preparation - 10
Dimensions - 40
Finishing - 10
Drilling - 30 Marks
Marking - 15
Finishing - 15
Viva – Voce - 10 Marks
Total - 100 Marks
Any one of the exercise from Drilling
Exercise No:1 –Plain turning .

Raw Material: MS Rod Ǿ32x77mm
70
Exercise No:2-Step turning
Raw Material: Exercise No:1
Exercise No:3-Step and taper turning

Exercise No: 4 -Step and taper turning

Raw Material: Exercise No: 3
71
Exercise No: 5 Knurling and step turning
Exercise No:6 BSW Thread cutting

Exercise No:7 – Metric thread cutting

72
Exercise No:8- Metric thread cutting
Exercise No: 9 -Shaft and bush mating

Raw Material: MS Rod Ǿ25x77mm and Ǿ32x30mm
Exercise No: 10- Thread cutting

1x45°M20(RH)(OR)3/4"BSW
73
Exercise No:11-Eccentric Turning
Make the following jobs using drilling machine.

Exercise No:1 Drilling & Tapping
Raw material 50mm X 50mm X 10 mm thick M.S. Flat
Exercise No:2 Drilling & Counter boring

74
Exercise No :3 Drilling & Counter sinking
Exercise No:4 Drilling and Reaming

75
List of Equipment’s (for a batch of 30 students)
Turning:
1. Center Lathe 4 ½ ‘ Bed length - 15 No’s
2. 4 Jaw / 3 Jaw Chucks - required Numbers
3. Chuck key (10 mm x 10 mm size) - 15 No’s
4. Box spanner - 15 No’s
5. Cutting Tool H.S.S ¼ ‘’ X ¼ ‘’ X 4 ‘’ long - 15 No’s
6. Pitch gauge - 5 Nos
7. Vernier Caliper (0-25 and 25-50) - 5 nos each
8. Micrometer, Inside and Outside(0-25 and 25-50) - 5 each
9. Vernier Height Gauge(300mm) - 1 no
10. Snap gauge - 1 set
11. Gear tooth Vernier - 1 No
12. Parallel Block - 2 Nos
13. Steel Rule (0-150) - 15 Nos.
14. Outside and Inside Calipers - 15 Nos. each
15. Thread gauge - 5 Nos.
16. Bevel Protractor - 1 No
17. Jenny Caliper - 5 Nos.
18. Dial Gauge with Magnetic Stand - 5 Nos.
19. Marking Gauge - 10 Nos.
20. Safety Glass - 15 Nos.
Drilling:
1. Upright drilling machine - 2 Nos.
2. Radial drilling machine - 1 No.
3. Drill bit & Tap set - Sufficient quantity
4. Reaming bit - Sufficient quantity
5. Counter sinking bit - Sufficient quantity
6. Counter boring bit - Sufficient quantity
7. Plug gauges - Sufficient quantity
8. Vernier Height Gauge - 1 No.
9. Surface plate - 2 Nos.
76

(TOOL& DIE)
II YEAR
N – SCHEME
III SEMESTER
2020 – 2021 onwards
4022370 – BASIC ENGINEERING PRACTICAL
77
N-SCHEME

Semester : III
Subject Title : BASIC ENGINEERING PRACTICAL

Hours/ Hours/ Marks
Week Semester
Internal Board Total Duration
BASIC
ENGINEERING 4 64 25 100* 100 3hrs
PRACTICAL
OBJECTIVES:
• Identify the tools and equipment’s used in Foundry & welding
• Prepare sand moulds for different patterns.
• Perform welding operation to make different types of joints.
• Identify the different welding defects.
• Appreciate the safety practices used in welding
• Study of two and four stroke engine and its parts
• performance test on two and four stroke engines
1. Foundry (25 Hrs)
Syllabus
1. Introduction of tools and equipment’s
2. Types of patterns
3. Types of sand
4. Preparation of sand moulds
5. Furnaces – crucible furnace and tilting furnace
6. Core sands, preparation of cores
78
Exercises :
Preparation of sand mould:
1. Solid pattern
a. Stepped pulley
b. Bearing top
c. Gear Wheel
d. T-pipe
2. Split pattern
a. Bent Pipe
b. Tumbles
3. Loose Piece Pattern – Dove tail
4. Cylindrical core making
5. Melting and casting – (not for Examination, only for class exercises)
2. Welding (18 Hrs)
Syllabus
1. Introduction of Safety in welding shop
2. Introduction to hand tools and equipment’s
3. Arc and gas welding equipment’s
4. Types of joints
Exercises :
1. Arc welding
• Lap joint (Material : 25 mm x 3mm Ms flat)
• Butt joint (Material : 25mm x 6mm Ms flat)
• T- joint (Material : 25mm x 3mm Ms flat)
• Corner joint (Material : 25mm x 3mm Ms flat)
2. Gas Welding
• Lap joint (Material : 25mm x 3mm Ms flat)
• Butt joint (Material : 25mm x 6mm Ms flat)
3. Gas cutting : Profile cutting
4. Spot welding – Lap joint (18/20swg)
5. Demonstration of Soldering and brazing
79
3. Thermal Engineering Lab (15 Hrs)
Syllabus
1. Introduction of two stroke and four stroke engine and its parts.
2. Determine the valve and port timing diagram of SI and CI engine.
3. Analyse the influence of variations in TDC and BDC operation
4. Calculate the performance characteristics of SI and CI Engine
Exercises:
1. Construction of valve timing diagram for four stroke engine.
2. Construction of port timing diagram for two stroke engine.
3. IC engine performance test for four stroke SI engine
4. IC engine performance test for four stroke CI engine
MODEL EXAM:7 Hrs
List Of Equipment’s (for a batch of 30 students)
Welding:
1. Arc welding booth – - 2 No’s with oil /air cooled
Welding transformer with accessories
2. Gas welding unit (Oxygen and acetylene cylinder) – 1 Set
3. Flux – 500grams
4. Electrode 10 SWG – 200 No’s
5. Face shield – 3 No’s
6. Gas welding goggles – 2 No’s
7. Leather Glows 18’’ – 4 Set
8. Flux chipping hammer – 4 No’s
9. Spot welding machine - 1 No
Foundry:
1. Crucible furnace - 1 No
2. Tilting furnace - 1 No
3. Shovel - 20 Nos
4. Rammer set - 30 Nos
5. Slick - 30 Nos
6. Strike-off bar - 30 Nos
7. Riddle - 15 Nos
8. Trowl - 30 Nos
9. Lifter - 30 Nos
80
10. Sprue pin - 60 Nos
11. Brush - 20 Nos
12. Vent rod - 30 Nos
13. Draw spike - 30 Nos
14. Gate cutter - 30 Nos
15. Cope box - 30 Nos
16. Drag box - 30 Nos
17. Core box - 10 Nos
18. Runner & riser - 60 Nos
19. Moulding board - 30 Nos
20. Patterns - 15 Nos each
Thermal Engineering Lab:
1. Two stroke petrol engine cut section model - 1 No

2. Four stroke diesel engine cut section model - 1 No
3. Four stroke petrol engine with belt /lamp load assembly - 1 No
4. Four stroke Diesel engine with belt /lamp load assembly - 1 No
Scheme of Examination:
For Board practical examination two exercises(ie one question

from each chapter) should be asked in the any of following
combination
Foundry & Welding
Or 45X2=90marks
Welding & Thermal Lab
Or
Thermal lab & Foundry
Viva Voce 10 marks
Total 100 marks
Scheme of Valuation:
Foundry : Mould Preparation - 30 marks

Gate cutting - 15 marks
Welding : Weld run - 30 marks
Finish - 15 marks
Thermal Engg Lab : Observation/ Reading - 30 marks
Calculation - 15 marks
81

(TOOL& DIE)
II YEAR / III YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022410 – ENGINEERING MATERIALS AND METALLURGY
82
N-SCHEME

Semester : IV
Subject title : ENGINEERING MATERIALS AND METALLURGY

Marks
SUBJECT Hours/ Hours/ Internal Board Duration
Week Semester Total
ENGINEERING
MATERIALS AND 5 80 25 100* 100 3hrs
METALLURGY
TOPICS AND TIME ALLOCATION:
I Metallurgy and Material Structure 15
II Phase diagrams and Iron Carbon equilibrium diagram 15
III Heat Treatment and Properties of Engineering Materials 15
IV Ferrous and Non – Ferrous Metals and their Alloys 14
Metallographic, Surface Treatment and Non Destructive
V 14
Testing
Total 80
83
Rationale:-
The knowledge about the various types of Engineering Materials, their properties and
applications are required for proper selection and use of materials in Tool Design and design of
mechanical engineering components. Thorough understanding of the methods of heat
treatment, their effect and applicability is essential to ensure the full service life of the tools and
components. The knowledge on various metallographic and non destructive testing methods is
necessary to verify the properties, condition and nature of various materials.
OBJECTIVES
To know about the different types of material structure.
To acquire knowledge on Deformation of Metals.
To Understand the Phase Diagrams.
To Understand and Use Iron – Carbon Equilibrium Diagram.
To Study about various Heat Treatment Process.
To Get Knowledge on Thermal & Magnetic properties of Materials.
To know about Superconductivity.
To study about various Ferrous & Non Ferrous Alloys.
To understand the process of Non – Destructive Testing.
84
DETAILED SYLLABUS
4022410- ENGINEERING MATERIALS AND METALLURGY
Unit NAME OF THE TOPICS Hours
No.
METALLURGY AND MATERIAL STRUCTURE:
I 1.1 Crystalline Structure Crystallography, crystal, single crystal,
crystallization of metals, crystal symmetry, elements of symmetry, 7
space lattice, unit cell, lattice parameters of unit cell, primitive cell,
crystal structure, crystal system – cubic system, Tetragonal system,
Hexagonal or trigonal system, orthorhombic system, monoclinic system,
triclinic system. Miller Indices, Crystal directions, coordinate number,
atomic radius, number of atoms per unit cell, density of crystal material.
Material structure –Face centered cubic (FCC), Body centered cubic
(BCC), Hexagonal close-packed (HCP).
1.2Bonding in solids Primary bonds – Metallic bond, Ionic bond,
Covalent bond. Imperfections in metal crystals- types of defect- point 4
defect, line defect, surface defect, volume defect, effect of imperfection
on metal properties
1.3Deformation of metals: Elastic deformation, plastic deformation,
elastic after effect. Deformation by slip, ideal plastic body. Plastic 4
deformation of a single crystal – slip, twinning. cold working and effect
of cold working on metals. Hot working of metals, advantages and
disadvantages of hot working.
PHASE DIAGRAMS AND IRON CARBON EQUILIBRIUM DIAGRAM:
2.1 Phase Diagrams: Solid solution – types of solid solution-
II
substitutional and interstitial solid solution- solid solution alloy – System, 8
Phase, Component, Degree of freedom or variance of the system.
Phase rule, Cooling curves – cooling curve of pure metal, solidification
or crystallization of metal, cooling curve of eutectic type alloy.
Construction of equilibrium diagrams, Interpretation of equilibrium
diagrams. Types of phase diagrams – Eutectic system, Peritectic
system, Eutectoid system, Peritectoid system. Iron-Carbon system –
allotropy of iron, micro constituents of iron and steel, Iron-iron carbide
equilibrium diagram, critical temperatures, effect of alloying elements on
Fe-Fe3C diagram.
2.2 Heat Treatment and Transformation Diagram: Purpose of Heat
Treatment, Heat treatment cycle, Time-Temperature-Transformation 7
85
(TTT) diagram – importance of T.T.T diagram, steps to construct T.T.T
diagram, T.T.T diagram for eutectoid steel, T.T.T diagram and cooling
curves.
HEAT TREATMENT, PROPERTIES OF ENGINEERING MATERIALS:
III
3.1 Heat Treatment of Steel: Annealing – stress relief annealing,
Process annealing, spheroidise annealing, Full annealing. Normalizing,
Hardening – process, quenching medium, hardenability, end quench 8
hardenability test. Tempering – low temperature tempering, medium
temperature tempering, High temperature tempering, Temper
brittleness, Austempering, Martempering. Case hardening – carburising
– pack carburising, liquid carburising, gas carburising. Nitriding,
cyaniding, carbonitriding. Surface hardening – flame hardening,
induction hardening.
3.2 Properties of Engineering Materials: Introduction, Mechanical
properties of Materials – Strength, Elasticity, Plasticity, Ductility,
Malleability, stiffness, toughness, brittleness, hardness, wear 7
resistance, machinability, castability, weldability, fatigue strength, creep.
Thermal Properties – Introduction, Heat capacity, Expansion,
conductivity, Thermal stress. Magnetic Properties – Introduction,
Diamagnetism, Para Magnetism, and Ferromagnetism, Influence of
Temperature on Magnetic Behavior. Superconductivity.
FERROUS AND NON – FERROUS METALS AND THEIR ALLOYS:
IV
4.1 Ferrous Metals & its Alloys: Pig Iron – classification, properties
and applications, Wrought Iron – composition, properties and uses.
Cast Iron – Introduction, classification, effects of alloying elements on 7
the structure of cast iron. Designation system of Cast Iron as per BIS.
Composition, Mechanical properties, applications of Grey cast iron,
Spheroidal graphite cast iron, Malleable cast iron .Steels –
Classification of steel, Effects of alloying elements in steel.
Composition, Mechanical properties, applications of low carbon steel,
medium carbon steel and high carbon steel. HSS , Tool steel, Stainless
steel - Composition ,Mechanical properties and applications
4.2 Non – Ferrous Metals & its Alloys: Aluminum & its alloys – types,
properties and applications. Designation system of aluminum and its 7
alloys as per BIS .Copper & its Alloys – Types , Brass, Gunmetal –
Composition, properties & applications, Zinc – Composition , properties
& applications.
86
V Metallography, Surface Treatment and Non Destructive Testing
5.1 Metallography: Metallurgical microscope – Preparation of
specimen, micro and macro examination. Study of micro structure of 5
Ferrous and Non Ferrous metals. Modern techniques of material studies
– electron microscope, photoelectron spectroscopy.
5.2 Surface Treatment: Mechanical cleaning and finishing – Vibratory
finishing, wire brush cleaning, buffing and electro polishing. Chemical
cleaning – Vapour degreasing, solvent cleaning, alkaline cleaning, 5
ultrasonic cleaning, acid pickling. Surface coatings – Electroplating,
painting, powder coating, blackening, vacuum Metalizing, Physical
vapour deposition, chemical vapour deposition.
5.3 Non Destructive Testing: Magnetic particle inspection, X-Ray
inspection, Gamma radiography, Ultrasonic Inspection, Electrical 4
methods, Damping test, Non-magnetic methods of crack detection.
Text Books:
1. Dr . O.P.Khanna , Material science and Metallurgy, Dhanpat Rai & Sons
2. Material Science and Engineering ,William .D.Callister JR , Sixth Edition
References Books
1. ASM Hand book, Vol.1, ASM International, Materials Park, Ohio, U.S.A,
2. S.K.Hajra Choudhury and A.K.Hajra Choudhury, Elements of Workshop
Technology, Media Promoters and publishers pvt. Ltd
87

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022420 – FLUID POWER AND THERMAL

ENGINEERING
88
N-SCHEME

Semester : IV
Subject Title : FLUID POWER AND THERMAL ENGINEERING

Marks
Week Semester Total
FLUID POWER AND

THERMAL 5 80 25 100* 100 3hrs
ENGINEERING
Topics and Time allocation
UNIT TOPIC TIME

(Hrs)
I PROPERTIES OF FLUIDS AND PRESSURE MEASUREMENTS 15
II PNEUMATIC SYSTEM 14
III HYDRAULIC SYSTEM 14
IV THERMODYNAMICS ,INTERNAL COMBUSTION ENGINES & 15
HEAT EXCHANGERS
V E- VEHICLES 15
Total 80
89
RATIONALE:
The growth of Engineering and Technology is associated with fluid power applications
and heat & work transfer. Low cost Automation using Pneumatics and Hydraulic machines and
presses are very common in Automobile and Die casting industries. Hence studying the
fundamentals of Pneumatics, Hydraulics and Heat transfer facilitates better understanding of
their applications in the area of Tool & Die Making and widens the employment opportunities.
OBJECTIVES
At the end of the study of this subject the student will be able to:
Define the properties of fluids
Explain the working of pressure measuring devices
Appreciate the use of fluid power
Explain the working of pneumatic system and its elements
Explain the working of Hydraulic system and its elements
Compare Pneumatic system with Hydraulic system
Design fluid power circuits for industrial applications
Explain the concept and types of thermodynamic systems
Explain the working of IC engines & heat exchangers
Concept of E vehicle, drives and its importance
Objectives of E V policy & recycling Ecosystem
90
DETAILED SYLLABUS
4022420 - FLUID POWER AND THERMAL ENGINEERING

