28.3.

0 PRODUCTION LINE PROCESSES

28.3.1 Introduction
This module is designed to equip the trainees with knowledge skills
and attitudes to enable them work as production managers in
manufacturing industry. The module covers the following areas:
computer programming, computer aided design, computer aided
manufacture robots and robotics project planning production planning
and control.

Production line Processes involves the operation of modern

production line machines, Robots and computer aided design and
manufacture. It also involves planning and control in industrial
manufacturing.

379
 The instructional approach will lay emphasis on demonstrations,
industrial visits, industrial attachment, practical and project work. The
assessment mode for this module shall be theory and practice. Some
of the reference materials for this module are listed at the end of the
module. The list is not exhaustive. The module unit will impart the
trainees with the technical skill required to work in formal sector.
Trainees undertaking this module will require knowledge of Computer
skills, Engineering drawing, Mathematics and Control Systems and
Instrumentation.

28.3.2 General Objectives

By the end of this module the trainee should be able to:
a) design a product using cad software
b) write a part program for a given product to be produced
c) work as production line operator
d) program and operate robots in a production line
e) plan a system for producing a given component
f) design products and estimate materials in production

28.3.3 Module Unit Summary and Time Allocation

PRODUCTION LINE PROCESSES

Code Sub-Module Content Theory Pract Time
Unit Hrs Hrs Hrs
28.3.1 Programming  Common system 2 4 6
programs
 Program specification
 Stages of programme
development
 Document the
program
28.3.2 Computer  Fundamentals
Program development
of 2 4 6
Aided Design  Structures
Computer ofAided
program
documentation
380
 Design
 Hardware in
Computer Aided
Design
 Computer graphics
software and database
28.3.3 Fundamentals  Application of 2 4 6
of Numerical Numerical Control
Control of  Basic components of
Machine Numerical Control
system
 Need for co-ordinate
drawing
 Need for reference of
drawing
 Plan of machining
operations
 Presentation of coded
data and interpretation
by the machine
control unit
 Numerical Control,
Direct Numerical
Control and Systems
28.3.4 Co-Ordinate  Standard X,Y,Z axes 2 4 6
System systems of machine
slide
 Supporting systems
 “Floating Zero”
datum point
 Difference between
absolute and
incremental
positioning
 Numerical Control
systems
28.3.5 Setting  Tool length offsets 2 4 6
Techniques  Techniques of
establishing work
datums
 Coding Proving
 Speeds and Feeds
 Part programme

381
 editing
 Fixing and clamping
28.3.6 Machine  Major components of 4 4 8
Structure and Numerical Control
Control machines
System  Operation of slide
elements
 Structure of drive
systems
 Accuracy and
reliability
 Digital signals applied
to control systems
used in feedback
 Operational
characteristics of
measuring devices
used to determine
position in the
feedback loop
28.3.7 Tooling  Concepts of pre-set 2 2 4
System and qualified tooling
 Use of Computer
Numerical Control,
control unit
 Organizational
requirements for tool
pre-setting station
 Tool identification
method
 Tooling identification
in library
28.3.8 Part  Binary layout 4 4 8
Programming  Variation of coded
information
 Word address format
 Advantages of using
floppy disks and
magnetic tapes
 storage
 speed of retrieving
 ease of editing
 Part Programming

382
  Simulate part
programs
28.3.9 Computer  Programming levels 4 4 8
Programming  Computing
Systems requirements for each
level
 Type of code output to
machine
 Benefits of computer
part programming
28.3.10 Numerical  Advantages of 4 4 8
Controlled Numerical Control
Machining machining
 Characteristics of
work suitable for
Numerical Control
machining
 Economic justification
of Numerical Control
 Savings in the use of
Numerical Control
machines
 Modern costing
techniques
28.3.11 Fundamentals  Definition of a robot 2 2 4
of Robots  Elements of a Robotic
System
 Needs for using robots
28.3.12 Types of  Robotic classification 1 2 3
Robots based on mechanical
configuration
 Freedom of motion
 Drive systems
 Control systems
 Functions
28.3.13 Performance  Performance 1 1 2
Capabilities of Capabilities
Robots Specifications
 Key Features of
Robots
28.3.14 Programming  Programming methods 4 5 9
Robots  Robot programming

383
 functions
 Robot programming
environment
 Programming
activities
 Basic types of robot
programming
languages
 On-line and off-line
programming
languages
28.3.15 Geometric  Geometric 1 1 2
Requirements requirements to
to Computer CAD/Robot linkage
Aided
Design/Robot
Linkage
28.3.16 Simulation  Simulation 2 2 4
28.3.17 Adaptive  Adaptive Control 1 1 2
Control
28.3.18 Robot  Robot Operation 1 1 2
Operation
28.3.19 End of Arm  End of arm tooling 1 1 2
Tooling
28.3.20 Application  Application of 1 1 2
Of Industrial industrial robots
Robots
28.3.21 Presentation  Presentation of work 1 1 2
Of Work to to robots in
Robots in production
Production
28.3.22 Product  Product design for 2 4 6
Design for automatic
Automatic manufacture by robots
Manufacture
By Robots
28.3.23 Project  Identification of 2 2 4
Planning different types of
charts
 Drawing of various
types of charts
 Application of various
types of charts

384
28.3.24 Production  Forecasting 4 2 6
Planning techniques
 Need for product
design and
development
 Stages of product
design and
development
 Computer-Aided
Process Planning
 Benefits of Computer-
Aided Process
Planning
28.3.25 Production  Objectives of 2 2 4
Control production control
 Activities involved in
production control
 Documentation used
in production control
 Types of inventories
and their functions
 Quality control
 Quality control
methods
 Quality control and
computer integrated
manufacturing
 Non contact
inspection methods
 Post process
metrology
Total Hours 54 66 120

28.3.01 PROGRAMMING By the end of the sub-

module unit, the
Theory trainee should be able
to:
28.3.01T0 Specific Objectives a) explain common
system programs

385
 b) explain what is - Document the
meant by program program
specification 28.3.01T4 Structures of program
c) state program documentation
development stages
d) explain structured Practice
programming
28.3.01P0 Specific Objective
28.3.01C Competence By the end of the sub-
The trainee should module unit, the
have the ability to: trainee should be able
i) Write a program to develop programs.
Execute a program
Content
Content 28.3.01P1 Program development
28.3.01T1 Common system in C++ and Intel
programs 8080/8086
- Monitor - Design programs
- Editor - Code programs
- Interpreter - Compile programs
- Compiler - Test programs
- Assembler - Document
- Debugger programs
- Linker
- Simulator/emulator 28.3.02 COMPUTER AIDED
- Utility DESIGN
28.3.01T2 Program specification
- Problem definition Theory
- Input
- Processes 28.3.02T0 Specific Objectives
By the end of the sub-
- Output
module unit, the
- Advantages/
trainee should be able
disadvantages
to:
28.3.01T3 Stages of programme
a) describe the
development in C++
fundamentals of
and Intel 8080/8086
Computer Aided
- Define the problem Design
- Design the data b) describe
- Design the program Computer Aided
- Code the program Design hardware
- Compile the systems
program
- Test the program