Contents: Theory
UNIT
NAME OF THE TOPIC Hrs
NO
I PROPERTIES OF FLUIDS AND PRESSURE MEASUREMENTS
Fluid-Definition-Classification of fluids-Ideal and real fluids-Newtonian and non-
Newtonian-Properties of fluids-Density, Specific weight, Specific volume, 7
Specific gravity, Compressibility, Viscosity, Surface tension and capillarity.
Pressure-Unit of pressure-Pressure head-Atmospheric pressure-Gauge
pressure and Absolute pressure-Problems-Pascal’s law-Proof-Applications of
Pascal’s law-Hydraulic press, Hydraulic jack.
Pressure Measurement -Piezometer tube-Simple U-tube manometer-
differential U- tube manometer-Inverted differential U-tube manometer-Micro 8
manometer-Inclined tube micro manometer-Problems-Mechanical Pressure
gauge-Bourdan tube pressure gauge-Diaphragm pressure gauge-Dead weight
pressure gauge.
II PNEUMATIC SYSTEM
Pneumatic system and its elements-Filter, Pressure regulator, Lubricator unit-
Pressure control value-3/2 DCV, 5/2DCV, and 5/3DCV-Check value- Flow
control value-Throttle value-Shuttle valve-Quick exhaust valve-Time delay 7
value-Pneumatic actuators-Single acting cylinder, Double acting cylinder, Air
motor, ISO symbols of Pneumatic components.
Pneumatic Circuits-Direct operation of single acting cylinder-Operation of
double acting cylinder-Operation of double acting cylinder with metering-in 7
control-Operation of double acting cylinder with metering-out control-Use of
shuttle valve in pneumatic circuit-Use of quick exhaust valve in pneumatic
circuits-Automatic operation of double acting cylinder-Merits and Demerits of
pneumatic system-Applications.
III HYDRAULIC SYSTEM
Hydraulic system and its elements-Merits, Demerits and applications of 2
hydraulic system.
Hydraulic pumps-types-positive displacement pumps and non - positive
displacement pumps -Gear pumps-External gear and internal gear type-vane 5
pump-Axial piston pump and Radial piston pump-Hydraulic cylinders and
Hydraulic motors - ISO symbols for hydraulic components -pressure relief
valve-Directional control valves-3/2DCV,4/2DCV,4/3DCV.
91
Hydraulic accumulator and its uses-Types-Gravity type accumulator, spring 2
loaded accumulator, Gas loaded accumulator-Pressure intensifier.
Hydraulic circuits-Operation of double acting cylinder using metering-in control
and metering out control-Operation of Hydraulic motor using metering-in and
metering out- control Hydraulic circuit using sequence valves and counter 5
balance valves - Hydraulic circuit for shaping machine, surface grinding
machine and Milling machine. Comparison of Hydraulic system and Pneumatic
system.
IV THERMODYNAMICS
Thermodynamic system-Types-Closed system, Open system and isolated
system-Property and state of a system-Intensive and Extensive properties -
Thermodynamic process-Cycle-Point and Path functions-Law of conservation 6
of energy-Thermodynamic equilibrium- laws of thermodynamics.
Laws of perfect gases- -Equation of state-Universal gas constant-Relationship
between the specific heats and gas constants.
INTERNAL COMBUSTION ENGINES
Introduction to IC Engines-Classification-Working of four stroke cycle petrol and
diesel engines-Merits & Demerits-Working of two stroke cycle petrol and diesel 3
engines-Merits & Demerits-Comparison of four stroke and two stroke engines.
HEAT EXCHANGERS
Heat transfer in engineering –Modes of heat transfer-Conduction, Convection
and Radiation.
Heat transfer by conduction-Fourier law of heat conduction-Thermal
conductivity of engineering materials-Heat conduction through plane wall-Heat 6
conduction through composite wall-Simple problems.
Newton’s law of cooling-Stefan Boltzmann law of radiation.
Heat exchanger-types, parallel flow heat exchanger, counter flow heat
exchangers-Application of heat exchangers.
92
V E-VEHICLES
Environmental impact and history: Air pollution – Petroleum resources –
History of Electric vehicles -History of Fuel Cell Vehicles Battery Electric 4
Vehicle (BEV) – Fuel Cell Electric Vehicle (FCEV) – Description.
Electric Vehicles: Configurations of Electric Vehicle – Performance of Electric
Vehicles – Tractive Effort in Normal Driving – energy consumption. Hybrid 7
Electric Vehicles: Concept of Hybrid electric drive trains – Architecture of
Hybrid Electric Drive trains. Electric Propulsion Systems: Drive Systems: DC
motor drives - Principle of operation – Induction Motor drives - Basic operation
principles Energy Storages: Electrochemical Batteries – Battery Technologies –
Lead Acid Batteries – Nickel Based Batteries – Lithium Based Batteries –
Charging system – DC charging – Wireless charging
Tamilnadu E-vehicle Policy 2019: Vehicle Population in Tamilnadu – Need of
EV Policy – Advantage of EV Eco system – Scope and Applicability of EV 4
Policy – Objectives of EV Policy – Policy Measures Recycling Ecosystem –
Battery and EVs.
Text Books:
1. Sundaramurthy, Fluid Mechanics and Fluid Power, Narayana publications.
2. Nag.P.K., Engineering Thermodynamics, Tata Mc Graw Hill.
3. R.Srinivasan, Hydraulic and Pneumatic controls, Vijay Nicole Imprints PVT.LTD, second
edition, Chennai.
4. Modern electric, Hybrid electric & Fuel cells vehicles –Mehrdad ehsani ,Yimin Gao,
Stefano Longo & Kambiz Ebrahimi.
Reference Books:
1. Khurmi.R.S, A Test book of Hydraulics, Fluid Mechanics and Hydraulic Machines, S
Chand & CO.
2. Khurmi R.S and Gupta.K, A Text book of Thermal Engineering, S Chand & CO.
3. Ballaney.B.L., Applied Thermodynamics , Khanna publishers.
4. Bansal.R.K, Fluid Mechanics and Hydraulic Machines .
5. Electric Vehicles and the end ICE age-Anupam Singh.
93

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022430 – TOOL ROOM SPECIAL MACHINES
94
N-SCHEME

Semester : IV
Subject Title : TOOL ROOM SPECIAL MACHINES

Marks
Week Semester Total
TOOL ROOM
SPECIAL 5 80 25 100* 100 3 hrs.
MACHINES
UNIT Topic Hrs.

I Cutting Tools and Mechanics of Metal Cutting 15
Boring, Jig Boring, Jig grinding, Tool and Cutter Grinder and Cylindrical 14
II
Grinder
III Milling Machines and Gear Generation Processes 14
IV CNC Machine and its Components 15
V Un-Conventional Machining 15
Total 80
95
RATIONALE:
Globalization and technological advances making tremendous growth in industrial
activities, which in turn needs tool and die makers for most of the engineering products
manufacturing industries. To meet out such demand and to sustain we have to explore the
knowledge about tool room special machines covering the various operations and skill set
required for the development of nation and its people.
OBJECTIVES:.
At the end of the study of this subject the student will be able to:
Describe the different forces in orthogonal and oblique cutting
Estimate the forces in metal cutting operations
Describe about various cutting tool materials
Explain the cutting force measurement principles
Compare the properties of different cutting fluids
Describe about jig boring and jig grinding
Explain about tool and cutter grinder
Explain the milling machine principles, types and its various operations
Explain the various gear generation processes
Explain the principle of operation of various un-conventional machining processes
Appreciate the use of un-conventional machining processes.
Distinguish between EDM and Wire-cut EDM machine operation
Describe about various types of CNC machines, operations and its components.
96
DETAILED SYLLABUS
Contents: Theory
Cutting Tools and Mechanics of Metal Cutting
Chapter: 1.1:Cutting tools-properties of cutting tool materials-cutting tool
5
materials; High carbon steels, high speed steel, carbides, ceramics. types of
cutting tools
Chapter: 1.2: Types of metal cutting – orthogonal and oblique cutting- chip
formation – continuous, discontinuous, built-up edge – shear angle. Tool
I
signature – importance cutting forces in orthogonal cutting – metal removal
10
rate [MRR] – tool life; Taylor’s life equation, factors influence in tool life.
measurement of cutting force – tool dynamometer – types of tool
dynamometer – machinability – machinability index – factors affecting
machinability – cutting fluids – properties of cutting fluids – selection of
cutting fluids – selection of cutting fluids
Boring, Jig Boring, Jig grinding, Tool and Cutter Grinder and
Cylindrical Grinder
Chapter: 2.1:Boring and jig boring -Boring machines- horizontal and vertical
3
types- fine boring machines- boring tools jig boring machine- measuring
system- hole location procedure- deep hole boring
Chapter: 2.2:Jig grinding Introduction- construction- operation techniques-
3
setting up and clamping- wheel travel- wheel selection- wheel dressing.
optical profile grinding- basic principle and operations
II
Chapter: 2.3:Tool and cutter grinder Introduction- selection of cutter-
5
grinding wheels- shape, abrasive grain size and bond, direction of rotation-
tooth rest, types, parts of universal tool and cutter grinder, clearance, width
of land- producing of clearance angle
Chapter: 2.4:Cylindrical Grinding Machine
Centre Type Cylindrical Grinding Machine – Centre less Grinding Machine –
3
Through feed Grinding – In feed Grinding
Milling Machines and Gear Generation Processes
Chapter: 3.1:Milling machines; Types-specification of milling machines-
7
III
principles of operation of column and knee type and universal milling
machine- work and tool holding devices; Arbor, spring collet, adapter –
97
milling cutters; cylindrical milling cutter, slitting cutter ,side milling cutter,
angle milling cutter, T-slot milling cutter, woodruff milling cutter, fly cutter-
nomenclature of cylindrical milling cutter-milling process; conventional milling
and climb milling-milling operations-milling attachments.
Chapter: 3.2:Generation process Gear shaper- gear hobbling- principle of
operation only gear finishing processes- gear burnishing- gear shaving- gear
grinding and gear lapping- gear materials; cast iron, steel, alloy steels brass, 7
bronze, aluminum ,nylons
CNC Machine and its Components
Chapter: 4.1:CNC machines; Numerical control- definition- working
principle of a CNC system- features of CNC machines- advantages of CNC
8
machines- difference between NC and CNC- construction and working
principle of turning principle- construction and working principle of machining
IV
centre- machine axes conventions turning centre and machining centre.
Chapter: 4.2:Components of CNC machine; slide ways- requirement-
types- friction slide ways and antifriction slide ways- linear motion bearings-
7
recirculation ball screw- ATC- tool magazine – feedback devices- linear and
rotary transducers- encoders- in process probing- tool material- tool inserts.
Un-Conventional Machining
Chapter: 5.1:Un- conventional Machining Processes: Construction,
working and applications of ultrasonic machining- chemical machining-
7
electro chemical grinding- plasma arc machining- LASER machining-
advantages- disadvantage,- Electron Beam Machining – Abrasive Jet
Machining
V Chapter: 5.2:Electrical discharge machining: Introduction- principle of

spark erosion and requirements of dielectric fluid- layout of spark machining
8
system, EDM machine- tool materials – electrical circuits in EDM- metal
removal rate- mean current- operation parameters and typical values and toll
wear- reasons- classification and types. EDM process characteristic-
advantages and disadvantages of EDM process- wire-cut EDM,CNC Wire-
cut EDM for machining punch and die cavities.
TEST & MODEL EXAMINATION 07
98
TEXT BOOKS
1. Hajra choudhry, “Work shop Technology", Vol. II, Media Promoters and Publishers Pvt.
Ltd.
2. Chapman.WAJ., “Work shop Technology", Vol. II & III, ELBS
REFERENCE BOOKS :
1. Paul De Garmo.E., & Others, "Materials and Processes in Manufacturing", Macmillan

Publishing Company
2. Jain & Gupta, Production Technology, Khanna Publishers, 2-B, North Market,
Naisarak, new Delhi
3. MOORE AND VICTORY, “ Holes, Contour And Surfaces”
4. HMT, “Production Technology”
5. BATTACHARYA, “Workshop Technology”, P.C.SHARMA, “A Text Book of Production
Engineering”, S.Chand & Co
99

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022440 – Forging Dies, Die Casting Dies and

Die Maintenance
100
N-SCHEME

Semester : IV
Subject Title : FORGING DIES, DIE CASTING DIES AND DIE MAINTENANCE

No of weeks per semester: 16weeks
Marks
Subject Hours/ Hours/ Internal Board Duration
Week Semester Total
FORGING DIES,
DIE CASTING
5 80 25 100* 100 3 hrs.
DIES AND DIE
MAINTENANCE
Unit. TOPIC TIME (Hrs.)
No.
I Forging Process and Forging Machines 15
II Design Of Drop Forging, Press Forging and Machine Forging Dies 15
III Die Casting Materials , Machines, Die Materials And Treatments 14
IV Die Casting Die Design, Defects And Finishing Of Die Casting Dies 15
V Die Maintenance 14

Total 80
101
RATIONALE:
Development and use of Forging & Die casting products is high in industries and
requires more knowledge on Forging dies and Die Casting Dies and understand of its
processes and the operations. This subject will develop the basic knowledge on Forging and
Die casting Dies with the process and the basic operations.
OBJECTIVES:
Explain the fundamentals of forgings, and forging processes.
Compare the different types of forging
Design Drop Forging dies.
Design press forging and Machine forging dies.
Explain the basics of Die casting process.
Explain the working of die casting machines.
Design die casting die
State the characteristics of the die steel
Explain the causes and remedies of die casting defects.
Practice on estimation and costing of dies
Estimate the cost of dies
Understand the necessity & importance of die maintenance
102
DETAILED SYLLABUS
Contents: Theory
Name of the Topic Hours
Unit
FORGING PROCESS AND FORGING MACHINES
I Introduction to Forgings: Uses and advantages of forgings, forged
parts Vs cast parts, Forging Temperatures, annealing of forgings, forging 4
properties. forge ability and forgeable metals
Forging processes: Hot-working and cold-working – Advantages –
comparison – hot-working operations: rolling, forging, smith forging, drop
forging, upset forging press forging – roll forging – Roll die forging, ,
skew rolling, ring rolling - power required calculations for rolling and 7
forging operations. Forging dies– drop hammers- board hammers, air lift
hammers, power drop hammers, capacity of drop hammers. Press
forging – Mechanical forging presses, Hydraulic press. Comparison of
press forging Vs hammer forging. Machine or upset forgings. Heat
treatment of forged parts
Heating devices–Box or batch type furnaces, rotary hearth furnaces,
continuous or conveyor furnaces, induction furnaces, resistance 4
furnaces. Open fire and stock fire.
DESIGN OF DROP FORGING, PRESS FORGING AND
II MACHINE FORGING DIES
DROP FORGING DIE DESIGN: Hammer dies for preparatory work –
fullering dies – edging dies – flattening dies – Drawing down dies – 6
bending die. Essential features of forging dies – generous radii, parting
line position, flash gutter, webs and panels, draft, air vents. Flash areas
and gutters in finishing dies. Elements of multi impression die block,
effect of grain flow.
PRESS FORGING DIES: Rating of forging press, steps in press forging 3
dies, design of press forgings, design of press forging dies.
MACHINE FORGING DIES:- General characteristics, techniques used
in making these forgings, machine forging description and range, 3
103
machine forging tools and operation, design of dies for forging machines
Laws governing forging machine die design, Examples of forgings
produced on forging machines, forging defects – causes and remedies.
FORGING DIE BLOCKS AND DIES: Materials and grade of die blocks,
applications of various grades of steel used for die blocks and dies-Die 3
insert-Re-sinking of dies- IS code for tool and die steels
DIE CASTING MATERIALS , MACHINES, DIE MATERIALS AND
III TREATMENTS
DIE CASTING MATERIALS: Types of die casting alloys –metallurgy,
melting & casting procedure and application of zinc based die casting 4
alloys, Aluminum base alloys, Magnesium base alloys, magnesium base
alloys, Copper base alloys, Lead base alloys and Tin base alloys.
DIE CASTING MACHINES: Plunger machine, air machine, modern
cold chamber machines. Die locking methods, injection systems,
automatic cycle control, and interlock and safety devices in die casting 6
machines. Operation of hot chamber and cold chamber die casting
machines. Machine specifications, process parameters and their effect
on product quality. Effect of die casting machine on the process –
accumulator pressure, injection line pressure, intensification, plunger
diameter, locking force, mode of injection, plunger diameter, casting
cycle, lubrication.
DIE MATERIALS AND TREATMENTS: Characteristics of Tool and Die
steels – Choosing of Tool Steels – Heat treatment of die steels – Tool 4
steel production methods – Die surface coatings and treatments –
wrought low carbon steels and Cast irons – Nonferrous and nonmetallic
die materials.
DIE CASTING DIE DESIGN, DEFECTS AND FINISHING OF DIE
IV CASTING DIES
DIE CASTING DIE DESIGN: Flow system – Importance, metal flow
systems in die casting dies, goose neck, nozzle, sprue, runners 6
systems, shock absorbers, gate, gate area, gate velocity, air vent,
overflow, determination of gate area. Procedure to calculate runner and
104
gating dimensions using PQ2 diagram, calculating runner and gating
dimensions without PQ2 diagram. Consideration of specification of die
casting machines. Ejection systems – need and working of ejection
system, Types of ejection system – sleeve, ring, blade
DIE CASTING DEFECTS: Definition, causes and remedies of defects –
Shrink holes, Gas holes, Segregation, Shrink cracks, Porosity, Cold 6
shuts, Flow lines & Blooms, Foliations, Hard spots, Surface draws and
Depressions, Soldering, sink mark and excessive flash.
FINISHING OF DIE CASTING DIES: Trimming and piercing of die 3
casting dies- comparison die casting dies with other products
DIE MAINTENANCE
V Good Maintenance Practice – Good grinding practice – Stress 3
relieving cutting tools – shimming die components – ball lock punches
and die buttons.
Die maintenance documentation and tracking – Die maintenance 3
team – Systematic die maintenance system – Request for maintenance
form – Continuous improvement.
Effective Die Maintenance Program Strategy – Understanding The
Die Maintenance Facility – Addressing Production- Scheduling 4
Programs – Planning Die Maintenance – Tracking The Cost Of
Maintenance And Down Time
Trouble Shooting Large Panel Stamping Dies – Die Bolting –
Nitrogen Pressure Systems – Systematic Approach To Die Tryout – 4
Draw Beads – Double Action Press Operations – Dirt Problems –
Forming Ribs And Embossments – Knockout Bars.
Text books:
1. S.K.Hajra Choudhury and A.K.Hajra Choudhury, Elements of Workshop Technology,
Media Promoters and publishers pvt. Ltd
2. Ivana Suchy, Hand book of Die Design, McGraw-Hill Book company, Second edition
Reference Books:-
1. Meswani., and R.H.Dattani, Design and Manufacture of forging dies
2. Kamenshichikov, S.Koltun and V.Naumov, Forging Practice, MIR publishers.
3. J.C.Sharman, Drop, Press and Machine Forgings, The machinery publishing co ltd.
105

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022450 – MECHANICAL MATERIAL TESTING

PRACTICAL
106
N-SCHEME

Semester : IV
Subject title : MECHANICAL MATERIAL TESTING PRACTICAL

Hours/ Hours/ Marks Duration
Week Semester
Internal Board Total
MECHANICAL
MATERIAL
4 64 25 100* 100 3 hrs.
TESTING
PRACTICAL
OBJECTIVES

Able to determine various strengths of Different Materials.
To calculate the Young’s modulus and Shear modulus of the given material.
To conduct Bend Test using the given specimen.
To differentiate hardness and toughness of the given Ductile and Brittle Materials.
To detect cracks on the given specimen
To handle Rockwell & Brinell hardness tester to determine the Hardness of the given
material.
To observe the microstructure of ferrous and nonferrous metal using metallurgical
microscope.
107
DETAILED SYLLABUS
Part – A (30 Hrs)
1. Estimation of Tensile Strength of the ductile material –Mild steel
2. Estimation of Tensile Strength of Brittle material - Cast Iron
3. Estimation of compressive Strength of the following materials
a) Ductile material (Mild Steel or Al)
b) Brittle material (Cast Iron or Bronze)
4. Estimation of shear strength of Mild steel specimen under (i) Single shear and
(ii) Double shear condition
5. Estimation of Toughness of mild steel specimen using (i) Izod impact test
(ii) Charpy impact test
6. Torsion test on mild steel – relation between torque and angle of twist, determination of
shear modulus and determination of elastic constants for mild steel.
7. Determination of stiffness, modulus of rigidity, strain energy stored and shear stress by
load deflection method on the coil springs.
8. Determination of Young’s modulus of steel by deflection test.
9. Determine the ductility of the given specimen using Bend Test.
Part – B (27 Hrs)

10. Determination of hardness of Mild steel, copper, aluminum using Rockwell
hardness tester
11. Determination of hardness of OHNS and HCHCr using Rockwell harness tester.
12. Determination of hardness of Mild steel, copper, aluminum using Brinell
hardness tester
13. Determination of hardness of OHNS and HCHCr using Brinell hardness tester.
14. Study of Metallurgical microscope and grain structures.
15. Preparation of specimen for study of micro structure of ferrous metals
16. Examine the micro structure of metal samples (i) Ferrous and (ii) Non- Ferrous.
17. Detection of Cracks in casting using Detection methods.
i. Visual Inspection and ring test
ii. Die penetrant test
18. Detection of Cracks in casting using Magnetic particle test
MODEL EXAM – 7 Hrs
108
Part -A (1½ Hours) : 45 marks
Part -B (1½ Hours) : 45 marks
Viva-Voce : 10 marks
Total : 100 marks

SCHEME OF VALUATION:
Observation / Reading - 15 marks
Tabulation / Formula - 15 marks
Calculation & Result - 15 marks
Details Of The Equipment’s (for a batch of 30 students)
NAME OF THE BRANCH / MECHANICAL ENGINEERING
COURSE (TOOL & DIE)
YEAR SECOND
SEMESTER IV
NAME OF THE LABORATORY 32245 MECHANICAL MATERIAL
TESTING PRACTICAL
QUANTITY
S.NO LIST OF THE EQUIPMENTS
REQUIRED
1 Universal Testing Machine (UTM) 1
2 Rockwell Hardness Testing machine 1
3 Torsion testing machine 1
4 Defection testing machine 1
5 Impact test machine 1
6 Torsion testing arrangement 1
7 Shear testing machine 1
8 Brinell hardness testing machine 1
9 Metallurgical microscope 2
10 Metallurgical specimens 1set
11 Double disk polishing machine 1
Electromagnetic crack detector with its
12 1
accessories
109

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022460 – HYDRAULICS AND PNEUMATICS

PRACTICAL
110
N-SCHEME

Semester : IV
Subject Title : HYDRAULICS AND PNEUMATICS PRACTICAL

Hours/ Hours/ Marks Duration
Week Semester
HYDRAULICS AND
PNEUMATICS 3 48 25 100* 100 3 hrs.
PRACTICAL
Objectives:
Study Pneumatic system and its functioning
Study Hydraulic system and its functioning
Control operation of cylinders using metering in and metering out control
Design and operate application oriented pneumatics circuits
Design and operate application oriented hydraulic circuits
Use special purpose valves such as shuttle valve and quick exhaust valve
Compare the functioning of pneumatic and hydraulic systems
Trouble shoot in pneumatic and hydraulic circuits
Note:
The students should be trained in Pneumatics and Hydraulics and all exercises
should be completed. The students should maintain a Record Note book and submit
the bonafide record for Board Practical Examination. Examination has to be conducted
in Pneumatics and Hydraulics lab.
111
List of exercises in Pneumatic System: (24 Hrs)
1. Study of Pneumatic System and its elements.
2. Direct operation of a Single Acting Cylinder.
3. Direct operation of a Double Acting Cylinder.
4. Operation of a Single Acting Cylinder controlled from two different positions using
Shuttle Valve.
5. Operation of a Double Acting Cylinder with quick return using quick exhaust valve.
6. Controlling the speed of a Double Acting Cylinder using metering –in and metering –
out controls.
7. Automatic operation of a Double Acting Cylinder in single cycle using limit switch and
memory valve.
8. Design a pneumatic circuit for operating a jack ,Brake, Clamps, push & move
parts.(one circuit design is to be asked compulsory for end examination with a
maximum of 10 marks)
List of exercises in Hydraulic System (21 Hrs)
1. Study of hydraulic System and its elements.
2. Direct operation of a Double Acting Cylinder.
3. Direct operation of a Hydraulic motor.
4. Controlling the speed of a Double Acting Cylinder using metering-in and metering-out
type control.
5. Controlling the speed of hydraulic motor using metering-in and metering-out control
6. Sequencing of two cylinders using Sequence Valve.
7. Design a hydraulic circuit for operating a hydraulic press, jack, milling machine table
movement. (one circuit design is to be asked compulsory for end examination
with a maximum of 10 marks)
MODEL EXAM: 3 Hrs
112
Scheme of Evaluation
Procedure 5 marks
Pneumatics Any one exercise (Ex No 2-7) Circuit Diagram 20 marks
(45 marks) & Execution 10 marks
Circuit Design (Ex No 8) Circuit Design & 10 marks
(Compulsory) Procedure
Any one exercise (Ex 2-6) Procedure 5 marks

Hydraulics & Circuit Diagram 20 marks
(45 marks) Circuit Design (Ex No 7) Execution 10 marks
(Compulsory) Circuit Design & 10 marks
Procedure
Viva voce 10 marks
Total 100 marks

1. Pneumatic system with necessary DCV, FCV and Actuators.
2. Hydraulic system with necessary DCV, FCV and Actuators.
113

(TOOL& DIE)
II YEAR
N – SCHEME
IV SEMESTER
2020 – 2021 onwards
4022470 – TOOL ROOM SPECIAL MACHINES

PRACTICAL
114
N-SCHEME

Semester : IV
Subject Title : TOOL ROOM SPECIAL MACHINES PRACTICAL

Marks
Subject Hours / Hours / Duration
Total
TOOL ROOM
SPECIAL
5 80 25 100* 100 3 Hrs.
MACHINES
PRACTICAL
OBJECTIVES:
Identify a milling machine and its parts
Identify a cylindrical grinder, surface grinder and tool and cutter grinder
Identify Shaping machine and its parts
Identify the tools and instruments
Handle the different types of work holding devices
Machine a component using different machine tools.
Calculate the indexing for a work
115
DETAILED SYLLABUS
Contents: Practical
Name of the Topics:
Syllabus
1. Introduction to shaping machine and its parts
2. Introduction to milling machine and its parts.
3. Introduction to grinding machine and its parts
4. Introduction to work holding devices.
5. Types of cutter used in milling machine
6. Types of grinding wheels used in grinding machines
7. Setting of work, tools and cutters in shaping, milling and grinding machines
8. Operations performed in shaping, milling and grinding machine
EXERCISES:
1. Machine a cube by using shaping machine
2. Machine a square block from round rod using Milling machine
3. Machine a ‘V’ Block using Milling machine
4. Machine Groove cuts using Vertical Milling machine
5. Grind a plain surface using surface Grinder
6. Grind a cylindrical surface using Cylindrical Grinding machine
7. Grind a Progressive type Plug gauge using Cylindrical Grinding machine
8. Machine a Spur Gear using milling machine by Simple Indexing
9. Machine a Helical Gear using milling machine.
10. Grind a Facing Tool using Tool and Cutter Grinder
BOARD EXAMINATION
Note to the faculty :- Last job of the raw material (MS Rod Ǿ32x33mm, MS Rod
Ǿ25x98mm and 13x13x75 mm MS square rod) to be retain in student wise or batch wise(not
more than 2 students)
This may be verifiable at the time of Board Practical Examination by the external examiner

Milling / Grinding/Shaping : 90 marks
Viva-voce : 10 marks
Total : 100 marks
Note: Sketches enclosed
Note : All dimensions are in mm
116
Board Examination-Question Paper Pattern
One Experiment should be carried out given in the question paper(1x90=90)
Procedure - 10marks
Calculation -10 marks
Dimensioning – 40 marks
Finish - 30 Marks
Viva – Voce - 10 Marks
Total – 100 Marks
1.To machine the component in a given raw material as per the sketch attached
Note : Attach the sketch with the question paper

EXERCISE NO: 1 SHAPING A PLAIN SURFACE
MANUFACTURE A SQUARE BLOCK USING SHAPING MACHINE.
Raw material size: 52 mm CI (or) MS cube
EXERCISE NO: 2 MANUFACTURE A MAXIMUM SIZE SQUARE BLOCK FROM

GIVEN ROUND ROD USING MILLING MACHINE.
RAW MATERIAL SIZE: Ø32X33 mm MS ROUND
Ø32
117
33
ALL
DIMENSIONS ARE IN mm
EXERCISE NO : 3
MACHINE A V BLOCK BY USING MILLING MACHINE
RAW MATERIAL SIZE:22 X33
14
90 °
8
22
22
EXERCISE NO:4 GROOVE MILLING

MACHINE THE REQUIRED GROOVES BY USING VERTICAL MILLING MACHINE
RAW MATERIAL SIZE:22X33
14
90 °
22 8 8
3 3
10
22
118
EXERCISE NO:5 SURFACE GRINDING
GRIND THE PLAIN SURFACE TO AN ACCURACY OF 0.01mm BY USING
SURFACE GRINDING MACHINE.
RAW MATERIAL SIZE:75X50X12 mm MS
11.6±0.0
1
FLAT
75.
0
EXERCISENO:6 CYLINDRICAL GRINDING
GRIND THE CYLINDRICAL COMPONENT TO AN ACCURACY OF 0.02MM
BY USING CYLINDRICAL GRINDING MACHINE
RAW MATERIAL SIZE:Ø32X150 MM MS POLISH ROD
EXERCISE NO:7 CYLINDRICAL GRINDING

MANUFACTURE A PROGRESSIVE TYPE PLUG GAUGE BY USING
CYLINDRICAL GRINDING
RAW MATERIAL SIZE:FINISHED WORKPIECE OF EX.NO:6
119
EXERCISE NO:8 SPUR GEAR MILLING
MACHINE A SPUR GEAR BY USING MILLING MACHINE
EXERCISE NO:9 HELICAL GEAR MILLING

MACHINE A HELICAL GEAR BY USING MILLING MACHINE
EXERCISE NO:10- FACING TOOL (TOOL AND CUTTER GRINDER)

TOOL AND CUTTER GRINDING
RAW MATERIAL:13 x13x 75
6°
6°
16° 8°
8°
8°
120
1. Vertical milling machine/ vertical milling attachment in Universal Milling Machine 2 No’s
2. Universal Milling Machine with indexing head- 2 Nos
3. Surface Grinding Machine (Horizontal) – 1 No
4. Cylindrical Grinding machine – 1 No
5. Tool and Cutter grinder – 1 No
6. Shaping machine –1 no
EQUIPMENT’S & TOOLS:
1. Milling Cutter (2 Module cutter) & accessories – complete sets
2. Milling Machine Handle and required accessories – 2 sets
3. Grinding wheel OD 150 mm , ID 1’’(AA-65, K5, V8) – 2 No’s
4. Grinding wheel OD 300 mm , ID 150mm(AA-56, K5, V8) – 1 No
121

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4022510 – JIGS, FIXTURES AND GAUGES
122
N-SCHEME

Semester : V
Subject Title : JIGS, FIXTURES AND GAUGES
Subject Marks
Hours/ Hours/ Duration
Total
JIGS,
FIXTURES 5 80 25 100* 100 3 hrs.
AND GUAGES
TOPICS AND ALLOCATION OF HOURS:
Unit No Topics Time Hours
Unit – I Basics of Work Holding Devices 14
Unit – II Clamping and Tool Guiding Elements 15
Unit – III Principles of Jig Design 15
Unit – IV Principles of Fixture Design 15
Unit – V Gauges 14
Total 80
123
Rationale:-
In the present competitive environment, elimination of non-productive time in the
processes is essential to improve productivity. For improving the productivity in the
engineering industries various types of production tools Viz., Jigs, Fixtures, Gauges etc., are
employed wherever necessary /possible. Hence thorough knowledge on the principles,
construction and working principle of various Work holding devices and gauges is
absolutely essential.
OBJECTIVES
Identify the Difference between Jig & Fixtures
Study the plane of movements
Explain possible freedom of movement of job in a jig, fixtures
Study locating of work piece in a jig, fixture
To understand the construction of various types of Jigs and Fixtures
Explain mounting of jig on a machine tool
Explain mounting of fixtures on the machine tool
To understand the construction of various types of gauges
124
DETAILED SYLLABUS
4022510 JIGS, FIXTURES AND GUAGES
Contents: Theory
Unit
No.
BASICS OF WORKHOLDING DEVICES:
I Work holding Concepts – Basic Work holders, work holder purpose 2
and function, General Considerations
Jigs and Fixtures – Introduction – Definition – Difference between Jigs 2
and Fixtures – Advantages of Jigs and Fixtures.
Locating and supporting principles - Location types, Degrees of
freedom - 12 degrees of freedom. Location methods - 6 points location 5
principle (or) 3-2-1 principle of location, concentric and Radial methods –
Basic rules, position and number of locators, Redundant locators,
Locational Tolerances, Fool proofing.
Locator Types : External – Fixed locators, Integral locators,
Commercial pin, Assembled locators, Pins, V Type, locating nests.
Adjustable locators, Sight locators. Internal – Machined internal, 5
Relieved, Diamond pins, Floating locating pin, conical locators, self-
adjusting locators, spring locating pins. Spring stop buttons. Chip and
burr problems
CLAMPING AND TOOL GUIDING ELEMENTS:
II CLAMPING: Clamping principles – Tool forces, clamping forces,
positioning clamps. Rigid Vs Elastic work holders.
Types of Clamps – Strap clamp, screw clamp, cam action clamps,
Toggle action clamps, wedge action clamps, latch clamps, rack and
pinion clamps, specialty clamps. 8
Chucks – Operations, Nomenclature. Lathe chucks – Solid Arbors and
Mandrels. Split collet and bushing work holders, axial location, self-
actuating wedge cam and wedge roller work holders.
VISES – Special jaws, independent jaws.
Non-Mechanical Clamping – Magnetic chucks, vacuum chucking,
125
Electrostatic chuck.
Power Clamping – Hydraulic and Pneumatic clamping. Multiple part
clamping.
TOOL GUIDING ELEMENTS:
Drill jig bushings and liners – Selection, Bushing / liner installation,
interference fit, chip clearance, accuracy and life.
Types of bushes – Head less press fit bushes, Headed press fit
bushes, Slip renewable and Slip fixed renewable bushings / liners,
Headless press fit liners, Headed press fit liners, Oil groove bushings, 7
Gun drill bushings, Special bushings. Bushings and liners for polymers,
castable and soft material tooling. Template bushings, Rotary bushings.
Drill bushing tips and accessories. Drill bush material and manufacture.
PRINCIPLES OF JIG DESIGN
III Introduction – General considerations – Machine considerations – 5
Process considerations. Basic requirements of Drill jigs.
TYPES OF JIGS – Template drill jigs, Plate jigs, Universal jigs, Leaf jig,
Channel and Tumble box jigs, Indexing Jigs, Boring jigs, – Post jig – Pot 10
jig. Miscellaneous drill jigs – Wooden drill jigs, Polymer Drill Jigs,
modified vises, collet fixtures, self-centering vises. Jig design Example
– Plate Jig design example
PRINCIPLES OF FIXTURE DESIGN
IV Introduction: General Considerations, fixture cost, production 2
capabilities, Production process, part considerations.
Types of fixtures – Milling fixture, Lathe fixture, Grinding fixture,
Broaching fixture, Assemble fixture, Inspection fixture, Boring fixture, 3
Indexing fixture, welding fixture and sawing fixture.
Basic Design Characteristics that apply to – Milling fixture, Lathe
fixture, Grinding fixture, Boring fixture, Broaching fixture, welding fixture 3
and sawing fixtures.
Fixture Design - Standard fixture mounting, Relationship between
fixture and cutting tool, Tool positioning, Relationship to locators, Cutter- 7
setting devices, Step by step approach to fixture design. Fixture design
126
Example – Plain Milling fixture.
Fixture design for numerically controlled machine Tools
GAUGES
V Introduction – limit gauges –Taylor’s principle of limit gauging – 7
Application of limit gauges – Gauging principles – Allocation of Gauge
Tolerance – Bilateral system, Unilateral system, Gauge wear allowance,
Gauge materials, Gauging policy.
Types of Gauges – Commercial Gauges – Screw pitch gauges, plug
gauges, Ring gauges, Snap gauges, Flush pin gauges– IS specifications 7
for gauges – Design of plug and Snap gauges.
Text Books:-
1. Cyril Donaldson, Tool Design, Special Indian Edition, 2012, Tata Mc Graw Hill
2. P.C.Sharma ,A Text Book of Production Engineering, , 2013, S.Chand & Co
3. P.H.Joshi ,Jigs & Fixtures
4. G.K.Vijayaraghavan, Design of Jigs,Fixtures and Press Tools, Suchitra publications
References:-
1. Edward Hoffman ,Jig & Fixture design
2. Roop Lal ,Jig & Fixtures design
3. W boyes,Handbook of Jig & Fixture Design
4. Elanchezhian C ,Design of Jigs, Fixtures & Press tool
127

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4022520– PRESS TOOLS
128
N-SCHEME

Semester : V
Subject Title : PRESS TOOLS

Marks
Hours/ Hours/ Duration
Subject Internal Board Total
Week Semester
PRESS 5 80 25 100* 100 3 hrs.

TOOLS
UNIT TOPIC TIME
(Hrs)
I Press working fundamentals, operations, and machinery 15
Press & Press Tool Accessories And Types Of Die 15
II
Construction
III Bending And Forming Dies 14
IV Drawing Dies And Dies For Secondary Operations 14
V Advanced Press Tool Applications and Trouble shooting 15
Total 80
129
Rationale:
Modern development of sheet metal industries require more understanding of
production of sheet metal products and the machinery and tools involved in the production of
the sheet metal products. This subject Press Tools will develop the basic knowledge on the
essentials of the production of sheet metal products, the machinery and Tools involved in its
production.
OBJECTIVES
To understand the fundamentals of press working, to be familiar with the various
press working operations and machines.
To learn the safety in press working operations.
To be familiar with the various press and press tool accessories
To learn about the different types of Die construction.
To know the various bending, forming and other miscellaneous press working
operations.
To learn about the construction and operation of the different bending dies.
To be familiar with the various drawing and other related processes
To know the construction and operating principle of drawing and combination
dies.
To know the basic concepts and the advantages of fine blanking process
To learn the construction and working principle of various fine blanking dies.
To learn about the concepts of SMED and quick die changes and its
advantages in bringing down the press set up time.
To learn to trouble shoot in various press tools.
To be familiar with the specialised press tool applications.
130
DETAILED SYLLABUS
Contents: Theory
UNIT
NO
I PRESS WORKING FUNDAMENTALS, OPERATIONS, AND MACHINERY
Press working operations- Shearing, cutting off, parting, blanking,
4
Punching, piercing, slotting, perforating, Notching, semi notching, lancing,
parting, Trimming , slitting, shaving. Safety in press working.
Press working mechanism: Presses according to their functions –
energy producing press, force producing presses, stroke controlled
presses. Press according to their energy supply – Mechanical, hydraulic,
Pneumatic, electromagnetic presses. Presses according to their
construction – Solid or gap frame, open back inclinable, knee frame, 6
horning, open end or end wheel. Press according to their operation – Single
action, double action, triple action, multi slide press. Press actuating
mechanisms.
Parts of press, press operating parameters – Tonnage, shut height,
stroke, shut height adjustment, strokes per minute, die space. Clearance,
cutting terminology, stages of cutting, penetration, burr. Effects of
5
clearance variation – Secondary shear, large clearance, clearance
selection, cutting characteristic – Dish distortion, spacing distortion, typical
wear.
Forces for cutting sheet metal – Cutting with square faces, cutting with
shear, shear on punch, slug bending force, shear on die steel, stripping
force.
PRESS & PRESS TOOL ACCESSORIES AND TYPES OF DIE