386
 c) describe computer - Operating input
graphics software and output devices
and databases 28.3.02T3 Computer graphics
software and database
28.3.02C Competence - Software
The trainee should configuration of
have the ability to: graphics system
i) Draw basic - Functions of
figures using computer graphics
computer aided - Database structure
design and content
ii) Combine basic - Wire-frame versus
figures to develop solid modelling
parts in Computer
Aided Design
iii) Present drawings Practice
in orthographic
projection 28.3.02P0 Specific Objectives
iv) Present working By the end of the sub-
drawings using module unit, the
Computer Aided trainee should be
Design able to:
v) Present drawing in a) Draw using
rectangular and Computer Aided
polar coordinates Design
b) Combine basic
Content figures to in
28.3.02T1 Fundamentals of Computer Aided
Computer Aided Design
Design c) Present drawings
- The design process in orthographic
- Applications of projection
computers for d) Prepare working
design drawings using
- Creating Computer Aided
manufacturing data Design
- Benefits of e) Prepare drawings
Computer Aided in rectangular and
Design polar coordinates
28.3.02T2 Hardware in Computer
Aided Design Content
- Design workstation 28.3.02P1 Basic figures
- Graphics terminals 28.3.02P1 Parts development

387
28.3.02P1 Orthographic presented in X, Y
projection and Z reference
28.3.02P1 Working drawings e) describe the role
preparation of planning the
28.3.02P1 Rectangular and polar machining
coordinates operations
f) describe how the
coded data is
presented and
interpreted by the
machine control
unit
g) describe the
differences
between
28.3.03. COMPUTER AIDED Numerical
MANUFACTURING - Control, Direct
FUNDAMENTALS Numerical Control
OF NUMERICAL and Computer
CONTROL OF Numerical Control
MACHINE TOOLS system

Theory 28.3.03C Competence

The trainee should
28.3.03T0 Specific Objectives have the ability to Plan
By the end of the sub- machining operation
module unit, the in coded data form
trainee should be able
to: Content
a) describe the 28.3.03T1 Application of
application of Numerical Control
Numerical Control - Metal cutting
in manufacture - Press work
b) explain the basic - Inspection
components of - Assembly
Numerical Control - Welding
system - Flame Cutting
c) explain the need 28.3.03T2 Basic components of
for drawings to be Numerical Control
presented with system
rectangular or
- Data
polar co-ordinates
Input/programming
d) explain the need
for drawings to be

388
 - Machine control z axes system of
unit/Central machine slide
processing unit displacement in
- Machine tools relation to varying
28.3.03T3 Need for co-ordinate tapes of
drawing Numerical Control
- Ease of machine
programming b) identify other
- Component supporting
geometry definition systems necessary
- Tool path for the operation
definition of Numerical
28.3.03T4 Need for reference of Control machine
drawing system
- Ease of c) describe “Floating
programming Zero‟ datum point
with respect to
- Component
programming and
geometry definition
work location.
- Tool path
d) describe the
definition
difference
28.3.03T5 Plan of machining
between absolute
operations
and incremental
28.3.03T6 Presentation of coded
positioning
data and interpretation
e) describe the three
by the machine control
basic types of
unit
Numerical Control
28.3.03T7 Numerical Control,
system
Direct Numerical
f) classify Numerical
Control and Computer
Control machines
Numerical Control
in terms of X, Y
system
and Z axes of
operation.
28.3.04 CO-ORDINATE
SYSTEM
28.3.02C Competence
The trainee should
Theory
have the ability to
identify the standard
28.3.04T0 Specific Objectives
and x, y, z axes
By the end of the sub-
system of machine
module unit, the
slide displacement in
trainee should be able
relation to varying
to:
tapes of Numerical
a) identify the
Control machine
standard and x, y,

389
 By the end of the sub-
Content module unit, the
28.3.04T1 Standard X,Y,Z axes trainee should be able
systems of machine to:
slide a) describe tool length
- Milling machine offset and how they
- Drilling machine are determined
- Lathe b) describe the
28.3.04T2 Supporting systems various techniques
- Spindle control of establishing
- Spindle speed work datums
- Feed rates c) explain the need
for and means of
- Tool changing
proving coding
- Coolant control
techniques
28.3.04T3 “Floating Zero” datum
d) explain selection of
point
speeds and feeds
- Consideration in for various
programming materials
- Work location e) edit part programs
28.3.04T4 Difference between of machine tool
absolute and f) describe clamping
incremental requirements for
positioning various types of
- Dimensioning of work
drawing
- Cutter location 28.3.05C Competence
with reference to The trainee should have
work the ability to fix and
28.3.04T3 Numerical Control clamp work on
systems Numerical Control
- Point to point machine
position control
- Line motion Content
control 28.3.05T1 Tool length offsets
- Contouring control - Drills
- Milling cutters
28.3.05T SETTING - Taps
TECHNIQUES - Lathe tools
28.3.05T2 Techniques of
Theory establishing work
datums
28.3.05T0 Specific Objectives 28.3.05T3 Coding Proving
- Dry run

390
 - Graphics construction of
- Use of soft Numerical Control
materials machines
28.3.05T4 Speeds and Feeds b) describe the
- Various materials operation of slide
- Operations elements on
- Tool cutting machines
materials c) describe the
28.3.05T4 Part programme structure of drive
editing systems in current
- Manual Data Input use on Numerical
(MDI) Control machines
d) compare the
- Saving of edited
accuracy and
programme on
reliability of
magnetic disks,
drives systems
removable storage
e) describe the
media, CD ROMs,
digital signal
and internet
applied to control
28.3.05T4 Fixing and clamping
systems used in
feed back
Practice
f) describe the
operational
28.3.05P4 Specific Objective
characteristics of
By the end of the sub-
the measuring
module unit the
devices used to
trainee should be able
determine position
to hold work on
in the feedback
Numerical Control
loop
machine
28.3.05C Competence
28.3.06T MACHINE
The trainee should have
STRUCTURE AND
the ability to operate
CONTROL
Numerical Control
SYSTEM
machine
Theory
Content
28.3.06T1 Major components of
28.3.06T0 Specific Objectives
Numerical Control
By the end of the sub-
machines
module unit, the
trainee should be able - Moving column
to: - Moving beds
a) describe the major - Moving slides
components in the - Moving quills