II
CONSTRUCTION
Mechanical handling devices: Feeding and reeling mechanisms for
7
coiled sheet metal – Reels and cradles (de-coiler), roll feeds and its types,
hitch feeds. Feeding mechanism for individual parts – Hopper feeds, dial
feeds, chutes, slides, magazine feeds, step feeds, special feeds.
131
Ejection mechanism – Gravity, air, kicker, lifter, shovel, mechanical hand,
ejection by next part. Transfer mechanisms – Conveyors, shuttle, turnover,
turnaround, stacker, rails.
Types of die construction: - Cut off, drop through, return type, compound,
combination, continental, sub press, follow die, progressive die, transfer die,
shuttle die. Function and nomenclature of die components: - Die, die set,
8
die plate, punch, stripper plate, die spring, rubber keeper, stripper bolt, solid
stripper, knockout plate, hold down plate, pad plate, blank holder, pressure
pin. Types of stock stop. Attachment components – Dowel, screw, key.
Miscellaneous components – Heal, stop block, bolster plate, backing plate,
pilot, gauges, insert, cams, hinges and rockers. Commercially available die
components – Die sets, die set attachment devices, punches, die buttons,
retainers, springs, fluid springs, die cushion and its types.
BENDING AND FORMING DIES:-
III
Bending of sheet metal – Bending theory, neutral axis, metal movement,
spring back, methods of overcoming spring back. Bending Operations –
7
Bending, flanging, hemming, curling, seaming, and corrugating. Types of
Bending dies (construction and working principle) – V bending and its types,
edge bending, u bending. Bending operations done using press brake.
Forming operations – Embossing, bulging, crimping, tube forming.
Miscellaneous press working operations – slugging, restrike or spank,
extrude (holes), coining, hot trimming, cold trimming of die castings and
7
plastic mouldings, riveting, burnishing or sizing, Ironing.
Forming dies – Construction and working principle of solid form dies, pad
form dies, curling dies, embossing dies, coining dies, swaging dies, bulging
dies. Assembly dies - Riveting, tab stake, upset stake, crimping.
132
DRAWING DIES AND DIES FOR SECONDARY OPERATIONS
IV
Drawing operations – Shallow drawing, deep drawing. Analysis of cup
drawing: - Stages of drawing - Bending, straightening, friction, compression, 5
tension, stretch forming. Variables of drawing - Bending and straightening
variables, friction variables, compression variables, stretch forming
variables, analysis of draw speed.
Draw dies &its construction and working principle – Conventional draw
die, redrawing die, reverse re drawing die, drawing of square or rectangular
shapes. Drawing with flexible tooling – Marform process, Hydro form
6
process, Hydro dynamic process, Verson- wheel on process. Draw die
details – Blank holders, blank holding pressure and its importance, air
vents, drawing inserts, draw beads. Drawing defects, causes and
remedies.
Dies for secondary operations: - Construction and working principle of –
Semi piercing dies, shear form dies, dies for formed contours, notching die, 3
shaving die, side piercing die.
FINE BLANKING TOOL AND SPECIALISED PRESS TOOL
V
APPLICATIONS, PRESS TOOL MAINTANANCE.
Fine blanking basics: Definition and Applications of fine blanking, Working
principle of fine blanking tool, V Ring – function of V ring, Dimensions of V
5
ring. Comparison of fine blanking with blanking. Strip width and margin
calculations, Calculation of press, Fixing minimum distance from die
aperture. Factors affecting Tool life. Importance of punch and die radius.
Materials suitable for fine blanking, work hardening during fine blanking,
steel, copper and copper alloys, aluminum and aluminum alloys
Fine Blanking Machines: Working principle – Ram movement, Drive
systems-Mechanical drives, hydraulic drives, Machine force, Ring indenter 2
force, counter force.
Fine blanking tools: Different types of tools – Compound die tooling
system with sliding punch, compound die tooling with fixed punch.
2
Clearance calculation – Importance of clearance
133
Specialized Press Tool Applications: Construction, advantage and
2
applications of advanced multistage tooling, unit tooling, angular piercing
tools, CNC turret press. Principle or Quick Die Change (QDC) – need and
advantages. Single Minute Exchange of Dies (SMED) – concept need and
advantages.
Factors Affecting Tool Service Life: Introduction, Elements of Tool
2
performance, Procedure for investigation of tool failure, Trouble shooting in
press tools, effect of heat treatment on service life of tools.
Maintenance and Recondition of press tools – Blanking tool – 2
Progressive Tool – Compound tool – wear and reconditioning of press tools
components. Causes of tool and die failure, types of failures.
Text Books:
1. Donald F. Eary., Edward A. Reed, Techniques of Press working sheet metal,
Prentice-Hall,Inc., Second Edition
2. Donaldson, Tool Design, Tata McGraw-hill Book Company
3. D.Eugene ostergaard, Advanced die making, McGraw-Hill Book company
References:-
1. Dr.John G.Nee, Fundamentals of Tool Design, Society of Manufacturing
Engineers, Fourth Edition
2. ASTME National Book Committee, McGraw-hill Book Company
3. J.R.Paquin, Die design fundamentals, Industrial Press Inc
4. D.Eugene ostergaard, Basic die making, McGraw-hill Book Company
134

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020531 – COMPUTER INTEGRATED

MANUFACTURING
135
N - SCHEME
Course Name : 1220: DIPLOMA IN MECHANICAL ENGINEERING(TOOL & DIE)

Semester : V
Subject Title : COMPUTER INTEGRATED MANUFACTURING

Hours Marks
Subject Hours /
/ Internal Board Duration
Semester Total
Week Assessment Examinations
COMPUTER
INTEGRATED 5 80 25 100* 100 3 hrs.
MANUFACTURING

I Computer Aided Design 15
II Computer Aided Manufacturing 14
III CNC programming 16
IV FMS, AGV, AS/RS, Robotics 14
V Advanced concepts of CIM 14
Total 80
136
RATIONALE:
As per the latest requirements in the Industries this enables to learn the various concepts of
Computer Aided Design and Manufacturing. They are able to operate CNC machines and
write part program. They are able to understand the advanced concepts adopted in
automated industries.
OBJECTIVES:
Acquire knowledge in the field of Computer aided Design
Explain the various concepts of Computer Aided manufacturing
Write part program for manufacturing components in CNC machines
Explain the concepts of automatic material handling and storage systems and robotics
Explain the advanced concepts of CIM
DETAILED SYLLABUS
Contents: Theory
I Computer Aided Design
Computer Aided Design: Introduction – definition – Shigley’s design 6
process – CAD activities – benefits of CAD - CAD software packages –
point plotting, drawing of lines, Bresenham’s circle algorithm,
Transformations: 2D & 3D transformations – translation, scaling, rotation
and concatenation.
Geometric modelling: Techniques - Wire frame modelling – applications – 6
advantages and disadvantages. Surface modelling – types of surfaces –
applications – advantages and disadvantages – Solid modelling – entities –
advantages and disadvantages – Boolean operations - Boundary
representation – Constructive Solid Geometry – Comparison.
Graphics standard: Definition – Need - GKS –IGES – DXF. Finite Element 3
Analysis: Introduction – Development - Basic steps – Advantages.
II Computer Aided Manufacturing
CAM – Definition - functions of CAM – benefits of CAM. Introduction of CIM 3
137
– concept of CIM - evolution of CIM – CIM wheel – Benefits – integrated
CAD/CAM.
Group technology: Part families - Parts classification and coding - coding 6
structure – Opitz system, MICLASS system and CODE System. Process
Planning: Introduction – Computer Assisted Process Planning (CAPP) –
Types of CAPP - Variant type, Generative type – advantages of CAPP.
Production Planning and Control (PPC): Definition – objectives - Computer 5
Integrated Production management system – Master Production Schedule
(MPS) – Capacity Planning – Materials Requirement Planning (MRP) –
Manufacturing Resources Planning (MRP-II) – Shop Floor Control system
(SFC) - Just In Time manufacturing philosophy (JIT) - Introduction to
Enterprise Resources Planning (ERP).
III CNC Programming 16
NC in CAM, tooling for CNC – ISO designation for tooling – CNC operating
system. Programming for CNC machining –part program - Manual part
programming - coordinate system – Datum points: machine zero, work
zero, tool zero - reference points - NC dimensioning – G codes and M
codes – linear interpolation and circular interpolation - CNC program
procedure - sub-program – canned cycles - stock removal – thread cutting
– mirroring – drilling cycle – pocketing. Rapid prototyping: Classification –
subtractive – additive – advantages and applications – materials – Virtual
machining.
IV FMS, AGV, AS/RS, Robotics
FMS: Introduction – FMS components – FMS layouts – Types of FMS: 5
Flexible Manufacturing Cell (FMC) – Flexible Turning Cell (FTC) – Flexible
Transfer Line (FTL) – Flexible Machining System (FMS) – benefits of FMS
- introduction to intelligent manufacturing system.
Material handling in CIM environment: Types – AGV: Introduction – AGV - 3
working principle – types – benefits. AS/RS – working principle –types –
benefits.
Robotics: Definition – robot configurations – basic robot motion – robot 6
programming method – robotic sensors – end effectors – mechanical
138
grippers – vacuum grippers – robot programming concepts - Industrial
applications of Robot: Characteristics - material transfer and loading –
welding - spray coating - assembly and inspection.
V Advanced Concepts Of CIM 14
Concurrent Engineering: Definition – Sequential Vs Concurrent engineering
– need of CE – benefits of CE. Quality Function Deployment (QFD):
Definition – House of Quality (HOQ) – advantages – disadvantages. Steps
in Failure Modes and Effects Analysis (FMEA) – Value Engineering (VE) –
types of values – identification of poor value areas – techniques – benefits.
Guide lines of Design for Manufacture and Assembly (DFMA). Product
Development Cycle: Product Life Cycle - New product development
processes. Augmented Reality (AR) – Introduction - concept –
Applications.
REFERENCES BOOKS:
1. R.Radhakrishnan, and S.Subramanian, “CAD/CAM/CIM”, New Age International Pvt.
Ltd.
2. Mikell P.Groover, and Emory Zimmers, “CAD/CAM”, Jr.Prentice Hall of India Pvt., Ltd.
3. Dr.P.N.Rao, “CAD/CAM Principles and Applications,”, Tata Mc Graw Hill Publishing
Company Ltd.
4. Ibrahim Zeid, “Mastering CAD/CAM”, Tata McGraw-Hill Publishing Company Ltd., New
Delhi.
5. Mikell P. Groover, “Automation, Production Systems, and Computer-Integrated
Manufacturing”, Pearson Education Asia.
6. Yoram Koren, “Computer control of manufacturing systems,”, McGraw Hill Book.
7. Chris Mcmahon and Jimmie Browne, “CAD/CAM – Principle Practice and
Manufacturing Management”, Addision Wesley England, Second Edition,2000.
8. Dr.Sadhu Singh, “Computer Aided Design and Manufacturing,”, Khanna Publishers,
NewDelhi, Second Edition,2000.
9. S.Kant Vajpayee, “Principles of Computer Integrated Manufacturing,”, Prentice Hall of
India, 1999.
10. David Bed worth, “Computer Integrated Design and Manufacturing,”, TMH, 1998.
139

(TOOL& DIE)
II YEAR / III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020533 – MECHATRONICS
140
N - SCHEME
Course Name : 1220 DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

Semester : V
Subject Title : MECHATRONICS

Marks
Week Semester Total
MECHATRONICS 5 80 25 100* 100 3 hrs.

I Introduction, Sensors & Transducers 15
II Actuation systems 14
III Basic system models, Input / Output systems 14
IV Programmable Logic Controller 14
V Design examples & advanced applications In Mechatronics 16
Test And Revision 7
Total 80
141
RATIONALE:
As per the latest requirements in the automation industries this enables to learn the various
concepts of automation components. They are able to write program, and operate PLCs.
They are able to select the electronic components for various industry applications.
OBJECTIVES:
Explain the working of sensors and transducers
Acquire knowledge about actuation systems
Explain the system models and I/O systems
Write program and operate PLCs
Explain the applications of mechatronics
DETAILED SYLLABUS
4020533 MECHATRONICS
Contents: Theory
I Introduction, Sensors & Transducers 15
Introduction – Systems – Measurement Systems – Control Systems –
Microprocessor Based Controllers. Examples – Mechatronics
approach. Measurement System terminology – Displacement, Position
& Proximity Sensors – Velocity and Motion Sensors – Force Sensors –
Fluid Pressure Sensors – Flow Sensors – Liquid Level Sensors –
Temperature Sensors – Light Sensors – Selection of Sensors –
Calibration of sensors.
II Actuation Systems 14
Mechanical Actuation Systems – Types of motion – Freedom and
constraints – Loading – Gear Trains – Pawl & Ratchet – Belt & Chain
drive – Bearing – Selection – Ball & Roller bearings – Mechanical
aspects of motor selection.
Electrical Actuation Systems – Switches & Relays – Solenoids – D.C
Motors – A.C. Motors – Stepper Motors – Specification and control of
stepper motors – Servomotors: D.C Servomotor and A.C Servomotor.
142
Pneumatic & Hydraulic Systems – Power supplies – DCV – PCV –
Cylinders – Rotary actuators.
III Basic System Models, Input/Output Systems 14
Mathematical Model – Introduction to mathematical model –
Mechanical System building blocks – Electrical System building blocks
– Fluid System building blocks – Thermal System building blocks.
System Model – Engineering Systems – Rotational – Translational
Systems – Electro-Mechanical System – Hydro- Mechanical System.
Interfacing – Input/Output ports – Interface requirements: Buffers,
Handshaking, Polling and interrupts, Serial interfacing – Introduction to
PIA – Serial communications interface – Example of interfacing of a
seven-segment display with a decoder.
IV Programmable Logic Controller 14
Definition – Basic block diagram and structure of PLC – Input/Output
processing – PLC Programming: Ladder diagram, logic functions,
latching and sequencing – PLC mnemonics – Timers, internal relays
and counters – Shift registers – Master and jump controls – Data
handling – Analog input/output – Selection of PLC – sample ladder
programs.
V Design Examples & Advanced Applications In Mechatronics 16
Design process stages – Traditional Vs Mechatronics designs –
Possible design solutions: Timed switch, Wind- screen wiper motion,
Bath room scale – Case studies of mechatronics systems: A pick-and-
place robot, Car park barrier, Car engine management system,
Automatic Camera and Automatic Washing Machine. Sensors for
condition monitoring systems of production systems – Examples of
monitoring methods: Vibration monitoring, Temperature monitoring,
Wear behavior monitoring – Mechatronics control in automated
manufacturing: Monitoring of manufacturing processes, On-line quality
monitoring, Model-based systems, Hardware-in-the-loop simulation,
Supervisory control in manufacturing inspection, Integration of
heterogeneous systems.
143
REFERENCES BOOKS:
1. W.Bolton, “Mechatronics”, 2nd Edition 2001, Pearson Education, New Delhi.
2. R.K.Rajput, A Text Book of Mechatronics, 1st Edition 2007, S.Chand & Co. Ltd., New
Delhi.
3. HMT, “Mechatronics”, 1st Edition 1998, Tata McGraw Hill, New Delhi.
4. Devdas Shetty & Kolk, “Mechatronics System Design”, 1 st Reprint, 2001, PWS
Publishing Co., Boston.
5. James H.Harter, “Electromechanics”, 1st Edition 2003, Prentice-Hall of India, New
Delhi.
6. M.D.Singh & J.G.Joshi, “Mechatronics”, 1st Edition 2006, Prentice-Hall of India, New
Delhi.
144

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020440 – PROCESS PLANNING AND QUALITY

CONTROL
145
N-SCHEME
Course Name : 1020 Diploma in Mechanical Engineering

Semester : V
Subject Title : PROCESS PLANNING AND QUALITY CONTROL

Subject Instructions Examination
Marks
PROCESS Hours Hours /
PLANNING AND / Week Semester Total
QUALITY Assessment Examinations
CONTROL 5 80 25 100* 100 3 Hrs.

I Process Planning and Selection 15
II Basic concepts of Total Quality Management 14
III TQM Tools 14
IV Statistical Fundamentals & Charts 15
V Lean Manufacturing Concepts 15
Test And Model Examinations 07

Total 80
146
RATIONALE:
In the product manufacturing the process selection and planning are important. Quality and
customer satisfaction in every product and every activity is the order of the day. As there is a
shift from quality control to quality management in all activities, the concept Total Quality
Management and the pillars of TQM are to be given to Engineers, who are designing
products and production systems.
OBJECTIVES:
Understand the process planning.
Study the process selection.
Define quality and appreciate its signature.
Explain the concept of TQM.
Appreciate the use of principles of TQM to meet customer satisfaction.
Solve problem using the Quality control tools.
Apply Brainstorming and quality circle to solve problems.
Use PDCA cycle for continuous improvement.
Appreciate the benefits of implementing 5S concepts.
Collect, classify and present the data.
Determine the process capability of a manufacturing process.
Practice on management planning tools.
Use Bench Mark and JIT concepts.
147
DETAILED SYLLABUS
Contents: Theory
Unit Name of the Topic Hours
I Process Planning And Selection
Chapter: 1.1: 3
Production: Types of Production – Mass production, batch production
and job order production
Chapter: 1.2: 6
Process Planning: Introduction – concept – Information required to do
processplanning – factors affecting process planning – process
planningprocedure – Make (or) Buy decision using Break Even Analysis –
simple problems. Manual process planning – Introduction ofAutomated
process planning and generator process planning –Advantage of
computer aided process planning – Principle of linebalancing – need for
line balancing – Value Engineering –Definition – cost control Vs cost
reduction – value analysis when todo – steps information needed –
selection of product.
Chapter: 1.3: 6
Process Selection: Process selection – technological choice – specific
componentchoice – Process flow choice – Factors affecting process
selection– machine capacity – analysis of machine capacity – process
andequipment selection procedure – Determination of man, machineand
material requirements – simple problems – selection ofmaterial – jigs –
fixtures etc. – Factors influencing choice of machinery – selection of
machinery – simple problems –Preparation of operation planning sheet
for simple components.
II Chapter: 2.1: Basic Concepts Of Total Quality Management 14
Quality-Definitions – Dimensions of quality – Brainstorming and
itsobjectives – Introduction to TQM - Characteristics – Basic concepts –
Elements - Pillars – Principles – Obstacles to TQMimplementation -
Potential benefits of TQM - Quality council – duties – Responsibilities -
Quality statements – Vision – Mission – Quality policy statements –
148
Strategic planning – Seven steps tostrategic planning – Deming
philosophy – Customer – Input / Output process model – Juran Trilogy -
PDCA (Deming Wheel) cycle.
III TQM Tools 14
Chapter: 3.1:
Seven tools of quality control (Q 7 tools): Check sheet – Types of
check sheet – Histogram – Cause and effect diagram – Pareto diagram –
Stratification Analysis – Scatter diagram-Graph/run charts – Control
charts – Construction of above diagrams.Quality circle – concept of
quality circle – Organisation of Qualitycircle and objectives of Quality
circle. Zero Defect Concepts.
Chapter: 3.2:
Management Planning Tools ( M 7 Tools)
Affinity diagram – Radar Diagram – Inter Relationship diagram (Inter
Relationship diagram) – Tree diagram – Prioritization matrix – Matrix
diagram – Decision tree – Arrow diagram – Matrix data analysis diagram
– Construction of above diagrams.
IV Statistical Fundamentals And Control Charts
Chapter: 4.1: 7
Types of Data – Collection of Data – Classification of Data – Tabular
presentation of Data - Graphical representation of afrequency distribution
– Comparison of Frequency distribution – Mean - Median – Mode –
Comparison of measures of centraltendency - Introduction to measures
of dispersion – Sample – sampling – Normal curve – Sigma – Concept of
six sigma – Principles – Process- Problems.
Chapter: 4.2: 8
Control chart – Types of control charts – Control chart for variables –
Construction of X bar and R charts – control limits Vs specification limits –
Process capability – Method of doing process capability Analysis –
Measures of process capability – Problems.
Attributes – Control charts - P chart – np chart – c chart – u chart –
Construction of above diagrams – Problems – Comparison between
149
variable chart and Attribute chart.
V Capter 5.1: Lean Manufacturing Concepts 15
5S Concepts (SEIRI, SEITON, SEISO, SEIKETSU and SHITSUKE) –
needs and objectives – effective implementation of 5S concepts in an
organisation – Housekeeping – Kaizen – Kanban System.Bench marking
- Objectives of bench marking – Types – Benchmarking process –
Benefits of Bench marking – Pit falls of Benchmarking-Just In Time(JIT)
concepts and its objectives – TotalProductive Maintenance(TPM) –
Introduction, Objectives of TPM –steps in implementing TPM. – Overall
Equipment Effectiveness( OEE)–Lean Six Sigma – Value Stream
Mapping – DMAIC(Define, Measure, Analyse, Improve, Control) –
DMADV (Define , Measure, Analyse, Design, Verify)
Reference Books:
1. Industrial Engineering & Management – O.P Khanna
2. Industrial Engineering & Production Management – Martand Telsang
3. Total Quality Management, Date H.Besterfiled, Pearson Education Asia.
4. Total Quality Management, V.Jayakumar, Lakshmi Publications.(reprint 2005)
5. Training manual on ISO 9001 : 2000 & TQM, Girdhar J.Gyani, Raj PublishingHouse,
Second Edition 2001
6. Quality Management, Howard Cuitlow, Tata Mc Graw Hill, 1998
7. Production Engineering – P.C.Sharma.
8. Production and Costing – GBS Narang and V.Kumar
9. Mechanical Estimating and Costing – Banga & Sharma.
10. Total Quality Management, Oakiand.J.S. Butterworth Heinemann Ltd. Oxford1989.
11. Quality Management – Concepts and Tasks- Narayana.V and
12. Sreenivasan.N.S., New Age International 1996.
13. Total Quality Management for engineers, Zeiri. Wood Head Publishers. 1991.
14. Quality Planning and Analysis, Juran J.M and Frank M.Gryna Jr., TMH. India.1982
15. ISO 9001, Brain Rethry, Productivity and Quality Publications.
16. ISO 9001, Brain Rethry, Productivity and Quality Publishing Pvt. Ltd. 1993.
17. Quality Auditing D.Mills, Chapman and Hall, 1993.
150