391
28.3.06T2 Operation of slide on Numerical
elements Control and
- Machines with Computer
electronic control Numerical
system Control machine
- Machine with b) describe the use
hydraulic control of a Computer
system Numerical
28.3.06T3 Structure of drive Control, control
systems unit
- Servo c) describe the
- Hydraulic organisational
- Electro-hydraulic requirements of
- Step motors tool pre-setting
28.3.06T4 Accuracy and station to be
reliability found on
Numerical
- Servo
Control centres
- Hydraulic
d) explain tool
- Electro-hydraulic identification
- Step motors method for pre-
28.3.06T5 Digital signals applied set tools located
to control systems in and automated
used in tool changer
feedback e) describe a method
28.3.06T6 Operational of identifying
characteristics of tools in a tool
measuring devices library
used to determine
position in the 28.3.07C Competence
feedback loop The trainee should
have the ability to:
28.3.07 TOOLING SYSTEM i) Pre-set tools on
Numerical Control
Theory and Computer
Numerical Control
28.3.07T0 Specific Objectives machine
By the end of the sub- ii) Arrange tools in
module unit, the magazine or turret
trainee should be able with respect to
to: machining
a) state the concept procedure
of pre-set and
qualified tooling Content

392
28.3.07T1 Concepts of pre-set Computer
and qualified tooling Numerical
28.3.07T2 Use of Computer Control machine
Numerical Control,
control unit Content
- Entry of tool data 28.3.07P1 Organizational
for pre-set and requirements for tool
qualified tooling pre-setting station
- Entry of tool offset - machining
and cutter diameter procedure
compensation to - Tooling for
guarantee complete presetting
accuracy - Handling of pre-set
28.3.07T3 Organizational tools
requirements for tool 28.3.07P2 Tooling sequence in
pre-setting station relation to machining
- Layout of station procedure
- Tooling for
presetting 28.3.08 PART
- Storage for pre-set PROGRAMMING
tools
- Handling of pre-set Theory
tools
28.3.07T4 Tool identification 28.3.08T0 Specific Objective
method By the end of the sub-
- Tool number module unit, the
station trainee should be
28.3.07T5 Tooling identification able to:
in library a) describe binary
- Tool coding layout of ISO
b) describe how coded
Practice information in
formatted blocks
28.3.07P0 Specific Objectives varies according to
By the end the sub- the machine control
module unit the trainee c) describe word
should be able to: address format
a) sequence tools d) state advantages of
with respect to using floppy disks,
machining magnetic tapes, and
procedure optical disks for
b) load tools on line programming
Numerical e) describe part
Control and programming

393
 - Use of sub-routines
28.3.08C Competence for fixed cycles
The trainee should - Use of canned
have the ability to: cycles
i) Convert decimal - Use of loops and
to binary numbers incremental values
system. with point to point
ii) Use floppy disks, functions
magnetic tapes, - Programming using
and optical disks tool radius offsets
in part to obtain sample
programming profiles
iii) Write part - Mixing of both
program rectangular and
iv) Edit part programs polar co-ordinates
v) Simulate part in profile work
programs - Special functions
(area clearance)
Content
- Simulate part
28.3.08T1 Binary layout
programs
28.3.08T2 Variation of coded
- G-SIMPLE
information
28.3.08T3 Word address format - SMARTCAM
28.3.08T4 Advantages of using - PRO-ENGINEER
floppy disks and
magnetic tapes Practice
28.3.08T5 storage
28.3.08T6 speed of retrieving 28.3.08P0 Specific Objectives
ease of editing By the end of the sub-
28.3.08T7 Part Programming module unit, the
- Languages (APT, trainee should be able
G CODES, M- to:
CODES GE- a) Convert decimal to
FANUC, and ISO binary numbers
CODES) system.
b) Use floppy disks,
- Point to point
magnetic tapes, and
motions, rapid and
optical disks in part
feed using
programming
rectangular co-
c) Write part program
ordinates
d) Edit part programs
- Point to point e) Simulate part
motions, rapid and
programs
feed using polar
co-ordinates

394
 Content
28.3.08P1 Binary layout 28.3.09T0 Specific Objectives
28.3.08P2 Use of floppy disks, By the end of the sub-
magnetic tapes, and module unit, the
optical disks in trainee should be able
storage of part to:
program a) state programming
28.3.08P3 Writing part program level suitable for
28.3.08P4 Part Programming given jobs
- Languages (APT, b) describe
G CODES and M- computing
CODES GE- requirements for
FANUC) each level of
- point to point programming
motions, rapid and c) state the type of
feed using computing
rectangular co- hardware and
ordinates software for given
- Use of sub-routines circumstances
for fixed cycles d) explain type of
- Use of canned code output to
cycles machine
- Use of loops and e) compare benefits
incremental values of computer part
with point to point programming with
functions manual
- Programming using programming
tool radius offsets
to obtain sample 28.3.08C Competence
profiles The trainee should
have the ability to
- Mixing of both
Compute
rectangular and
requirements for each
polar co-ordinates
level
in profile work
28.3.08P5 Simulate part - Interpolation:
programs Linear and circular
part surfaces
- G-SIMPLE
- SMARTCAM
Content
- PRO-ENGINEER 28.3.09T1 Programming levels
- contouring on two
28.3.09 COMPUTER
axes (2C)
PROGRAMMING
- contouring on two
SYSTEMS
axes and linear

395
 contour on one
axes (C) 28.3.10T0 Specific Objectives
- contouring on three By the end of the sub-
axes (3C) module unit, the
28.3.09T2 Computing trainee should be able
requirements for each to:
level a) state main
- Interpolation: advantages of
Linear and circular Numerical Control
part surfaces machining
28.3.09T3 Selection of computer b) describe the
hardware and software general
- Peripheral devices characteristics of
- Memory capacity work most
- Storage capacity suitable for
- Resolution Numerical Control
machining
- Speed of
c) state economic
processing
justification of
- Post processors
Numerical Control
- Capability software machining
- Capability of d) describe direct
micro-computer and indirect
system savings involved
- Working memory in the use of
- Storage capacity Numerical Control
- Speed of machines with
processing those of
28.3.09T4 Type of code output to conventional
machine machine
- ISO e) state modern
28.3.09T5 Benefits of computer costing techniques
part programming applied to
- Speed in production of
programming components on
- Computing Numerical Control
requirements machines
- Accuracy of
programmes 28.3.10C Competence
- Ease of editing The trainee should
have the ability to
28.3.10 NUMERICAL develop general
CONTROLLED characteristics of
MACHINING work most suitable

396
 for Numerical 28.3.10T5 Modern costing
Control machining techniques

Content 28.3.11 FUNDAMENTALS

28.3.10T1 Advantages of OF ROBOTS
Numerical Control
machining Theory
- Increased cutting
efficiency 28.3.11T0 Specific Objectives
- Reduction of By the end of the sub-
setting up time module unit, the
- Increased trainee should be able
production to:
flexibility a) define a robot
- Reduction of lead b) explain the
time elements of
- Improved quality robotic system
standards c) explain the need
28.3.10T2 Characteristics of for using robots
work suitable for
Numerical Content
Control machining 28.3.11T1 Definition of a robot
- Quantities 28.3.11T2 Elements of a Robotic
System
- Repeatability
- Components of
- Geometric shape
robot manipulator
(complexity)
- Control system
- High quality
standards - Computer system
28.3.11T3 Needs for using robot
- High quality metal
removal
28.3.10T3 Economic justification 28.3.12 TYPES OF
of Numerical Control ROBOTS
- Calculation of
Theory
machine hour rate
for Numerical
28.3.12T0 Specific Objectives
Control and
By the end of the sub-
conventional
module unit, the
machines
trainee should be able
28.3.10T4 Savings in the use of
to:
Numerical Control
a) classify robots
machines
based on
- Direct savings mechanical
- Indirect savings configuration