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020561 – COMPUTER INTEGRATED

MANUFACTURING PRACTICAL
151
N – SCHEME

Semester : V
Subject Title : COMPUTER INTEGRATED MANUFACTURING PRACTICAL

Marks
Week Semester Total
COMPUTER
INTEGRATED
4 64 25 100* 100 3 hrs.
MANUFACTURING
PRACTICAL
RATIONALE:
Computer Integrated Manufacturing. They are able to write part program and able operate
CNC lathe and Milling machines. They are able to understand the advanced concepts
adopted in CIM.
OBJECTIVES:
Acquire knowledge in the field of Computer Integrated Manufacturing
Create 3D Solid models of machine components using modelling software
Execute and perform machining operations in CNC Lathe and CNC Milling machines.
152
DETAILED SYLLABUS
Contents: Practical
PART A: SOLID MODELLING
Introduction to Part modelling - Datum Plane – constraint – sketch – dimensioning – extrude
– revolve – sweep – blend – protrusion – extrusion – rib – shell – hole – round – chamfer –
copy – mirror – assembly – align – orient – drawing and detailing –creating assembly views
Exercise No. 1. Geneva Wheel
Exercise No. 2. Bearing Block
153
Exercise No. 3. Bushed bearing
Exercise No. 4. Gib and Cotter joint
154
Exercise No. 5. Screw Jack
Exercise No. 6. Universal Coupling
155
Note: Print the orthographic view and sectional view from the above assembled 3D drawing.
PART B: CNC Programming and Machining
Introduction: 1. Study of CNC lathe, milling. 2. Study of international standard codes: G-
Codes and M-Codes 3. Format – Dimensioning methods. 4. Program writing – Turning
simulator – Milling simulator, IS practice – commands menus. 5. Editing the program in the
CNC machines. 6. Execute the program in the CNC machines.
Exercises Note: Print the part program from the simulation software and make the component
in the CNC machine.
CNC Turning Machine Material: M.S / Aluminium / Acrylic fibre / Plastic
1. Using Linear and Circular interpolation - Create a part program and produce component in
the Machine.
2. Using Stock removal cycle – Create a part program for multiple turning operations and
produce component in the Machine.
156
3. Using canned cycle - Create a part program for thread cutting, grooving and produce
component in the Machine.
CNC Milling Machine Material: M.S / Aluminum / acrylic fibre / plastic
4. Using Linear interpolation and Circular interpolation – Create a part program for grooving
and produce component in the Machine.
157
5. Using canned cycle - Create a part program for drilling, tapping, counter sinking and
produce component in the Machine.
6. Using subprogram - Create a part program and produce component in the Machine.
158
BOARD EXAMINATION
Note:
All the exercises in both sections should be completed. Two exercises will be given for
examination by selecting one exercise from PART A and one exercise from PART B.
All the exercises should be given in the question paper and students are allowed to
select by a lot or question paper issued from the DOTE should be followed.
All regular students appearing for first attempt should submit record notebook for the
examination.
The external examiner should verify the availability of the facility for the batch strength
before commencement of practical examination.
The external examiner should verify the working condition of machinery’s / equipment
Note: Part A – The given component drawing should be created and solid modelling after
assembly should be printed and submitted along with the answer paper for evaluation by the
external examiner.
Part B – The program for the given component should be written in the answer paper. The
program should be entered in the CNC machine and the component should be submitted for
evaluation by the external examiner. The machined component should be kept under the
custody of examiner.
Allocation of marks for Board Examination
PART A: Solid Modelling
Creation of sketch : 15
Modelling : 25
Accuracy : 5
PART B: CNC Programming
Program writing : 15
Editing and Machining : 25
Finish : 5
Viva voce : 10
159
Total Marks : 100
LIST OF EQUIPMENTS (for a batch of 30 students)

1. Personal computer - 30 Nos.
2. 3D Solid Modelling and Simulation software - Sufficient to the strength
3. CNC Lathe –2 Nos.
4. CNC Mill –2 Nos.
5. Consumables - Sufficient quantity
6. Laser / Inkjet Printer – 1 No.
160

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020563 – MECHATRONICS PRACTICAL
161
N-SCHEME
(implemented from the Academic year 2020-2021 onwards)
Course Name : 1220: Diploma in Mechanical Engineering (TOOL & DIE)

Semester : V
Subject Title : MECHATRONICS PRACTICAL

Marks
Subject Hours/ Hours/
Week Semester Total
MECHATRONICS
4 64 25 100* 100 3 Hrs.
PRACTICAL
*Examinations will be conducted for 100 marks and it will be reduced for 75 marks for result
RATIONALE:
industrial automation. They are able to write ladder logic program and able operate PLCs.
They are able to understand the advanced concepts adopted in industrial automation.
OBJECTIVES:
Acquire knowledge in the field of mechatronics
Explain the various components of electro pneumatics and electro hydraulics
Handle PLC, HMI, SCADA and DCS components
162
DETAILED SYLLABUS
ELECTRO PNEUMATICS: Introduction to Electro Pneumatics -Applications of pneumatics -

Pneumatic and electro pneumatic controllers - Components and assemblies in the electrical
signal control section: Power supply unit - Push button and control switches - Sensors for
measuring displacement and pressure - Relays and contactors. Electrically actuated
directional control valves - Construction and mode of operation - Functions - Electrical
connection of solenoid coils. Procedure for developing a control system.
ELECTRO HYDRAULICS: Basic principles of electro hydraulics - Function and use of
electrohydraulic components - Production and interpretation of standard hydraulic and
electrical circuit diagrams
PROCESS CONTROL INSTRUMENTATION: Process control - Types of processes –
Structure of control system – Controllers - Digital controllers – Types of process control –
ON/OFF Control – Analog control – Digital control. Data Acquisition System - Objectives of
DAS - Types of DAS: Single channel DAS – Multichannel DAS – Computer based DAS. Data
Loggers - Block diagram of Data Loggers – Control facilities in Data Logger – Uses of Data
Logger - Different stages of Direct Digital Control.
SCADA - Fundamental principles of modern SCADA systems - SCADA hardware - SCADA
software - Landlines for SCADA - SCADA and local area networks - Modem used in SCADA
systems - Remote terminal units. Human Machine Interface – components of HMI.
Distributed Control System - Parts of DCS – Layered structure of DCS – Communication
options in DCS.Variable Frequency Drives - Construction, Working, Operation, Applications
and Specifications
Experiments
PART A
(ELECTRO PNEUMATICS)
1. Direct control of a 3/2 NC Single solenoid valve and a 3/2 NO Single solenoid valve
2. Direct control of a 5/2 single solenoid valve and a 5/2 double solenoid valve
3. Simple circuit using OR Logic and AND Logic
4. Limit switch and proximity switch application circuits
(ELECTRO HYDRAULICS)
1. Sorting device using double acting cylinder, directly actuated, manually
163
2. Component selection on conveyor belt using double acting cylinder and directly
actuated, manually
3. Lifting station using single acting cylinder and directly actuated, manually
4. Door control using double acting cylinder and interlocking
PART B
PROCESS CONTROL INSTRUMENTATION
1. Wiring practice of HMI
2. Design of HMI screen
3. HMI Configuration and Interfacing with PLC and PC
4. Configuring Alarms in SCADA
5. Real time project development and interfacing with PLC
6. Monitoring & Control of Pneumatic System using HMI
BOARD EXAMINATION
Note:
1. All the experiments in both sections should be completed. Two experiments will be
given for examination by selecting one from PART A and one from PART B.
2. All the experiments should be given in the question paper and students are allowed to
select by a lot or Question paper issued from the DOTE should be followed.
3. All regular students appearing for first attempt should submit record notebook for the
examination.
4. The external examiner should verify the availability of the facility for the batch strength
5. The external examiner should verify the working condition of machinery’s / equipment
ALLOCATIONOFMARKS
PART A: Electro Pneumatic circuit/Electro Hydraulic circuit (bylot):
Circuit diagram : 15
Components connections & execution : 20
Output : 10
PARTB: Process Control Instrumentation
Circuit diagram : 15
164
Execution &Programming : 20
Output : 10
Vivavoce : 10
Total Marks : 100
List of Equipment (for the batch of 30 students)

Electro Pneumatics:
1. Basic Pneumatic Trainer Kit with FRL Unit, Compressor and Accessories – 2 Nos
3/2 NC Single Solenoid Valve - 2Nos
3/2 NO Single Solenoid Valve - 2Nos
5/2 Single Solenoid Valve - 2Nos
5/2 Double Solenoid Valve - 2Nos
Limit Switch – 6 Nos
Proximity Sensor (Inductive, Capacitive & Optical) – Each 2 Nos
Single Acting Pneumatic Cylinder – 4 Nos
Double Acting Pneumatic Cylinder – 2 Nos
Power Supply Unit, Connecting Leads and Hoses – As per Requirements
Electro Hydraulics:
1. Basic Hydraulics Trainer Kit with Hydraulic Pump, Regulator and Hoses Accessories – 2
Nos
Double Acting Cylinder – 2 Nos
Single Acting Cylinder – 2 No
Manual Actuator Switch – 4 Nos
Material Sorting assembly set up – 1 No
Conveyor Assembly set up – 1 No
Lifting Station Assembly Set up – 1 No
Limit Switch - 4 Nos
Process Control Instrumentation:
Programmable Logic Controller (PLC) with Software – 3 Nos
Human Machine Interface (HMI) with Software - 3 Nos
SCADA Software – 1 No or Integrated Software for PLC, HMI and SCADA)
Personnel Computer – 3 Nos
Water Tank Assembly set up with Level Sensor and Flow Controller (Actuator) to
interface with PLC and HMI – 1 No
165

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020540 – PROCESS AUTOMATION PRACTICAL
166
N – SCHEME

Semester : V
Subject Title : PROCESS AUTOMATION PRACTICAL

Marks
Week Semester Total
STRENGTH OF
4 64 25 100* 100 3 hrs.
MATERIALS
OBJECTIVES:
Design and operate pneumatic circuits.
Design and operate fluid power circuits
Use PLC system and its elements for process control
Familiarize the working of function blocks in PLC
Use ON-Delay timer to control a motor
Use OFF-Delay timer to control a motor
Use counter function block (Up counter and Down counter)
Control the automatic operation of pneumatic cylinder using PLC
Record of work to be prepared.
167
Exercises
PART A
Pneumatics Lab.
1. Direct operation of single and double acting cylinder.
2. Operation of double acting cylinder with quick exhaust valve.
3. Speed control of double acting cylinder using metering-in and metering-out circuits.
4. Automatic operation of double acting cylinder in single cycle - using limit switch.
Hydraulics Lab.
5. Direct operation of double acting cylinder.
6. Direct operation of hydraulic motor.
7. Speed control of double acting cylinder metering-in and metering-out control.
PART B
PLC Lab.
1. Direct operation of a motor using latching circuit.
2. Operation of a motor using ‘AND’ logic control.
3. Operation of a motor using ‘OR’ ‘control.
4. On-Delay control of a motor and Off –Delay control of a motor.
5. Automatic operation of a Double acting cylinder-single cycle - forward, time delay,
return.
6. Automatic operation of Double acting cylinder-Multi cycle.
7. Sequential operation of double acting cylinder and a motor.
168
BOARD EXAMINATION
Note:
All the experiments in both sections should be completed. Two experiments will be
given for examination by selecting one exercise from PART A and one exercise from
PART B.
All the experiments should be given in the question paper and students are allowed to
examination.
Detailled Allocation of Marks
Part A: 45
Procedure / Circuit diagram 10
Identification of Components 15
Connection and execution 20
Part B: 45
Procedure / Circuit diagram 10
Ladder diagram / Programming 25
Execution 10
Viva Voce 10
Total 100
LIST OF EQUIPMENTS (for a batch of 30 students)
1. Pneumatic Trainer Kit – 3Nos
(All Cylinders, Control Valves, Limit switches and other accessories)
2. Hydraulics Trainer Kit – 2No.
(All Cylinders, Control Valves, Limit switches and other accessories)
3. PLC kit – 3 Nos.
4. Computer with software – 10 Nos.
169

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4022550 – JIGS AND FIXTURES PRACTICAL
170
N-SCHEME

Semester : V
Subject Title : JIGS AND FIXTURES PRACTICAL

Marks
Week Semester Total
JIGS AND
FIXTURES 5 80 25 100* 100 16 hrs.
PRACTICAL
OBJECTIVES:
Manufacture of template type drill jig
Manufacture of Channel drill jig and indexing drill jig
Manufacture of milling fixture
Manufacture of inspection fixture
Manufacture of welding fixture
Use different machine tool in Manufacture of jigs and fixtures.
A. Manufacture of following Jigs
1. Template drill jig
2. Channel drill jig
3. Indexing drill jig
171
B. Manufacture of following Fixtures
4. Milling Fixture
5. Inspection Fixture
6. Welding Fixture
DETAILED SYLLABUS
Ex. Name of the exercise Time in Hours

No.
14
1. Manufacture of Template drill jig
13
2. Manufacture of Channel drill jig
13
3. Manufacture of Indexing drill jig
4. Manufacture of Milling Fixture 14
5. Manufacture of Inspection Fixture 13
6. Manufacture of Welding Fixture 13
80
TOTAL
Note: -
1. Batch size should not be more than 5 students for class work.
2. For examination, exercise should be given to students individually and not in batches.
3. The examination duration is 16 hours.
4. Students should be trained in setting the Jig/Fixture on the machine tool, to make
necessary adjustments, trial production using the tool fabricated by them and
rectification of tool defects if any.
5. For Board examination any one of the above tool (sl no 1 to 6) is to be manufactured,
fitted in the machine tool and trial production should be taken. The evaluation of the
performance should be based on the component dimensions and finish obtained from
the Jig / Fixture manufactured by the student during the 16 hours examination.
172
Manufacture of Jig / Fixture - 50marks
Tool finish - 20 marks
Component finish / accuracy - 10 marks
Tool setting & trial production - 10 Marks
Viva Voce - 10 Marks
Total - 100 Marks

NAME OF THE BRANCH / COURSE MECHANICAL ENGINEERING
(TOOL & DIE)
YEAR THIRD
SEMESTER V
NAME OF THE LABORATORY 4022550 JIGS AND FIXTURES PRACTICAL
LIST OF THE EQUIPMENTS WITH SPECIFICATIONS
S.N REMARKS, IF QUANTITY
ANY REQUIRED
1 Centre Lathe, 4 ½' bed length 5
2 Drilling machine 2
3 Shaping machine, stroke length 300mm 2
4 Vertical milling machine 2
5 Surface grinding machine 2
6 Bench vice 10
7 Fitting file set 10
8 Tap set 4
9 Surface plate 2
12 Angle plate 2
13. Tool maker’s straight edge – 150 mm 1
14. Digital Micrometer – 0.-25mm range, 0.001mm least count 3
Exercise – I Template Jig

Pl refer the sketches available in subject code:4022340 – Computer Aided Machine &
Tool Drawing Exercise no.7
173
Exercise – II Channel Jig
174
175
176
177
178
Exercise – III Indexing Jig
179
180
181
182
183
184
185
186
Exercise – IV Milling Fixture
187
188
189
Exercise – V Inspection Fixture
190
191
192
Exercise – VI Welding Fixture
Pl refer the sketches available in subject code:4022340 – Computer Aided Machine &
193