397
 b) classify robots 28.3.12T4 Control systems
based on 28.3.12T5 Functions
Freedom of - Generating the path
motion of motion for the
c) classify robots manipulator
based on Drive - Feedback devices
systems - Co-ordinate
d) classify robots transformation
based on Control - Safety controls
systems - Interfaces
e) describe the - Robot control
functions of through non-servo
control system in operation
robots
- Servo-controlled
robots
28.3.12C Competence
The trainee should have
Practice
the ability to identify
various types of robots
28.3.12P0 Specific Objectives
By the end of the sub-
Content
module unit, the
28.3.12T1 Robotic classification
trainee should be able
based on mechanical
to:
configuration
a) identify robots
- Rectangular co- based on
ordinate system mechanical
- Cylindrical co- configuration
ordinate system b) classify robots
- Spherical co- based on
ordinate system Freedom of
- Revolute co- motion
ordinate system c) classify robots
28.3.12T2 Freedom of motion based on Drive
- Roll systems
- Pitch d) classify robots
- Yaw based on Control
28.3.12T3 Drive systems systems
- Pneumatic actuator
systems Content
- Hydraulic actuator 28.3.12P1 Classification of robots
systems based on mechanical
- Electric actuator configuration
systems - Rectangular co-
ordinate system

398
 - Cylindrical co- The trainee should have
ordinate system the ability to perform
- Spherical co- various capabilities
ordinate system specifications of robots
- Revolute co-
ordinate system Content
28.3.12P2 Classification of robots 28.3.13T1 Performance
based on freedom of Capabilities
motion Specifications
- Roll - Axes of motion
- Pitch - Work envelope
- Yaw - Speed
28.3.12P3 Classification of - Acceleration
robots based on drive - Payload capacity
systems - Accuracy
- Pneumatic actuator - Resolution
systems - Repeatability
- Hydraulic actuator - Reliability
systems 28.3.13T2 Key Features of
- Electric actuator Robots
systems - Quality
28.3.12P4 Classification of - Serviceability
robots based on - Safety
control systems - Modularity
- Dexterity
28.3.13 PERFORMANCE
CAPABILITIES OF 28.3.14 PROGRAMMING
ROBOTS ROBOTS
Theory Theory
28.3.13T0 Specific Objectives 28.3.14T0 Specific Objectives
By the end of the sub- By the end of the sub-
module unit, the trainee module unit, the
should be able to: trainee should be able
a) describe the to:
performance a) explain
capability of a programming
robot methods
b) outline the b) describe robot
features of a robot programming
functions
28.3.12C Competence

399
 c) describe robot 28.3.14T0 Specific Objectives
programming By the end of the sub-
environment module unit, the
d) describe robot trainee should be able
programming to develop simple
activities programs to
e) describe basic manipulate robots
types robot
programming Content
languages 28.3.14T1 Programming methods
f) describe on-line - Guiding
and off-line - Teach pedant
programming - Off-line
languages programming
28.3.14C Competence
The trainee should have 28.3.15 GEOMETRIC
the ability to develop REQUIREMENTS
simple robot program TO CAD/ROBOT
LINKAGE
Content
28.3.14T1 Programming methods Theory
- Guiding
- Teach pedant 28.3.15T0 Specific Objective
- Off-line By the end of the sub-
programming module unit the trainee
28.3.14T2 Robot programming should be able to
functions outline the geometric
- World modelling requirements to
- Path generation Computer Aided
- Sensing Design/Robot linkage
- Programming
support 28.3.15C Competence
28.3.14T3 Robot programming The trainee should
environment have the ability to
28.3.14T4 Programming transform geometric
activities information into co-
28.3.14T5 Basic types of robot ordinates
programming
languages Content
28.3.14T6 On-line and off-line 28.3.15T1 Geometric
programming requirements to
languages Computer Aided
Design/Robot linkage
Practice

400
28.3.16 SIMULATION 28.3.17C Competence
The trainee should
Theory have the ability to
modify program
28.3.16 Specific Objective during operation
By the end of the sub-
module unit the trainee Content
should be able to 28.3.17T1 Adaptive Control
explain how
simulation is carried
out.
28.3.18 ROBOT
32.3.16C Competence OPERATION
The trainee should
have the ability to Theory
simulate robot
movement in tool 28.3.18T0 Specific Objective
change By the end of the sub-
module unit the trainee
Content should be able to
28.3.16T1 Simulation describe modes of
operation of a robot
Practice
28.3.18C Competence
28.3.16P0 Specific Objective The trainee should
By the end of the sub- have the ability to
module unit the trainee operate a robot to pick
should be able to a part and place in
simulate robot production
movement
Content
Content 28.3.18T1 Robot Operation
28.3.16P1 Simulation - Pick and place
- Point to point
28.3.17 ADAPTIVE - Continuous path
CONTROL - Controlled path

28.3.17T0 Specific Objective Practice

By the end of the sub-
module unit the trainee 28.3.18P0 Specific Objective
should be able to By the end of the sub-
explain adaptive module unit the
control in robots trainee should be able
to operate a robot

401
 By the end of the sub-
Content module unit the trainee
28.3.18P1 Robot Operation should be able to
- Pick and place describe applications
of industrial robots
28.3.19 END OF ARM
TOOLING 28.3.20C Competence
The trainee should
Theory have the ability to:
i) Operate a robot
28.3.19T0 Specific Objective in loading
By the end of the sub- ii) Operate a robot
module unit the trainee in machining
should be able to iii) Operate a robot
describe operation of in tool change.
end of arm tooling
28.3.19C Competence Content
The trainee should have 28.3.20T1 Application of
the ability to operate a industrial robots
robot to grip - Material handling
- Machine tending
Content - Welding
28.3.19T1 End of arm tooling - Arc welding
- Surface coating
Practice - Machining
- Assembly
28.3.19P0 Specific Objective
- Inspection
By the end of the sub-
module unit the trainee
Practice
should be able to
28.3.20P0 Specific Objective
operate end of arm
By the end of the sub-
tooling of robot
module unit the trainee
should be able to
Content
describe applications
28.3.19P1 End of arm tooling
of industrial robots
28.3.20 APPLICATION OF Content
INDUSTRIAL 28.3.20P1 Application of
ROBOTS industrial robots in
- loading
Theory
- machining
28.3.20T0 Specific Objectives - material handling