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4022560 – PRESS TOOLS

2021 – 2022 PRACTICAL
onwards
194
STATE BOARD OF TECHNICAL EDUCATION & TRAINING, TAMIL NADU
N-SCHEME

Semester : V
Subject Title : PRESS TOOLS PRACTICAL

Marks
Week Semester Total
PRESS
TOOLS 5 80 25 100* 100 16 hrs.
PRACTICAL
OBJECTIVES:
At the end of the practice, the students will be able to
Manufacture press tool components as per the given drawing.
Assemble the components manufactured.
Set the tools manufactured in the OBI / gap frame / Fly press as per requirement.
Adjust the shut height; operate the press to take trial production.
Compare the result with the requirement and to do the necessary corrections if
needed.
195
DETAILED SYLLABUS
Ex. No. Name of the exercise Time in Hours
16
1 Manufacture of Blanking Tool – Drop through type
16
2 Manufacture of Progressive Tool – Drop through type
16
3 Manufacture or Compound Tool
4 Manufacture of V Bending tool 16
5 Manufacture of drawing tool ( single stage) 16
80
TOTAL
Note:-
1. Batch size should not be more than 5 students for Practical classes.
4. Students should be trained in Press Setting, Tool setting, shut height
Adjustment, trial production using the tool fabricated by them and rectification of tool
defects if any.
5. For Board examination any one of the above tool ( sl no 1 to 4) is to be fabricated by
each student, fitted in the press and trial production should be taken. The evaluation of
the performance should be based on the component dimensions and finish obtained
from the tool fabricated by the student during the 16 hours examination.
6. For all the four exercises, the sketches are given and should be followed.
Manufacture of Tool - 50 marks
Tool finish - 20 marks
Component finish / accuracy - 10 marks
Tool setting & trial production - 10 Marks
. Viva Voce - 10 Marks
Total - 100 Marks
196
(TOOL & DIE)
YEAR THIRD
SEMESTER V
NAME OF THE LABORATORY 4022560 PRESS TOOLS PRACTICAL
LIST OF THE EQUIPMENT’S WITH SPECIFICATIONS QUANTITY
S.NO REMARKS IF ANY REQUIRED
6 Bench vice 10
8 Tap set 4
9 Surface plate 2
12 Angle plate 2
13 Mechanical power press (15tons- 100 tons) 1
14 Tool maker’s straight edge – 150 mm 1
15 Digital Micrometer – 0.-25mm range, 0.001mm least count 3
197
Exercise-I Blanking Tool – Drop through type
Pl refer the sketches available in the subject 4022340 Computer Aided Machine &
Exercise-II Piercing Tool
198
199
200
201
Exercise – III Progressive Tool
202
203
204
205
206
207
208
209
210
211
Exercise – IV Compound Tool
212
213
214
215
216
217
218
219
220
221
222
223
(TOOL & DIE)
YEAR THIRD
SEMESTER V
NAME OF THE LABORATORY 4022560 PRESS TOOLS PRACTICAL
ANY REQUIRED
6 Bench vice 10
8 Tap set 4
9 Surface plate 2
12 Angle plate 2
13 Mechanical power press (15tons- 100 tons) 1
224

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4020570–ENTREPRENEURSHIP AND START UP
225
N-SCHEME
(Implemented from the Academic year 2020-2021 onwards)
Course Name : 1220: Diploma in Mechanical Engineering (TOOL & DIE)

Semester : V
Subject Title : ENTREPRENEURSHIP & STARTUP

Subject Marks
Hours/ Hours/
Week Semester Total
ENTREPRENEURSHIP
& STARTUP 4 64 25 100* 100 3 Hrs.
*Examinations will be conducted for 100 marks and it will be reduced for 75 marks for result

UNIT Topic Hours
1 Entrepreneurship – Introduction and Process 10
2 Business Idea and Banking 10
3 Start ups, E-cell and Success Stories 10
4 Pricing and Cost Analysis 10
5 Business Plan Preparation 10
Revision, Field visit and Preparation of case study report 14
Total 64
226
RATIONALE:
Development of a diploma curriculum is a dynamic process responsive to the society

and reflecting the needs and aspiration of its learners. Fast changing society deserves
changes in educational curriculum particularly to establish relevance to emerging socio-
economic environments; to ensure equity of opportunity and participation and finally
promoting concern for excellence. In this context the course on entrepreneurship and start
ups aims at instilling and stimulating human urge for excellence by realizing individual
potential for generating and putting to use the inputs, relevant to social prosperity and thereby
ensure good means of living for every individual, provides jobs and develop Indian economy.
OBJECTIVES:
At the end of the study of 5th semester the students will be able to
o To excite the students about entrepreneurship
o Acquiring Entrepreneurial spirit and resourcefulness
o Understanding the concept and process of entrepreneurship
o Acquiring entrepreneurial quality, competency and motivation
o Learning the process and skills of creation and management of entrepreneurial
venture
o Familiarization with various uses of human resource for earning dignified means
of living
o Know its contribution in and role in the growth and development of individual
and the nation
o Understand the formation of E-cell
o Survey and analyze the market to understand customer needs
o Understand the importance of generation of ideas and product selection
o Learn the preparation of project feasibility report
o Understand the importance of sales and turnover
o Familiarization of various financial and non financial schemes
o Aware the concept of incubation and starts ups
227
DETAILED SYLLABUS
1 ENTREPRENEURSHIP – INTRODUCTION AND PROCESS 10
Concept, Functions and Importance

Myths about Entrepreneurship
Pros and Cons of Entrepreneurship
Process of Entrepreneurship
Benefits of Entrepreneur
Competencies and Characteristics
Ethical Entrepreneurship
Entrepreneurial Values and Attitudes
Motivation
Creativity
Innovation
Entrepreneurs - as problem solvers
Mindset of an employee and an entrepreneur
Business Failure – causes and remedies
Role of Networking in entrepreneurship
2 BUSINESS IDEA AND BANKING 10
Types of Business: Manufacturing, Trading and Services

Stakeholders: Sellers, Vendors and Consumers
E- Commerce Business Models
Types of Resources - Human, Capital and Entrepreneurial
tools
Goals of Business and Goal Setting
Patent, copyright and Intellectual Property Rights
Negotiations - Importance and methods
Customer Relations and Vendor Management
Size and Capital based classification of business enterprises
Role of Financial Institutions
228
Role of Government policy
Entrepreneurial support systems
Incentive schemes for State Government
Incentive schemes for Central Government
3 STARTUPS, E-CELL AND SUCCESS STORIES 10
Concept of Incubation centre’s

Activities of DIC, financial institutions and other relevance
institutions
Success stories of Indian and global business legends
Field Visit to MSME’s
Various sources of Information
Learn to earn
Startup and its stages
Role of Technology – E-commerce and Social Media
Role of E-Cell
E-Cell to Entrepreneurship
4 PRICING AND COST ANALYSIS 10
Calculation of Unit of Sale, Unit Price and Unit Cost

Types of Costs - Variable and Fixed, Operational Costs
Break Even Analysis
Understand the meaning and concept of the term Cash
Inflow and Cash Outflow
Prepare a Cash Flow Projection
Pricing and Factors affecting pricing
Understand the importance and preparation of Income
Statement
Launch Strategies after pricing and proof of concept
Branding - Business name, logo, tag line
Promotion strategy
229
5 BUSINESS PLAN PREPARATION 10
Generation of Ideas,
Business Ideas vs. Business Opportunities
Selecting the Right Opportunity
Product selection
New product development and analysis
Feasibility Study Report – Technical analysis, financial
analysis and commercial analysis
Market Research - Concept, Importance and Process
Marketing and Sales strategy
Digital marketing
Social Entrepreneurship
Risk Taking-Concept
Types of business risks
REFERNCE BOOKS:
1. Dr. G.K. Varshney, Fundamentals of Entrepreneurship, Sahitya Bhawan Publications,

Agra - 282002
2. Dr. G.K. Varshney, Business Regulatory Framework , Sahitya Bhawan Publications,
Agra - 282002
3. Robert D. Hisrich, Michael P. Peters, Dean A. Shepherd, Entrepreneurship , McGraw
Hill (India) Private Limited, Noida - 201301
4. M.Scarborough, R.Cornwell, Essentials of Entrepreneurship and small business
management, Pearson Education India, Noida - 201301
5. Charantimath Poornima M. Entrepreneurship Development and Small Business
Enterprises, Pearson Education, Noida - 201301
6. Trott, Innovation Management and New Product Development, Pearson Education,
Noida - 201301
7. M N Arora, A Textbook of Cost and Management Accounting, Vikas Publishing House
Pvt. Ltd., New Delhi-110044
8. Prasanna Chandra, Financial Management, Tata McGraw Hill education private
230
limited, New Delhi
9. I. V. Trivedi, Renu Jatana, Indian Banking System, RBSA Publishers, Rajasthan
10. Simon Daniel, HOW TO START A BUSINESS IN INDIA, BUUKS, Chennai - 600018
11. Ramani Sarada, The Business Plan Write-Up Simplified - A practitioners guide to
writing the Business Plan, Notion Press Media Pvt. Ltd., Chennai 600095.
Board Examination – Evaluation Pattern

Internal Mark Allocation
Assignment (Theory portion)* - 10

Seminar Presentation - 10
Attendance - 5
Total - 25
Note: * Two assignments should be submitted. The same must be evaluated and
converted to 10 marks.
Guidelines for assignment:

First assignment – Unit I
Second assignment – Unit II
Guidelines for Seminar Presentation - Unit III
Each assignment should have five three marks questions and two five marks questions.
BOARD EXAMINATION
Note
1. The students should be taught all units and proper exposure and field visit also
arranged. All the portions should be completed before examinations.
2. The students should maintain theory assignment and seminar presentation.
The assignment and seminar presentation should be submitted during the
Board Practical Examinations.
3. The question paper consists of theory and practical portions. All students
231
should write the answers for theory questions (45 Marks) and practical
portions (55 Marks) should be completed for board examinations.
4. All exercises should be given in the question paper and students are allowed
to select by lot. If required the dimensions of the exercises may be varied for
every batch. No fixed time allotted for each portion and students have liberty to
do the examination for 3Hrs.
5. For Written Examination: theory question and answer: 45 Marks
Ten questions will be asked for 3 marks each. Five questions from each unit 1
& 2. (10 X 3 = 30).
Three questions will be asked for 5 marks each. One question from each unit
1, 2 & 3. (3 X 5 = 15)
6. For Practical Examination: The business plan/Feasibility report or Report on
Unit 4 & 5 should be submitted during the board practical examinations. The
same have to be evaluated for the report submission (40 marks).
Sl. Description Marks

No
Part A Written Examination - Theory Question and answer 45
10 questions x 3 marks = 30 marks
3 questions x 5 marks = 15 marks
Part B Practical Examination – Submission on Business 40

Plan/Feasibility Report or Report on Unit 4 & 5
Part C Viva voce 15
Total 100
232

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4022610 – TOOL DESIGN AND DRAWING
233
N-SCHEME

Semester : VI
Subject Title : TOOL DESIGN AND DRAWING

Marks
Total
TOOL DESIGN
AND 5 80 25 100* 100 3 hrs.
DRAWING
TOPIC TIME
(Hrs)
I. Design of Press Tools 40
II. Design of Jigs and Fixtures 20
III. Design of Gauges 13
TOTAL 80
234
DETAILED SYLLABUS
Contents: Theory

I. DESIGN OF PRESS TOOLS:
Fourteen steps to design a Die – strip layout types of strip layout – wider win,
narrow and other layout – calculating of percentage utilization and percentage
stop – method of increasing strip utilization – calculation of cutting force, 40
calculation press capacity – Design of die plate strip; die and punch clearance
land, angular clearance – design blanking punches – design piercing punches
– method of reducing cutting force in progressive dies – Design punch plate,
design plots, Design a stop – finger stop, Automatic stops – Design of
strippers, Selection of fasteners and moulds - Selection of die sets drawing –
Assembly the pillar draw of dies, Adding plunger of die moulds
II. DESIGN OF JIGS AND FIXTURES:
Design of Plate jig (turn over type) - Indexing jig - Milling fixture - Grinding 20
fixture.
III. GAUGE DESIGN
1. Design of Plain plug gauge as per IS 3455, IS 6137, IS 6244, IS 6246 and
IS 7018 : Part 2 13
2. Design of snap gauge as per IS 3477
3. Design of plain ring gauges as per IS 3485
Total 80
235
Design of Blanking Tool:
Design of piercing Tool
Design of Progressive Tool
236
Design of Compound Tool
Channel Drill Jig
Inspection Fixture
237
Template Drill Jig
Milling Fixture
238
Indexing Drill Jig
Welding Fixture
References:-
1. J.R.Paquin, Die design fundamentals, Industrial Press Inc, 1990.
2. Donaldson, Tool Design , Tata McGraw-hill Book company, 23rd edition, 2006
3. Donald F. Eary., Edward A. Reed, Techniques of Press working sheet metal,
Prentice-Hall,Inc.,Second Edition, 1974.
4. Indian Standard Specifications IS 3455, IS 6137, IS 6244, IS 6246 ,IS 7018 : Part 2,
IS 3477 and IS 3485.
INSTRUCTIONS FOR QUESTION PAPER SETTING:
1. Part A is Tool Design and drawing Question for 50 marks. Either or Type question is
to be asked. One question from UNIT I and one question from Unit II. The
question asked should be such that it could be answered in 135 minutes time. Please
avoid components of very complicated profiles which consumes more time.
2. Part B is gauge design and drawing question from UNIT III for 25 marks . Please
ensure that the tolerance grade for gauge design dimensions are given in question
paper which is an essential data for gauge design using standards.
3. For mark and time allocation please refer the model question paper enclosed herewith
239

(TOOL& DIE)
III YEAR
N – SCHEME
V SEMESTER
2020 – 2021 onwards
4022620 PLASTIC MOLDING TECHNOLOGY
240
N-SCHEME

Semester : VI
Subject Title : PLASTIC MOULDING TECHNOLOGY

Marks
Subject Hours/ Hours/ Internal Board Duration
Week Semester Assessment Total
Examination
PLASTIC
MOULDING 5 80 25 100* 100 3 hrs.
TECHNOLOGY

I Plastic Materials and Processing techniques 14
II Injection Moulding Machine, Injection Mould and its functional 15

system
III Injection Mould Design 15
IV Compression, Blow and Transfer moulding machine and Mould 14
Design
V Plastic Product Design , Decoration of Plastic Products & 15
Maintenance and repairs of injection moulds
Total 80
241
RATIONALE: -
Plastic plays an important role in the present day industrial products and for the manufacture of
plastic components lot of moulds are used. Hence Considering the immense potential in the
fields of Plastic processing, mould design, making and maintenance, it is essential to
understand the basics of plastic materials, processing and moulding technology adopted to
convert the raw plastic material into desired products.
OBJECTIVES
Familiarise different plastics materials and their properties
Familiarise of the conventional injection-moulding machine types, their specification,
Operation terminology and their parts.
Compare different moulding processes used in industries, their application
Explain the design procedure for injection moulding.
Explain the design procedure for compression moulding
Explain the concepts in the design of blow moulds.
Appreciate the decoration techniques, plating techniques used for plastic components.
Explain the working of injection moulding machine
Understand the intermediate injection moulding design concepts
242
DETAILED SYLLABUS
4022620 - PLASTIC MOULDING TECHNOLOGY
Contents: Theory
No.
Plastic Materials and Processing techniques
1.0 Plastics: Introduction – type of Plastics - Thermo Plastic Materials –
Thermo setting Materials – Commodity Plastics – Engineering materials –
Density - Melting Temperature – Shrinkage – Bulk Factor – Moulding 7
Properties – Applications – Additives - Master Batches – Pigments.
Injection Moulding: Hot Runner Injection Moulding Process, Multi colour
and multi component Injection Moulding Process, Reaction Injection
I
Moulding Process.
1.2 Blow Moulding: concept and working principle only 2
1.3 Compression & Transfer Moulding – Compression Moulding
Procedure- Difference between Injection and Compression moulding.- 3
Transfer Moulding -Advantages and Disadvantages.
1.4 Other processes: Rotational Moulding, Thermoforming, Extrusion- Pipe 2
extrusion, Blown film, Cast film extrusion, Rod Extrusion– Co extrusion,
Injection Moulding machine, injection mould and its functional
systems
2.1 Injection Moulding Machines: Basic parts and functioning of an
injection moulding machine. Types of injection moulding machine (Screw
type & Plunger Type) – Single stage and two stage – Clamping unit 3
(Toggle & Hydraulic) - Types of nozzles – Typical injection. Moulding cycle,
II Cycle time - Machine specifications (Definition only).
2.2 Injection Mould: - Terms used in connection with injection moulds,
classification of moulds, Functions of the injection moulds. 3
2.3 Functional systems of injection mould – Sprue and runner system -
Runner, Cross section shape, Runner size, Runner layout – Gates,
Necessity, Centre gate, Edge gate, Balanced gating, Types of Gates. 3
Core and Cavity- Shrinkage calculation - Core and cavity dimension.
243
Parting surface: Flat Parting surface – Non flat parting surface - Venting –
Mould clamping - direct, indirect.
2.4 Cooling System – Cooling Integer type cavity plates – Cooling
integer type core plate - Cooling bolster – Cooling cavity inserts – Cooling 3
core inserts – Water connection and seals. (Concept & Description of
design only)
2.5 Ejection system: Ejector grid - Ejector plates assembly – Ejector rod,
Ejector plate and ejector retaining plate - Methods of Ejection – Ejection 3
from fixed half- Sprue puller.
Injection Mould Design & Intermediate Moulds
3.1 –Basic procedure for mould design – Determination of mould size –
Maximum number of cavities, Clamping force , Maximum clamping area,
Required opening stroke. Computation of number of cavities, cavity layouts, 4
number of parting lines, Design of runner and gate.
3.2 Intermediate Moulds: Moulding external undercuts-Split mould - Finger
cam, dog leg cam & track. Hydraulic & spring actuation of split - Side
core and side cavity, Methods of actuation - Mould with internal undercut
: Form pin, actuation, split core, jumping off - Mould for threaded 6
III component: Manual & automatic unscrewing methods hand mould for
rotating & lose core methods - Multi day light mould – Under feed mould –
Triple day light mould – Hot runner unit mould, Advantages and Limitations,
Hot runner nozzles & sprue, runner less mould - Materials for Injection
Mould – Standard Mould systems, Advantages and limitations (Concept
& Description of design only).
3.3 Alignment of Moulds: Functions of alignment, alignment with the axis
of the plasticizing unit, internal alignment and interlocking, alignment of large 5
moulds. Changing of moulds – system for a quick change of moulds for
thermoplastics, mould exchanger for elastomer moulds.
244
Compression, Blow and Transfer Moulding machines and Mould
Design
4.1 Compression & Transfer Moulding Machines: - Type of compression 4
Moulding Machine – Toggle type mechanical machine – Hydraulically
operated Machine – Auxiliary Ram type machines (Vertical Transfer
Machine) – Bottom Transfer Machine – Machine Parts – Machine
Specifications- Pot and plunger Transfer machines
4.2 Compression mould Design: Economic determination of no. of 4
cavities, flash thickness allowances, design of mould cavity, design of
loading chamber, bulk factor, loading chamber depth & heat requirement for
IV
heating the mould related to - curing time, breathing time. Materials for 3
Compression mould.
4.3 Blow moulding Machines - Extrusion Blow Moulding Machine (EBM) –
Stretch Blow Moulding Machine (SBM) – Injection Blow Moulding Machine 3
(IBM) – Machine Parts – Machine Specifications.
4.4 Blow Mould Design: Mould layout, pinch off, venting, Head die design,
parison diameter calculation, shrinkage calculation, design of mould
clamping accessories.
Plastic Product Design, Decoration of Plastic Products and
Maintenance & Repair of Injection Moulds:
5.1 Plastic Product Design: Wall thickness - Ribs and profiled structures –
Gussets or support ribs - Bosses - Holes - Radii & Corners - Tolerances - 4
Coring - Undercuts – Draft angle.
5.2 Decoration of Plastic Parts: Painting and coating (Dipping, Spraying
and Depositing) – Metalizing (Vacuum metallization, Vacuum evaporation, 7
V
sputtering) – Plating (Electroless plating, Electrolytic plating) - Flame and
arc spraying - hot foil stamping – hot transfer – In mold decorating - Water
transfer – Printing– Laser Marking, Vapor polishing, Decals -
Understanding Recycling Codes.
5.3 Maintenance of Injection Moulds: Advantages of Preventive 4
maintenance, maintenance of - cooling lines, mould surfaces, heating &
control systems. Action taken after examination and cleaning. Repair and
245
alterations of injection moulds.
Text Books:
1. Pye.R.G.W., "Injection Mould Design", Affiliated East – west press pvt Ltd, 2000
2. Athalye.A.S., 'Injection Moulding", 2nd Edn., Multi Tech Publishing Co., 1998
3. George menges and Paul mohren, “How to make Injection moulds”, Hawer publishers,
1991
Reference Books:
1. Briston and Gosselin, “Introduction to Plastics", Newnes-Butterworths, London, 1970
2. Mills.N.J., “Plastics", ELBS, 1986
3. Dominick V.Rosato and Donald V.Rosato., "Injection Moulding Hand Book", CBS
Publishers & Distributors, Delhi, 1987
4. Athalye.A.S., "Plastics Materials Handbook", Multi Tech Publishing Co., 1995
246