402
28.3.21 PRESENTATION The trainee should have
OF WORK TO the ability to design a
ROBOTS part for automatic
IN production.
PRODUCTION
Content
Theory 28.3.22T1 Product design for
automatic
28.3.21T0 Specific Objective manufacture by robots
By the end of the sub-
module unit the trainee Practice
should be able to
describe presentation 28.3.22P0 Specific Objectives
of work to robots in By the end of the sub-
production. module unit the trainee
should be able to
28.3.21C Competence design product for
The trainee should automatic manufacture
have the ability to by robots
present the work of
robots in production Content
28.3.22P1 Design product for
Content automatic manufacture
28.3.21T1 Presentation of work by robots
to robots in
production 28.3.23 PROJECT
PLANNING
28.3.22 PRODUCT DESIGN FOR
AUTOMATIC Theory
MANUFACTURE
BY ROBOTS 28.3.22T0 Specific Objectives
By the end of the sub-
Theory module unit, the
trainee should be
28.3.22T0 Specific Objective able to:
By the end of the sub- a) identify different
module unit the trainee types of charts
should be able to b) draw various types
describe product of charts
design for automatic c) apply various types
manufacture by robots of charts

28.3.22C Competence 28.3.25C Competence

403
 The trainee should b) prepare work
have the ability to: breakdown
i) Use Routing structures
techniques c) draw networks
ii) Use Scheduling d) determine
techniques critical paths of
iii) Use Loading networks
techniques e) techniques in
iv) Use quality control production
methods control
f) apply quality
control methods.

Content
28.3.23T1 Identification of Content
different types of 28.3.25P1 Routing in production
charts control
- Bar 28.3.25P2 Scheduling in
- Gantt production control
- Activity Sampling 28.3.25P3 Loading in production
- Critical Path control
Method (CPM) and 28.3.25P4 Quality control
Part Evaluation and
Review Technique Suggested Learning
(PERT) Resources
28.3.23T2 Drawing of various - Reference books
types of charts
28.3.22T3 Application of Content
various types of 28.3.23P1 Types of charts
charts - Bar
- Maintenance - Gantt
- Production - Activity
projects Sampling
- Draw Bar chart
Practice - Gantt chart
28.3.23P2 Prepare work break
28.3.23P0 Specific Objectives down structures
By the end of the 28.3.23P3 Draw a network
sub-module unit, 28.3.23P4 Determine the
the trainee should be Critical Path
able to: - Networks Critical
a) draw different Path Method
types of charts (CPM) and Part
Evaluation and

404
 Review Technique - optimization of
(PERT) manufacturing
process
28.3.24 PRODUCTION - reduction of costs
PLANNING - Simplification
- Scrap rates and
Theory efficiency factors
- Standardization
28.3.24T0 Specific Objectives - Specification
By the end of the sub-
- Market
module unit, the
requirement
trainee should be able
28.3.24T3 Stages of product
to:
design and
a) describe
development
forecasting
- Idea generation
techniques in
production - Preliminary
b) describe the need design
for product - Analysis
planning - Evaluation
c) state stages of - Functional design
product design and - Final Design
development - Prototyping
d) describe computer- - Production design
aided process 28.3.24T4 Computer-Aided
planning Process Planning
e) describe computer- - Automated process
aided process planning
planning - Retrieval type
process planning
28.3.24C Competence system
The trainee should have - Generative process
the ability to carry out planning systems
computer –aided process 28.3.24T5 Benefits of Computer-
planning Aided Process
Planning
Content
28.3.24T1 Forecasting techniques 28.3.25 PRODUCTION
- Qualitative CONTROL
- Quantitative
28.3.24T2 Need for product design Theory
and development
- optimization of 28.3.25T0 Specific Objectives
material resources

405
 By the end of the sub- - cost effectiveness
module unit, the 28.3.25T2 Activities involved in
trainee should be able production control
to: - Processing
a) explain the - Estimating
objectives of - Dispatching
production control - Programming
b) describe the 28.3.25T3 Documentation used
activities involved in production control
in production - Job cards
control
- Work order (route
c) describe the
card)
documentation
- Demand note
used in production
control - Control sheet
d) explain the types of - Internal delivery
inventories and note
their functions - Progress or move
e) explain quality note
control 28.3.25T4 Types of inventories
f) describe quality and their functions
control methods - Store size
g) describe quality - Buffer
control and - Anticipated
computer - Fixed reorder
integrated quantity system
manufacturing - Fixed time interval
h) describe non system
contact inspection 28.3.25T5 Quality control
methods - Need for quality
control
28.3.24C Competence - Total quality
The trainee should have management
the ability to carry out o Quality of design
Computer Aided o Selection of
Quality Control and appropriate
Computer Integrated process and
Manufacturing equipment
o Choice of
Content o Training of
28.3.25T1 Objectives of personnel
production control Equipment
- achievement of 28.3.25T6 Quality control
planned objectives methods

406
 - Statistical - Laser
- Part by part interferometric
analysis measuring system
28.3.25T7 Computer Aided - Laser telemetric
Quality Control and measuring system
Computer Integrated - Vision system
Manufacturing - Non-contact CNC
- Objectives of CMM
Computer Aided 28.3.25T9 Post process metrology
Quality Control
(CAQC) Practice
- The Computer in
Quality Control 28.3.25P0 Specific Objectives
(QC) By the end of the sub-
- Coordinate module unit, the
measuring machine trainee should be able
- Advantages of to:
Computer a) apply routing
Numerical Control techniques in
(CNC) operation of production control
Computer b) apply scheduling
- Integrated techniques in
Manufacturing production control
(CIM) - use loading
28.3.25T8 Non contact inspection Computers and
methods appropriate
software

29.3.0 FOUNDRY TECHNOLOGY

29.3.1 Introduction
This module unit has been designed to equip the trainee with the
necessary knowledge, skills and attitudes required in casting of
metallic and plastic components and machine parts. The graduates of
this module will be able to work in both formal and informal industrial
sectors.

Foundry technology is the study of producing components and

machine parts by casting. The process of casting involves pattern
making, making of moulds, melting and pouring of molten metal into
the moulds and fettling.

407
 In this module unit, various casting methods such as sand casting,
investment casting, shell moulding, die casting, centrifugal casting
and plastic moulding are covered.
The instructional approach will lay emphasis on demonstrations,
industrial visits, practical, project work and industrial attachment.
The assessment mode for this module shall be mainly practical.
Some of the reference materials for this module are listed at the end of
the module.

Trainees undertaking these modules require knowledge in engineering

materials, engineering drawing, bench work, fitting and machining.