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020610 – INDUSTRIAL ENGINEERING &

MANAGEMENT
247
N - SCHEME

Semester : VI
Subject Title : INDUSTRIAL ENGINEERING AND MANAGEMENT

Hours Marks
Subject Hours /
/ Internal Board Duration
Semester Total
Week Assessment Examinations
INDUSTRIAL
ENGINEERING 5 80 25 100* 100 3 hrs.
MANAGEMENT

I Plant Engineering and Plant Safety 14
II Work Study, Method Study and Work Measurement 15
III Principles, Personnel Management and Organizatioal 16
Behavior:
IV Financial and Material Management 14
V Engineering Ethics and Human Values 14

Total 80
248
RATIONALE:
In the Indian Economy, Industries and Enterprises always find prominent place. After
globalization, the students should be trained not only in manufacturing process but also in
managing activities of industries. The knowledge about plant, safety, work study techniques,
personnel management, financial management and engineering ethics and human values will
definitely help the students as managers to suit the industries.
OBJECTIVES:
To study the different types of layout.
To study the safety aspects and its impacts on an organization.
To study different work measurement techniques.
To study engineering ethics and human values.
To study the staff selection procedure and training of them.
To study capital and resources of capital.
To study inventory control system.
To study about organization and it’s behavior.
DETAILED SYLLABUS
4020610 INDUSTRIAL ENGINEERING AND MANAGEMENT
Contents: Theory
Unit Name of the Topics Time
I Plant Engineering and Plant Safety
Chapter: 1.1: Plant Engineering : Plant – Selection of site of industry – 7
Plant layout – Principles of a good layout – types – process, product and
fixed position – techniques to improve layout – Principles of material
handling equipment – Plantmaintenance – importance – Break down
maintenance, preventive maintenance and scheduled maintenance.
Chapter: 1.2: Plant Safety: Importance – accident - causes and
cost of an accident-accident proneness - prevention of accidents - 7
Industrial disputes - settlement of Industrial disputes-Collective bargaining,
conciliation, Mediation, arbitration - Indian Factories Act 1948 and its
provisions related to health, welfare and safety.
249
II Work Study, Method Study and Work Measurement
Chapter: 2.1: Work Study: Productivity – Standard of living – method of 3
improving productivity – Objectives – Importance of good working
conditions.
Chapter: 2.2: Method Study: Definition – Objectives – Selection of a 5
job for method study –Basic procedure for conduct of method study
– Tools used – Operation process chart, Flow process chart, two handed
process chart, Man Machine chart, String diagram and flow diagram.
Chapter: 2.3: Work Measurement: Definition – Basic procedure in
making a time study – Employees rating factor – Application of time 7
allowances – Rest, Personal, Process, Special and Policy allowances –
Calculation of standard time – Problems – Basic concept of production
study – Techniques of work measurement-Ratio delay study, Synthesis
from standard data, analytical estimating and Pre determined Motion Time
System (PMTS).
III Principles, Personnel Management and Organizational Behavior:
Chapter: 3.1: Principles of Management: Definition of management – 6
Administration - Organization – F.W. Taylor’s and Henry Fayol’s Principles
of Management – Functions of Manager – Directing – Leadership –Types
of Leadership – Qualities of a good leader – Motivation – Positive and
negative motivation --Modern management techniques- Management
Information Systems – Strategic management – SWOT Analysis -
Business Process Re-engineering (BPR) – Enterprises Resource
Planning (ERP) –Activity Based Management (ABM) – Global Perspective
– Principles and brief description.
Chapter: 3.2: Personnel Management: Responsibility of human
resource management – Selection procedure – Training of workers – 6
Apprentice training – On the job training and vestibule school
training – Job evaluation and merit rating – objectives and
importance – wages and salary administration – Components of wages –
Wage fixation – Type of wage payment – Halsey’s 50% plan, Rowan’s
plan and Emerson’s efficiency plan – Problems.
250
Chapter: 3.3: Organizational behavior: Definition – organization--
Types of Organization – Line, Staff, Taylor’s Pure functional types – Line 4
and staff and committee type –Organizational Approaches, individual
behavior - causes - Environmental effect - Behavior and Performance,
Perception - organizational implications.
IV Financial and Material Management
Chapter: 4.1: Financial Management:Fixed and working capital – 7
Resources of capital – shares preference and equity shares – debentures
– Type of debentures – Public deposits, Factory costing – direct cost –
indirect cost – Factory overhead – Selling price of a product – Profit –
Problems. Depreciation – Causes – Methods - Straight line, sinking fund
and percentage on diminishing value method – Problems.
Chapter: 4.2: Material Management: Objectives of good stock control
system – ABC analysis of inventory – Procurement and consumption 7
cycle – Minimum Stock, Lead Time, Reorder Level - Economic order
quantity - problems – supply chain management - Introduction –
Purchasing procedure – Store keeping – Bin card.
V Engineering Ethics and Human Values
Chapter: 5.1: Engineering Ethics: Definition-engineering ethics-personal 8
and business ethics- duties and rights-engineering as a profession - core
qualities of professional practitioners-environment and their impact-code
of ethics- procedure for solving ethical conflicts - ethical judgement-
Kohiberg’s stages of moral development - value based ethics- engineers
as managers, consultants and leaders- environmental ethics- computer
ethics- Intellectual Property Rights (IPRs).
Chapter: 5.2: Human values : morals – values – integrity- service
learning-civic virtue - respect for others- living peacefully- caring – sharing 6
– honesty- courage - valuing time cooperation - commitments – empathy-
selfconfidence – character- stress management.
251
Reference Books :
1. Industrial Engineering and Management, O.P. Khanna, Revised Edition
Publications(P)Ltd – 2004, 67/4 Madras House, Daryaganj, NewDelhi– 110002.
2. Engineering Economics and Management, T.R. Banga& S.C. Sharma, McGraw Hill
Editiion. 2 – 2001, NewDelhi.
3. HeraldKoontz and Heinz Weihrich,’ Essentials of Management’, McGraw Hill
Publishing Company, Singapore International Edition.Latest
4. Govindarajan .M, Natarajan. S, Senthilkumar V.V, Engineering ethics , prentice hall of
India New Delhi, 2004.
5. Management, Aglobal perspective, Heinz Weihrich, Harold Koontz, 10th Edition,
McGraw Hill International Edition.Latest.
6. Essentials of Management,4th Edition, Joseph L.Massie,Prentice- Hall of India,
NewDelhi 2004.
7. S.Chandran, Organizational Behaviours,Vikas Publishing House Pvt. Ltd. Latest
8. M.Govindarajan and S.Natarajan ,Principles of Management ,Prentce Hall of India
Pvt.Ltd. NewDelhi.Latest.
9. Charles B. Fledderman, Engineering ethics, pearson prentice hall, New Jersey, 2004.
252

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020631 – INDUSTRIAL ROBOTICS AND 3D

PRINTING
253
N – SCHEME

Semester : VI
Subject Title : INDUSTRIAL ROBOTICS AND 3D PRINTING

Marks
Week Semester Total
INDUSTRIAL
ROBOTICS AND 5 80 25 100* 100 3 hrs.
3D PRINTING

I Fundamentals of Robot Technology 12
II Drive Systems, End Effecters, Sensors and Machine Vision
12
System
III Robot Programming, Robot Applications in Maufacturing 12
IV Introduction and Design for Additive Manufacturing 18
V Additive Manufacturing Processes 19
TEST AND MODEL EXAMINATION 07
Total 80
254
RATIONALE:
Rapid industrialization and globalization needs industries to be more competitive and deliver
cost effective quality products. This needs industries to implement flexible manufacturing
systems where Robotic technology plays major role. Hence study of robotic technology is
very essential.
3Dprinting is often utilized when manufacturers need to create a product accurately, quickly
and at a low quantity. This has lead to 3D printers being brought in to prototype industrial
robots, helping to aid the development of better, more efficient robots in the industrial sector.
OBJECTIVES:
Understand fundamentals of robotics
Acquire knowledge structure and elements of robot
Gain knowledge on controller and various drives used in robotics
Develop knowledge on role of sensors and vision system
Acquire skill to program and control robot
Understand to adopt robot to various industrial applications.
To acquire the knowledge on 3D Printing and design principles for additive
manufacturing
To understand the principles of latest manufacturing processes in Additive
manufacturing
DETAILED SYLLABUS
Contents: Theory
Unit Name Of The Topic Hours
I Fundamentals of Robot Technology 12
Introduction – History of robot– Definitions– Basic configuration of
Robotics – Robot Components – Manipulator, End effecter,
Driving system, Controller and Sensors – Degrees of freedom –
Links and joints – Types of joints – Joint notation scheme – Pitch,
Yaw, Roll – Classification of robots – Work envelope and Work
Volume – Effect of structure on Control ,Work envelop and Work
255
volume- Introduction to PUMA robot- Robot controller –
Configuration - Four types of controls – Open loop and closed
loop controls – Speed of response and stability – Precision of
movements: Spatial resolutions, accuracy and repeatability.
II Drive Systems, End Effecters, Sensors and Machine Vision 12
System
Pneumatic drives – Hydraulic drives – Mechanical drives –
Electrical drives – Stepper motors, DC Servo motors and AC
Servo motors– Applications and Comparisons of Drives. End
effecters – Grippers – Mechanical Grippers, Magnetic Grippers,
Vacuum Grippers- Selection and design considerations in robot
gripper- Requirements of Sensors – Position sensors: LVDT,
Resolvers, Optical encoders- Proximity sensors: Inductive,
Capacitive, Ultrasonic and Optical proximity sensors- Touch
Sensors – Range Sensors- Machine Vision System: Sensing &
Digitizing Image Data – Image Processing and Analysis -
Application
III Robot Programming, Robot Applications In Manufacturing 12
Forward kinematics, Inverse kinematics and differences –
Forward kinematics and Reverse kinematics of manipulators with
Two and Three degrees of freedom – Derivations. Robot
programming –Lead through programming, Textual programming
– Teach Pendant for Robot system– Robot programming
languages – Motion commands, Sensor commands, End effecter
commands. Robot applications – Material handling-Spot welding –
Arc welding – Spray painting – Assembling – Finishing-AGV-RGV.
IV Introduction and Design for Additive Manufacturing
Introduction to Additive Manufacturing 9
Additive Manufacturing – 3D Printing – Rapid prototyping –
Overview – Need – Additive manufacturing Vs CNC Machining -
Development of Additive Manufacturing Technology – Principle of
AM Process – Generalised Additive Manufacturing Process Chain
256
- Classification - Benefits – Direct and Indirect process,
Prototyping, Manufacturing and Tooling
Design for Additive Manufacturing 9
Design tools: Data processing - CAD model preparation – STL file
- Part orientation and support structure generation - Model slicing
- Tool path generation. Design for Additive Manufacturing:
Concepts and objectives - AM unique capabilities - DFAM for part
quality improvement – strategies – Design Rules – Quality
aspects – Software for AM – MIMICS, etc.
V Additive Manufacturing Processes
Photo polymerization and Powder Bed Fusion Processes 7
Photo polymerization: SLA - Photo curable materials - Process -
reaction rates – scan patterns - Advantages and Applications.
Powder Bed Fusion: SLS - Process description - powder fusion
mechanism – material feed system - Process Parameters -
Materials and Applications. Electron Beam Melting
Extrusion Based And Sheet Lamination Processes 5
Extrusion Based System: FDM – Introduction - Basic Principle –
plotting and path control - Materials - Applications and Limitations
- Bio-extrusion. Sheet Lamination Process: LOM – Materials -
Gluing or Adhesive bonding - Thermal bonding – Ultrasonic AM.
Printing Processes And Beam Deposition Processes 7
Droplet formation technologies - Continuous mode - Drop on
Demand mode - Three Dimensional Printing – Advantages – Bio-
plotter - Beam Deposition Process: LENS- Process description -
Material delivery - Process parameters – Materials – Benefits.
Applications of AM technologies in Automotive, Manufacturing,
Architectural, Healthcare, and Consumer products.
Reference Books:
1. Industrial Robotics – Technology, Programming and Applications, P.Groover, MCGraw
Hill, 2001
257
2. Chua C.K., Leong K.F., and Lim C.S., “Rapid prototyping: Principles and applications”,
Third edition, World Scientific Publishers, 2010.
3. Ian Gibson, David W. Rosen, Brent Stucker “Additive Manufacturing Technologies:
Rapid Prototyping to Direct Digital Manufacturing” Springer, 2010.
4. Robotics Control, Sensing, Vision and Intelligence, Fu.K.S.Gonzalz.R.C., and Lee
C.S.G, McGraw-Hill Book Co., 1987
5. Robotics for Engineers, Yoram Koren, McGraw-Hill Book Co., 1992
6. Robotics and Image Processing, Janakiraman.P.A, Tata McGraw-Hill, 1995
7. Andreas Gebhardt “Understanding Additive Manufacturing: Rapid Prototyping, Rapid
Manufacturing” Hanser Gardner Publication 2011.
8. Kamrani A.K. and Nasr E.A., “Rapid Prototyping: Theory and practice”, Springer,
2006.
9. Liou L.W. and Liou F.W., “Rapid Prototyping and Engineering applications: A tool box
for prototype development”, CRC Press, 2007.
10. Tom Page, “Design for Additive Manufacturing” LAP Lambert Academic Publishing,
2012.
11. Amit Bandyopadhyay, and Susmita Bose, “Additive Manufacturing”, CRC Press.
12. John O Milewski., “Additive Manufacturing of Metals: From Fundamental Technology
to Rocket Nozzles, Medical Implants, and Custom Jewellery”, Springer Series in
Materials Science
13. Sabrie Soloman. “Additive Manufacturing: Advanced Manufacturing Technology in 3d
Print Deposit”
14. David Ian Wimpenny and Pulak M Pandey, “Advances in 3D Printing and Additive
Manufacturing Technologies”
15. Andreas Gebhardt, Hanser, “Understanding Additive Manufacturing”
258

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020620 – E VEHICLE TECHNOLOGY & POLICY
259
N - SCHEME

Semester : V
Subject Title : E VEHICLE TECHNOLOGY & POLICY

Marks
Week Semester Total
E VEHICLE
TECHNOLOGY & 5 80 25 100* 100 3 hrs.
POLICY

I Environmental impact and history, Types of Electric vehicles 15
II Electric vehicle, Electrical Propulsion System 15
III Energy Storages, Charging System, Effects and Impacts 14
IV Electric Mobility Policy Frame Work 14
V Tamilnadu E-Vehicle Policy 2019 15
Total 80
260
RATIONALE:
The world is transitioning to cleaner mobility options with the aim at improving air quality and
reducing dependency on fossil fuels. Electric Vehicles (EVs) have emerged a popular clean
mobility choice to reduce emissions. EVs are powered fully or partially by batteries, they can
help to reduce dependence on fossil fuels also air quality. Tamil Nadu is one of the most
advanced states in India. Tamil Nadu has a highly developed industrial eco-system and is
very strong in sectors like automobiles and auto-components. Many globally renowned
companies have setup their manufacturing facilities in Tamil Nadu. Due the rapid depletion of
fossil fuel and increase in fuel cost, environmental pollution, the shift to clean transport is
necessary. This subject introduced by keeping all the above factors.
OBJECTIVES:
To learn the environmental impact and history of Electric Vehicles.
To understand the concept of Electric Vehicle and its types.
To study the configurations of Electric Vehicles
To acquire knowledge about Energy Storages, Charging System, Effects and Impacts
To appreciate the Electric Mobility Policy Frame work India and EV Policy Tamil Nadu
2019.
261
DETAILED SYLLABUS
4020620 E Vehicle Technology & Policy
Contents: Theory

I Environmental impact and history: 8
Environmental impact of conventional vehicle - Air pollution – Petroleum
resources – History of Electric vehicles & Hybrid Electric Vehicles -
Conventional drive train system – Rear Wheel, Front Wheel and All
wheel - Parts of Drive train system
Types of Electric Vehicles:
Introduction to Battery Electric Vehicle (BEV) – Definition BEV – 7
Necessity BEV – Different between BEV and Conventional Vehicle -
Advantages of BEV - Block diagram of BEV – Hybrid electric Vehicle
(HEV) - Plug-in Hybrid Electric Vehicle (PHEV) – Fuel Cell Electric
Vehicle (FCEV) – Description.
II Electric Vehicles: 7
Configurations of Electric Vehicle – Performance of Electric Vehicles –
Tractive Effort in Normal Driving – energy consumption.
Hybrid Electric Vehicles: Concept of Hybrid electric drive trains –
Architecture of Hybrid Electric Drive trains – Series, Parallel and Series &
Parallel
Electric Propulsion Systems: 8
Types of EV motors - DC motor drives– Permanent Magnetic Brush Less
DC Motor Drives (BLDC) – Principles, Construction and Working – Hub
motor Drive system – Merits and Demerits of DC motor drive, BLDC
motor drive
III Energy Storages: 6
Electrochemical Batteries – Battery Technologies – Construction and
working of Lead Acid Batteries, Nickel Based Batteries and Lithium
Based Batteries - Role of Battery Management System (BMS)– Battery
pack development Technology– Cell Series and Parallel connection to
262
develop battery pack. 6
Charging:
Battery Charging techniques - Constant current and Constant voltage,
Trickle charging – Battery Swapping Techniques – DC charging –
Wireless charging – Maintenance of Battery pack – Latest development
in battery chemistry.
Effects and Impacts:
Effects of EV – Impacts on Power grid – Impacts on Environment – 2
Impacts on Economy.
IV Electric Mobility Policy Frame Work 14
Government of India Electric Mobility Policy Frame work – Global
Scenario of EV adoption – Electric mobility in India – National Electric
Mobility Mission Plan 2020 – Action led by Original Equipment
Manufacturers – Need of EV Policy – Advantage of EV Eco system –
Scope and Applicability of EV Policy – ARAI Standards for Electric
Vehicle – AIS 038, AIS 039 &AIS 123 - Key Performance Indicator -
Global impact – Trends and Future Developments
V Tamil Nadu E-Vehicle Policy 2019 15
Tamil Nadu E-vehicle Policy 2019: Vehicle Population in Tamil Nadu –
Objectives of EV Policy – Policy Measures – Demand side incentives –
Supply side incentives to promote EV manufacturing – Revision of
Transport Regulation of EV – City building codes – Capacity Building and
Skilling – Charging structure – implementing agencies – Reasearch
&Development and Business Incubation – Recycling Ecosystem –
Battery and EVs
263
Reference Books
1. Modern Electric, Hybrid Electric and Fuel Cell Vehicles, Mehrdad Ehsani, Yimin Gao,
Sebastien E.Gay, Ali Emadi, CR Press, London, New York.
2. Comparison of Electric and Conventional Vehicles in Indian Market: Total Cost of
Ownership, Consumer Preference and Best Segment for Electric Vehicle (IJSR),
Akshat Bansal, Akriti Agarwal
3. A Comprehensive Study of Key Electric Vehicle (EV) Components, Technologies,
Challenges, Impacts, and Future Direction of Development (MDPI), Fuad Un-Noor,
Sanjeevikumar Padmanaban, Lucian Mihet-Popa, Mohammad Nurunnabi Mollah and
Eklas Hossain.
4. Electric Vehicles: A future Projection CII October 2020 report.
5. Design and analysis of aluminum/air battery system for electric vehicles, Shaohua
Yang, Harold Knickle, Elsevier.
6. Propelling Electric Vehicles in India, Technical study of Electric Vehicles and Charging
Infrastructure
7. ZERO EMISSION VEHICLES (ZEVs): TOWARDS A POLICY FRAMEWORK – NTI
Aayog.
8. FASTER ADOPTION OF ELECTRIC VEHICLES IN INDIA: PERSPECTIVE OF
CONSUMERS AND INDUSTRY, The Energy and Resources Institute, New Delhi.
9. India EV Story: Emerging Opportunities by Innovation Norway.
10. Automotive Industry Standards – AIS 038, AIS 039 & AIS 123 – Manual
264

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020640 – SOLID MODELLING PRACTICAL
265
N - SCHEME

Semester : VI
Subject Title : SOLID MODELLING PRACTICAL

Marks
Week Semester Total
SOLID
MODELLING 5 80 25 100* 100 3 hrs.
PRACTICAL
RATIONALE:
A Mechanical Engineering Diploma Engineer is expected to possess a thorough
understanding of drawing, which includes clear visualization and proficiency in reading and
interpreting a wide variety of production drawing. The market driven economy demands
frequent changes in product design to suit the customer requirements. The introduction of this
subject is to provide hands on experience in sketching and modeling of the industrial
components using any one of the Computer Aided Design and Modelling packages. The aim
of this subject is to help the student to attain the industry identified competency through
practice in CAD software.
266
OBJECTIVES:
Prepare 2D Drawing using sketcher or part modelling of any parametric CAD software.
Generate 3D Solid models from 2D sketch or part modelling of any parametric CAD
software.
Prepare assembly of part models using assembly of any parametric CAD software.
Generate orthographic views of 3D solid models/assemblies using drafting of any
parametric software.
Plot a drawing for given part model/assembly.
DETAILED SYLLABUS
Contents: Practical
Introduction
Parametric CAD software – sketch – elements – entities: line – circle – arc – ellipse – polygon
– text – dimensions – sketch tools – fillet – chamfer – offset – trim – extend – mirror – rotate –
block. Partmodelling– reference planes – reference point – reference axes – co-ordinate
system – extrude – revolve – swept – helix and spiral – lofts – dome – shell – draft – rib –
wrap – intersect – holes – patterns. Assembly – approaches – mate – coincident – sub
assembly –rebuild – isolate. Drawing views – Save – Plot – model view – exploded view –
projected view – section view – import – export – Appearance – rendering.
Exercises
PART A: Draw the given 3D drawing using 3D modelling commands.
1. Model 1
2. Model 2
3. Model 3
4. Model 4
5. Model 5
6. Model 6
PART B: Draw the part models and assemble the components using 3D modelling.
1. Revolving Centre
2. Tail stock
3. Machine Vice
267
4. Crane hook
5. Petrol Engine Connecting Rod
6. Pipe Vice
Board Examination
Note: All the exercises should be completed All the exercises should be given for
examination, the students are permitted to select by lot or the question paper from DOTE
should be followed. Record note book should be submitted during examination.
Two exercises will be given for examination by selecting one exercise in each PART. The
printout of exercises of the student work should be submitted with answer paper and the
same have to be evaluated as per the allocation.
DETAILLED ALLOCATION OF MARKS
Sl. No. Performance Indicator Marks
Part A – 3D Component Modelling
1 Sketching 15
2 3D Modelling 15
Part B – Assemble Drawing Modelling
3 Sketching / Part modelling 20
4 Assembly 30
5 Solid Model / Views 10
6 Vivavoce 10
Total 100
LIST OF EQUIPMENTS (for the batch of 30 students)

Personal computer : 30 Nos.
Laser Printer : 1 No.
Software : GUI System Software
: Modelling package – Sufficient to the strength.
Exercises
PART A: Draw the given 3D drawing using 3D modelling commands.
268
Model 1 Model 2
Model 3 Model 4
Model 5 Model 6
269

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020651 – INDUSTRIAL ROBOTICS AND 3D

PRINTING PRACTICAL
270
N – SCHEME

Semester : VI
Subject Title : INDUSTRIAL ROBOTICS AND 3D PRINTING PRACTICAL

Marks
Week Semester Total
INDUSTRIAL
ROBOTICS AND
5 80 25 100* 100 3 hrs.
3D PRINTING
PRACTICAL
Objectives
Study of Robot / Study of robot simulation software
To study the components required.
To study the techniques of programming for various industrial manufacturing
applications.
Prepare a record of work done.
Acquire knowledge in the field of Additive Manufacturing
Explain the various concepts of Solid Modelling
Create STL files to manufacture components using 3D Printer
271
DETAILED SYLLABUS
Contents:
3D Printing : Getting to know the User Interface of the Modelling software – Home Screen –
Navigating the main Screen – Options Bar – Application Menu & Quick Access Toolbar –
Describe the function of a sketch - Describe the various types of sketches. Create sketches
of 3D models. Basic Modelling Considerations – Describe part creation within the design
process. Add placed features to existing parts. Create complex shapes by sweeping or lofting
profiles. Assemblies - Managing the assemblies - Assemble a mechanical piece of
equipment using constraints. STL files – introduction – conversion of parts from other file
formats to STL file – Additive Manufacturing – types of 3D Printers – orientation and
positioning of parts - producing 3D working models using 3D Printers.
Exercises:
PART A- Robot Programming
1. Position recording using Cartesian co-ordinate system - (No. of positions - 9)
2. Position recording using Polar co-ordinate system - (No. of positions - 9)
3. Pick and place the objects - No. of objects - 6)
4. Pick and stack the objects - (No. of objects - 6)
5. Spray painting practice - (Area - 300mm x 300mm)
6. Spot welding practice - (No. of spots - 9)
7. Arc welding practice – (Length of weld 50 mm)
8. Assembling practice - (Minimum 3 Components)
9. Profile cutting practice - (Complicated profile – combination of lines and arcs)
10. Machine loading and unloading practice with time delay - (No. of times - 9)
PART B - 3D Printing
1. Create the model and produce the Gear Train in 3D printing.
2. Create the model and produce the Sun-planetary gear mechanism.
3. Create the model and produce the Geneva Gear & Ratchet mechanism.
272
4. Create the model and produce the Slide-crank mechanism.
Note: Every student is asked to design and produce only one component of an assembly.
After the completion of the product, individual parts are checked for its precision and matting
in the assembly. Hence group exercises can be given. The models can be scaled according
to the print area of the 3D Printer.
Board Examination
Note:
All the exercises should be completed. Two exercises will be given for examination by
selecting one exercise in each PART.
All the exercises should be given for examination, the students are permitted to select
by lot or the question paper from DOTE should be followed.
Record note book should be submitted during examination.
DETAILLED ALLOCATION OF MARKS

Sl. No. Performance Indicator Marks
Part A – Robot Programming
1 Robot Program 20
2 Simulate / Execution 30
3 Result 10
Part B – 3D Prinitng
4 CAD - Modelling 15
5 3D Printing 15
6 Vivavoce 10
Total 100
Personal computer : 15 Nos.
6 Axis Robot : 1 No.
3D Printer : 1 No.
Software : GUI System Software
: Modelling package / 3D Printer–Sufficient to the strength.
273

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4020550 – THERMAL ENGINEERING PRACTICAL
274
N - SCHEME

Semester : VI
Subject Title : THERMAL ENGINEERING PRACTICAL

Marks
Week Semester Total
STRENGTH OF
5 80 25 100* 100 3 hrs.
MATERIALS
OBJECTIVES:
Determine the flash and fire point and viscosity of oil.
Draw the valve timing diagram of petrol and diesel engines.
Draw the port timing diagram of petrol and diesel engines.
Conduct performance test on petrol and diesel engines.
Prepare heat balance sheet for an IC engine.
Conduct of C.O.P of Refrigerators.
Determine the volumetric efficiency of the Air Compressor.
275
Experiments:
PART-A
1. Determine flash and fire point of the given oil using open cup and closed cup
apparatus.
2. Determine the absolute viscosity of the given lubricating oil using Redwood
viscometer.
3. Determine the absolute viscosity of the given lubricating oil using Say bolt viscometer.
4. Port timing diagram of two stroke petrol Engine
5. Valve time diagram for four stroke petrol Engine.
6. Valve time diagram for four stroke diesel engines.
PART-B
1. Load test (Performance test) on Four Stroke Petrol Engine.
2. Load test (Performance test) on Four Stroke diesel Engine.
3. Morse test on Multi-cylinder petrol engine.
4. Heat balance test on Four Stroke Diesel / Petrol Engine.
5. Volumetric efficiency of Air Compressor.
6. Determination of COP of Refrigeration System.
276
BOARD EXAMINATION
Note:
All the experiments in both sections should be completed. Two experiments will be
given for examination by selecting one exercise from PART A and one exercise from
PART B.
All the experiments should be given in the question paper and students are allowed to
examination.
Detailled Allocation of Marks
Part A: 35
Observation and Tabular Column 5
Calculations 20
Result / Graph 10
Part B: 55
Observation and Tabular Column 10
Formulae, Calculations 30
Result / Graph 15
Viva Voce 10
Total 100
277
1. Open cup apparatus - 2 Nos.
2. Close cup apparatus - 2 Nos.
3. Redwood viscometer - 2 Nos.
4. Say bolt viscometer - 2 Nos.
5. Four stroke petrol engine Model - 2 Nos.
6. Four stroke diesel engine Model - 2 Nos.
7. Two stroke petrol engine Model - 2 Nos.
8. Four stroke Petrol Engine Test rig - 1 No.
9. Four stroke Diesel engine Test rig - 1 No.
10. Multi -cylinder petrol engine test rig - 1 No.
11. Air compressor test rig – 1 No.
12. Refrigeration Test rig – 1 No.
13. Guarded Plate Apparatus – 1 No.
14. Measuring instruments - Required quantity
15. Consumables - Required quantity
278

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4022650 - PLASTIC MOULDS PRACTICAL
279
N-SCHEME

Semester : VI
Subject Title : PLASTIC MOULDS PRACTICAL

Marks
Week Semester
PLASTIC MOULDS
6 96 25 100* 100 16 hrs.
PRACTICAL
OBJECTIVES
Design and fabricate single cavity injection mould
Design and fabricate multi cavity injection mould
Design and fabricate blow mould.
Design and fabricate of compression mould
Practice on different machining operations
Use different machine tools in making plastic moulds
280
DETAILED SYLLABUS
i) Design of Plastic Moulds: (16 Hrs)
1. Injection Mould Design: Methodical approach to mould design.

Design of Hand injection mould
Design of three plate mould
2. Design of simple Compression Mould.

3. Design of simple Blow mould.
ii) Mould Design and Manufacture Exercises: (48 Hrs )

1. Design and Fabrication of single cavity hand injection mould with flat parting surface
( To suit to Hand Injection Moulding Machine)
2. Design and fabrication of multi cavity injection mould
(To suit to Hand injection Moulding Machine)
3. Design and fabrication of simple compression mould.
4. Design and fabrication of simple blow mould.
Note:-
1. Batch size should not be more than 5 students for class work.
4. Students should be trained in setting the mould and to make necessary adjustments,
trial production using the mould manufactured by them and rectification of mould
defects if any.
5. For Board examination any one of the above tool (S.No 1 to 4) is to be manufactured
and trial production should be taken. The evaluation of the performance should be
based on the component dimensions and finish obtained from the mould manufactured
by the student during the 16 hours examination.
281
Record: Mould drawings for all the exercises should be drawn in A2 sheet Manually, with all
calculations filed neatly for Record work. The Design should include the Sectional Elevation,
plan view, Bill of materials with all necessary calculation using methodological mould design.
Examination:
In the examination students have to Design and fabricate moulds for similar
components as practiced in the class work
Design of Mould -50 marks
Mould making -20 marks
Mould setting & trial production -10 Marks
Component quality -10 marks
Viva Voce -10 Marks
Total -100 Marks
282

(TOOL & DIE)
YEAR THIRD
SEMESTER VI
NAME OF THE LABORATORY 4022650 PLASTIC MOULDS PRACTICAL
ANY REQUIRED
6 Hand Injection Moulding Machine – 1 OZ 1
7 Bench vice 10
9 Tap set 4
10 Surface plate 2
13 Angle plate 2
16 Hand injection moulding machine 1
17 Hand injection Blow moulding machine 1
283
Exercise – I Single Cavity Injection Mould
For exercise I, refer the subject 4022340 and the Drawings are available in the
subject 4022340 – Computer Aided Machine & Tool Drawing in Exercise no.10
Exercise – II Multi Cavity Injection Mould
284
285
286
287
288
289
290
Exercise – III Compression Mould
291
292
293
294
Exercise – IV Blow Mould
295
296
297
298
299
300
301

(TOOL& DIE)
III YEAR
N – SCHEME
VI SEMESTER
2020 – 2021 onwards
4022660- PROJECT WORK AND INTERNSHIP
302
N-SCHEME
Semester : VI
Subject Title : PROJECT WORK & INTERNSHIP

Hours/ Hours/ Marks
Subject
Week Semester Duration
PROJECT WORK &

6 96 25 100* 100 3hrs
INTERNSHIP
* Minimum marks for pass is 50 out of which minimum 50 marks should be obtained out of
100 marks in the board Examination alone.
RATIONALE:
This subject ’Project work & Internship’ is the continuation of the previous semester
subjects. The students are to implement the detailed project plan, which they have prepared.
This project is generally an integration of the various types of skills acquired during their
course of study. Hence it is essential that students are given opportunity to develop and
integrate the highly essential industry-oriented competencies and skills. The subject build up
greater confidence to face in the world of work.
OBJECTIVES:
Implement the theoretical & practical knowledge gained through the curriculum
in to an application suitable for a real practical &working environment preferably
in an industrial environment.
Implement the planned activity as a team.
303
Take appropriate decisions on collected information.
Carry out cooperative learning through synchronous guided discussions with in
the class in key dates, a synchronous document sharing and discussions, as
well as to prepare collaborative edition of final project report.
PROJECT WORK & INTERNSHIP:
The students of all Diploma Courses have to do a Project Work as a part of curriculum
and in partial fulfillment for the award of Diploma by the State Board of Technical Education
and Training, Tamilnadu. In order to encourage students to do worthwhile and innovative
projects, every year prizes are awarded for best three projects i.e. Institution wise, region
wise & state wise. The project work must be reviewed twice in the same semester. The
project work is approved during the Vth semester by the properly constituted
committee with guidelines.
a) Internal Assessment Mark for Project Work & Internship:

Detail of Assessment Period of Assessment Max Marks
Project review I 6th week 10 marks
Project review II 12th week 10 marks
Attendance Entire semester 05 marks (Award of marks same as
theory subject pattern)
Total 25 marks
Proper record should be maintained for the two projects review and preserved for one
semester after the publication of board exam results. It should be produced to the flying
squad and the inspection team at the time of inspection/verification.
b) Allocation of marks for Project Work and Internship in Board Examination:
Details Of Marks Allocation Max Marks
Demonstration/Presentation 25 marks
Report 25 marks
Viva Voce 30 marks
Internship Report 20 marks
Total 100* marks
*Examination will be conducted for 100 marks and will be converted to 75 marks.
304
c) Internship Report:
The internship training for a period of two weeks shall be undergone by every
candidate at the end of IV/V semester during vacation. The certificate shall be produced
along with the internship report for evaluation. The evaluation of internship training shall be
done along with final year” Project Work and Internship” for 20 marks. The internship shall be
taken in any Industry/Government are Private Certified Agencies which are in social
sector/Govt.skill centers/Institution/Schemes.
A neatly prepared PROJECT REPORT as per the format has to be submitted by
individual student during the Project Work and Internship Board Examination.
305

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DIPLOMA IN ENGINEERING AND TECHNOLOGY

IMPLEMENTED FROM 2020 - 2021

CURRICULUM DEVELOPMENT CENTRE

DIRECTORATE OF TECHNICAL EDUCATION

Tmt G.LAXMI PRIYA I.A.S.

1220 DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

1. Description of the Course:

b. Sandwich (3½ years)

c. Part Time (4 years)

2. Condition for Admission:

3. Admission to Second year (Lateral Entry):

A pass in 2 Years ITI with appropriate Trade or Equivalent examination.

English & English & Co-operative

English & Marketing &

4. Age Limit: No Age limit.

5. Medium of Instruction: English

The minimum and maximum period for completion of Diploma Courses is

The total marks for result are 75 + 25 = 100 Marks.

A. For Theory Subjects:

# From the Academic Year 2020 – 2021 onwards.

iii) Assignment 5 Marks

iv) Seminar Presentation 5 Marks

11. Project Work and Internship:

a) Internal assessment mark for Project Work & Internship:

A neatly prepared PROJECT REPORT as per the format has to be

12. Scheme of Examinations:

13. Criteria for Pass:

2. A candidate shall be declared to have passed the examination in a subject if

14. Classification of successful candidates:

15. Duration of a period in the Class Time Table:

Col. HOURS PER WEEK

Col. HOURS PER WEEK

@@ - Common subject with Mechanical Engineering

@@ - Common subject with Mechanical Engineering

TOTAL 175 700 700

@@ - Papers Common with Diploma in Mechanical Engineering Branch

List of Equivalent Subjects for M & N-Scheme subjects

2 32232 Manufacturing Technology Not Equivalent

3 32233 Engineering Metrology 4022330 Engineering Metrology

Time: 3 Hrs. Max.Marks:100

DIPLOMA IN MECHANICAL ENGINEERING

2020 – 2021 onwards

4020310 –STRENGTH OF MATERIALS

CURRICULUM DEVELOPMENT CENTRE

Course Name : 1220: DIPLOMA IN MECHANICAL ENGINEERING (TOOL&DIE)

TEACHING AND SCHEME OF EXAMINATION

Topics and Allocation of Hours

Assumptions – torsion equation - Strength of solid and

DIPLOMA IN MECHANICAL ENGINEERING

2020 – 2021 onwards

4022320 – MANUFACTURING TECHNOLOGY

CURRICULUM DEVELOPMENT CENTRE

Course Name : 1220: DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

TEACHING AND SCHEME OF EXAMINATION

Topics and Allocation of Hours

Acquire knowledge about various metal joining processes

Appreciate the safety practices used in welding

Explain the lathe working principles and its various operations

Explain the Semi-Automatic and Automatic lathe working principles