29.3.2 General Objectives

By the end of the module the trainee should be able to:
a) practice safe working habits in foundry workshop
b) develop patterns for specific foundry applications
c) operate equipment used in various casting processes in the
workshop
d) produce high quality moulds for various casting processes
e) perform various casting processes
f) carry out quality control measures when casting
g) acquire skills necessary for proper use, care and maintenance of
tools and equipment in a foundry workshop

29.3.3 Module Unit Summary and Time Allocation

FOUNDRY TECHNOLOGY
Code Sub- Content Theory Pract Time
Module Hrs Hrs Hrs
29.3.01 Safety  Principles of 2 2 4
developing safety
policy
 Classes of fires
 Procedure of fire
fighting
 Causes of fire
29.3.02 Casting  Types of casting 4 4 8
Process processes

408
  Definition of sand
casting
 Steps in sand casting
29.3.03 Sand  Foundry tools and 2 2 4
Casting equipment
Tools and  Foundry tools and
Equipment equipment
29.3.04 Pattern  Types of patterns 4 4 8
Making  Pattern making
materials
 Pattern design
29.3.05 Moulding  Types of moulding 4 4 8
 Moulding processes
 Factors in selecting a
moulding process
 Testing methods for
moulds and
moulding sand
29.3.06 Core  Types of cores 4 4 8
Making  Core making and
baking process
 Tools and equipment
 Types of sand
29.3.07 Gating  Element of a gating 2 2 4
System system
 Types of gates
 Characteristics of
gates
29.3.08 Melting and  Melting process 4 4 8
Pouring  Types of melting
furnaces
 Pouring techniques
 Pyrometers
 Melt additives
29.3.09 Cleaning  Casting defects 4 4 8
and  Cleaning processes
Inspection  Testing and
inspection
29.3.10 Die Casting  Types of die design 4 6 10
 Types of die casting
processes
29.3.11 Centrifugal  Types of centrifugal 4 4 8

409
 Casting casting
 Centrifugal casting
process
29.3.12 Investment  Investment process 6 6 12
Casting  Types of investment
casting
 Design of investment
die
29.3.13 Shell  Process of shell 6 6 12
Moulding moulding
 Material used in shell
moulding
 Equipment in shell
moulding
29.3.14 Plastic  Processing methods 6 8 14
Processing  Types of plastics
Methods
Total Time 56 60 116

By the end of the sub-

module unit, the
trainee should be able
to:
a) explain the
principles of
developing an
effective safety
policy
b) identify different
types of fires
c) observe the
procedure of
fighting fires
d) explain causes of
fire in the foundry
workshop

29.3.01 SAFETY 29.3.01C Competence

The trainee should
Theory have the ability to
observe correct safe
29.3.01T0 Specific Objectives working procedures

410
 Content Theory
29.3.01T1 Principles of
developing safety 29.3.02T0 Specific Objectives
policy By the end of the sub-
29.3.01T2 Classes of fires module unit, the
- Class A trainee should be
- Class B able to:
- Class C (a) describe the types
- Class D of casting
processes
29.3.01T3 Procedure of fire (b) describe sand
fighting casting
29.3.01T4 Causes of fire (c) identify steps in
sand casting

Practice
29.3.01P0 Specific Objectives 29.3.02C Competence
By the end of the sub- The trainee should
module unit, the have the ability to
trainee should be able follow the correct
to: procedure for sand
a) identify different casting
types of fires
b) practice relevant Content
fire drills 29.3.02T1 Types of casting
processes
Content - Sand casting
29.3.01P1 Classes of fires - Special casting
- Class A processes
- Class B 29.3.02T2 Definition of sand
- Class C casting
- Class D 29.3.02T3 Steps in sand casting
29.3.01P2 Fire drills - Pattern making
- Moulding
Suggested Learning - Core making
Resources - Metal melting and
- Factories Act pouring
- Fire fighting - Cleaning and
equipment inspection

29.3.02 CASTING Practice

PROCESS
29.3.02P0 Specific Objectives

410
 By the end of the sub- b) describe the uses
module unit, the of various types of
trainee should be able tool and
to: equipment
a) identify steps in
sand casting 29.3.03C Competence
b) prepare sand for The trainee should
moulding have the ability to
c) operate sand select correct tools
shifting machine and equipments given
d) analyse sand for task
correct quality
Content
Content 29.3.03T1 Foundry tools and
29.3.02P1 Steps in sand casting equipment
- Pattern making - Hand tools
- Moulding o shovel
- Core making o handle
- Metal melting and riddle\Trowel
pouring - Mechanical tools
- Cleaning and o power riddles
inspection o sand mixers
29.3.02P2 Moulding preparation o sand aerator
29.3.02P3 Analyses - Containers
o moulding boxes
Suggested Learning o ladles
Resources o crucibles
- Casted models 29.3.03T2 Foundry tools and
equipment
29.3.03 SAND CASTING - Vent wire
TOOLS AND - Strike off bar
EQUIPMENT - Draw spike

Theory Practice

29.3.03T0 Specific Objectives 29.3.03P0 Specific Objectives

By the end of the sub- By the end of the sub-
module unit, the module unit, the
trainee should be able trainee should be able
to: to:
a) classify foundry a) identify the correct
tools and tools for a given
equipment task

411
 b) use the correct 29.3.04C Competence
tools The trainee should
have the ability to
Content produce a pattern for a
29.3.03P1 Tools and equipment given casting
identification
- Hand tools Content
o Shovel 29.3.04T1 Types of patterns
o Handle 29.3.04T2 Pattern making
riddle\Trowel materials
- Mechanical tools - Wood
o power riddles - Plasters
o sand mixers - Plastic and rubbers
o sand aerator - Metals
- Containers - Wipes
o moulding boxes 29.3.04T3 Pattern design
o ladles - Colours pattern
o crucibles making
29.3.03P2 Foundry tools and - Allowances in
equipment application pattern making
- Vent wire
- Strike off bar Practice
- Draw spike
29.3.04P0 Specific Objectives
Suggested Learning By the end of the sub-
Resources module unit, the trainee
- Sand casting tools should be able to:
a) select materials for
29.3.04 PATTERN pattern making
MAKING b) design a pattern for
a given casting
Theory
29.3.04T0 Specific Objectives Content
By the end of the sub- 29.3.04P1 Pattern making
module unit, the materials
trainee should be able - Wood
to: - Plasters
a) describe different - Plastic and rubbers
types of patterns - Metals
b) select materials for - Wipes
pattern making - Pattern allowance
c) design a pattern
- Colours pattern
for a given casting
making

412
 - types of moulding
Suggested Learning sand
Resources - moulding sand
- Models preparation
- Pattern materials - Floor moulding
- Wood working - Bench moulding
machines and tools - Shell
29.3.05T3 Factors in selecting a
29.3.05 MOULDING moulding process
- Size of casting
Theory - Material
- Shape
29.3.05T0 Specific Objectives - Complexity of
By the end of the sub- design
module unit, the 29.3.05T4 Testing methods (sand
trainee should be able and mould)
to:
- Permeability –
a) outline types of
calculating
moulding sands
permeability
and their
number
preparation
- Strength
b) describe various
moulding process - Moisture content
c) explain factors - Hardness
influencing the - Grain fineness test
selection of – calculating green
moulding process fineness number
d) describe the GFN
methods of testing
moulds and Practice
moulding sand
29.3.05P0 Specific Objectives
29.3.05C Competence By the end of the sub-
The trainee should module unit, the
have the ability to: trainee should be able
i) prepare a mould to:
and test it. a) prepare moulding
ii) Prepare moulding sand
sand b) analyse the content
of moisture in the
Content moulding sand
29.3.05T1 Types of moulding c) mix moulding sand
29.3.05T2 Moulding processes in good proportion

413
 Content - Core boxes
29.3.05P1 Moulding sand - Core machine
29.3.05P2 Moisture analyses - Blowing machine
29.3.05P3 Sand mixing - Core making and
baking
Suggested Learning 29.3.06T4 Core making and
Resources baking process
- Testing equipment
Practice
29.3.06 CORE MAKING
29.3.06P0 Specific Objectives
Theory By the end of the sub-
module unit, the
29.3.06T0 Specific Objectives trainee should be able
By the end of the sub- to:
module unit, the a) identify tools and
trainee should be able equipment used in
to: core making
a) describe different b) prepare core
types of cores making
b) explain types of c) test core making
sand for cores sand
making d) produce a core
c) identify tools and
equipment used in Content
core making 29.3.06P1 Tools and equipment
d) describe the - Core boxes
process of core - Core making
making and machine
baking - Blowing machine
29.3.06P2 Core making and
29.3.06C Competence baking
The trainee should 29.3.06P3 Tests
have the ability to 29.3.06P4 Core
make a given core and
bake it Suggested Learning
Resources
Content
- Tools and
29.3.06T1 Types of cores
equipment for core
- Balanced cores making
- Cover core
- Hanging core 29.3.07 GATING SYSTEM
29.3.06T2 Types of sand
29.3.06T3 Tools and equipment Theory

414
 29.3.07P0 Specific Objectives
29.3.07T0 Specific Objectives By the end of the sub-
By the end of the sub- module unit, the
module unit, the trainee should be to:
trainee should be to: a) design a gating
a) explain the system
elements of a b) produce a proper
gating system gating system for
b) outline the types of given cast design
gates
c) explain the Content
characteristics of 29.3.07P1 Design
gates 29.3.07P2 Gating system

Suggested Learning
29.3.07C Competence Resources
The trainee should have - Models
the ability to design a - Patterns
proper gating system for
a given task 29.3.08 MELTING AND
POURING
Content
29.3.07T1 Element of a gating Theory
system
- Riser 29.3.08T0 Specific Objectives
- Spruce By the end of the sub-
- Runner module unit, the
- Chrorinov‟s rule of trainee should be able
calculating to:
solidification time a) explain the
29.3.07T2 Types of gates process of melting
- Top gate various casting
- parting gate metals
- bottom gates b) describe various
29.3.07T3 Characteristics of types of furnaces
gates c) describe various
- Design of gating pouring
parameter techniques
o base diameter of d) outline melt
gates, area of additives
well depth e) describe various
temperature
Practice measuring
instruments

415
 By the end of the sub-
33.3.08C Competence module unit, the
The trainee should trainee should be able
have the ability to: to:
i) Melt molten a) identify correct
material and pour charges for a given
into a mould metal
Measure furnace b) light and operate
temperature melting furnaces
c) measure furnace
Content temperature
29.3.08T1 Melting process
- Charging Content
- Heating 29.3.08P1 Melting process
29.3.08T2 Types of melting - Charging
furnaces - Heating
- Open hearth 29.3.08P2 Types of melting
- Crucible furnaces
- Cupola - Open hearth
- Electric - Crucible
- Melting of ferrous - Cupola
and non ferrous - Electric
metals - Melting of ferrous
29.3.08T3 Pouring techniques and non ferrous
- Left hand pouring metals
- Right hand pouring 29.3.08P3 Pyrometers
- Up pouring - Thermocouple
- Bottom pouring pyrometer
- Tea pot - Optical pyrometer
- Melt additives - Radiation
- Fluxes pyrometer
- Alloying Elements
29.3.08T4 Melt additives Suggested Learning
29.3.08T5 Pyrometers Resources
- Thermocouple - Model
pyrometer - Furnace
- Optical pyrometer
- Radiation 29.3.09 CLEANING AND
pyrometer INSPECTION

Practice Theory

29.3.08P0 Specific Objectives 29.3.09T0 Specific Objectives

416
 By the end of the sub- Practice
module unit, the
trainee should be able 29.3.09P0 Specific Objectives
to: By the end of the sub-
a) identify various module unit, the
casting defects trainee should be able
b) describe methods to:
of inspection and a) perform non
testing castings destructive test on
c) explain various a casting
cleaning processes b) perform a visual
examination to
29.3.09C Competence establish cast
The trainee should defect
have the ability to: c) clean the casting of
i) Identify casting unwanted portions
defects
Carry out tests and Content
inspection on 29.3.09P1 Non destructive tests
casting 29.3.09P2 Visual Examination
29.3.09P3 Cleaning and
Content smoothening
29.3.09T1 Casting defects
- Slag inclusion Suggested Learning
- Shift Resources
- Cold shut and - Castings
misrun - Inspection tools
o cleaning/fettling - Cleaning tools
o knocking out of
dry sand cores 29.3.10 DIE CASTING
o removing gates
and risers Theory
o removal of fins
and unwanted 29.3.10T0 Specific Objectives
projections By the end of the sub-
o cleaning and module unit, the
smoothening of trainee should be able
castings to:
29.3.09T2 Testing and inspection a) outline the various
- Visual inspection types of die
- Dimensional casting processes
inspection b) identify various
29.3.09T3 Cleaning processes types of die design

417
29.3.10C Competence - Single impression
The trainee should die
have the ability to: - Multi impression
i) To produce a die
casting using die - Combination die
casting operation
ii) Design a die Suggested Learning
Resources
Content - Charts
29.3.10T1 Types of die casting
processes 29.3.11 CENTRIFUGAL
- Gravity die casting CASTING
process
- Pressure die casting Theory
o hot chamber
o cold chamber 29.3.11T0 Specific Objectives
29.3.10T2 Types of die design By the end of the sub-
- Single impression module unit, the
die trainee should be able
- Multi impression to:
die a) describe the
- Combination die centrifugal casting
process
Practice b) explain various
types of centrifugal
29.3.10P0 Specific Objectives casting process
By the end of the sub-
module unit, the 29.3.11C Competence
trainee should be able The trainee should
to: have the ability to
a) operate die casting produce a casting
machines using centrifugal
b) design die for process
moulding a given
casting Content
29.3.11T2 Centrifugal casting
Content process
29.3.10P1 Die casting machines 29.3.11T3 Types of centrifugal
- Gravity die casting casting
process - True centrifugal
- Pressure die casting casting
o hot chamber - Semi-centrifuging
o cold chamber - Centrifuging
29.3.10P2 Types of die design

418
 Practice b) design investment
die
29.3.11P0 Specific Objectives c) explain types of
By the end of the sub- investment
module unit, the casting
trainee should be able 29.3.12C Competence
to: The trainee should have
a) identify the type of the ability to design
centrifugal casting simple pattern for
machines investment casting
b) operate centrifugal
casting machines Content
29.3.12T1 Investment process
Content 29.3.12T2 Design of investment
29.3.11P1 Centrifugal casting die
process 29.3.12T3 Types of investment
29.3.11P2 Types of centrifugal casting
casting - Lost wax
- True centrifugal - Mercast
casting
- Semi-centrifuging Practice
- Centrifuging
29.3.12P0 Specific Objectives
Suggested Learning By the end of the sub-
Resources module unit, the
- Models trainee should be able
- Centrifugal casting to:
machine a) prepare materials
for investment
29.3.12 INVESTMENT casting
CASTING b) design investment
die
Theory
Content
29.3.12T0 Specific Objectives 29.3.12P1 Investment casting
By the end of the sub- process
module unit, the - Types of
trainee should be able investment casting
to: - Lost wax
a) outline various - Mercast
processes in
investment Suggested Learning
casting Resources
- Models

419
 b) Design a shell
29.3.13 SHELL mould
MOULDING
Content
Theory 29.3.13P1 Material for shell
moulding
29.3.13T0 Specific Objectives - Process of shell
By the end of the sub- moulding
module unit, the - Equipment in shell
trainee should be able moulding
to: - Material used in
a) Explain the process shell moulding
of shell moulding 29.3.13P2 Design
b) Describe
equipment used in Suggested Learning
shell moulding Resources
c) Outline casting - Shell mould
material for shell models
moulding - Tool and
equipment for shell
29.3.13C Competence moulding
The trainee should
have the ability to 29.3.13 PLASTIC
produce a casting PROCESSING
using shell moulding METHODS
process
Theory
Content
29.3.13T1 Process of shell 29.3.13T0 Specific Objectives:
moulding By the end of the sub-
29.3.13T2 Equipment in shell module unit, the
moulding trainee should be able
29.3.13T3 Material used in shell to:
moulding a) explain various
types of plastics
Practice b) outline the types of
plastics processing
29.3.13P0 Specific Objectives methods
By the end of the sub-
module, trainee should 29.3.11C Competence
be able to: The trainee should
a) Prepare material have the ability to
for shell moulding ability to produce
plastic articles using

420
 various plastic produce a
moulding processes component
b) operate a given
Contents plastic processing
29.3.13T1 Types of plastics plant
- Thermosetting
- Thermoplastics Contents
29.3.13T2 Processing methods 29.3.13P1 Types of plastics
- Compression - Thermosetting
moulding - Thermoplastics
- Transfer moulding 29.3.13P2 Processing methods
- Injection moulding - Compression
- Extrusion moulding
- Blow moulding - Transfer moulding
- Calendering - Injection moulding
- Vacuum moulding - Extrusion
- Blow moulding
Practice - Calendering
- Vacuum moulding
29.3.13P0 Specific Objectives:
By the end of the sub- Suggested /learning
module unit, the /resources
trainee should be able - Injection moulding
to: machine
a) select a given - Assorted moulded
plastic material to products

30.3.0 ENGINEEERING MATHEMATICS III

30.3.1 Introduction
This module unit is designed with knowledge, skills, techniques and
attitudes necessary to enhance the understanding other analytical areas
of study in this course. The module unit will also be very useful to
trainees who aspire to further their training in this course.

This module is a build up of Engineering Mathematics I and II of this

course. Trainees undertaking this module unit require to have
successfully completed Engineering Mathematics I and II of this
course or its equivalent. Timed tests, assignment, end of Module
examinations and any other suitable method are the recommended
mode of evaluation for this Module unit.

421
30.3.2 General Objectives
By the end of this module unit, the trainee should be able to:
a) apply mathematics concepts in fabrication design and data
analysis
b) organize, draw simple deductions and conclusions from the given
data
c) apply probability Mensurations in structural fabrication

30.3.3 Module Unit Summary and Time Allocation

ENGINEERING MATHEMATICS III

Code Topic Sub Topic Time
Hrs
30.3.01 Vector Field Theory  Definition of dot and cross 10
products of vectors
 Solution of problems
involving dot and cross
products of vectors
 Definition of operators
 Definition of vector field
 Solutions of problems
involving F
 Solutions of problems
involving curl F
 Definition of curl F
30.3.02 Matrices  Matrix operation 8
 Determinant of 3x3 matrix
 Inverse of 3x3 matrix
 Solution of linear
simultaneous equations in 3
unknowns
 Application of matrices
30.3.03 Numerical Methods  Definition of interpolation 6
and extrapolation
 Application of interpolation
and
 Application of interactive
methods to solve equations
 Application of interactive
methods to areas and volumes
30.3.04 Double And Triple  Definition of double and 8
Integrals triple integrals
 Use of multiple integrals to

422
 find areas and volume
 Consideration of double
integrals in polar and
cylindrical coordinates
 Use of triple integrals in
solving problems
30.3.05 Differential  Types of first order 10
Equations differential equations
 Formation of first order
differential equations
 Solutions of first order
differential equations
 Application of first order
8differential equations
 Formation of the second order
differential equations for
various systems
 Solution of second order
differential equations
 Application of second order
differential equations
30.3.06 Laplace Transforms  Definition of laplace 10
transforms Deriving laplace
transforms from first
principles
 State properties of laplace
transform
 Determination of inverse LT
of simple transforms and
partial fractions
 Solution of differential
equations by LT
 Solution of simultaneous
differential equations by
given initial conditions
30.3.07 Fourier Series  Determination of the fourier 10
series as a periodic function
of period 2 and extended to

 Determination of fourier
series of non-perodic
functions over a given range
 Determination of fourier

423
 series for even and odd
functions and the half-range
series for a given function
30.3.08 Loci  Definition of a point 4
 Locus of a point in relation to
a circle
 Loci of points for given
mechanism
Total Time 66

30.3.01 VECTOR FIELD

THEORY

Theory

30.3.01T0 Specific Objectives

By the end of the sub-
module unit, unit the
trainee should be able
to:
a) define dot and
gross products of
vectors
b) solve problems
involving dot and
cross products of
vectors
c) define operators
d) define vector field f
e) define curl f
f) define div f
g) solve problems
involving curl f
h) solve problems
involving div F

30.3.01C Competence
The trainee should
have the ability to
apply knowledge of

424
 vector field theory to problems in real
engineering life

Content 30.3.02C Competence

30.3.01T1 Definition of dot and The trainee should
cross products of have the ability to
vectors apply knowledge of
30.3.01T2 Solution of problems matrices to
involving dot and engineering
cross products of
vectors Content
30.3.01T4 Definition of operators 30.3.01T1 Matrix operation
30.3.01T5 Definition of vector 30.3.01T2 Determinant of 3x3
field matrix
30.3.01T6 Definition of curl F 30.3.01T3 Inverse of 3x3 matrix
30.3.01T7 Solutions of problems 30.3.01T4 Solution of linear
involving curl F simultaneous
30.3.01T8 Solutions of problems equations in 3
involving F unknowns
30.3.01T5 Application of matrices
30.3.02 MATRICES
Suggested Learning
Theory Resources
- Charts
30.3.02T0 Specific Objectives - Square boards
By the end of the sub-
module unit, unit the 30.3.03 NUMERICAL
trainee should be able METHODS
to:
a) carry out matrix Theory
operations
b) determine the 30.3.03T0 Specific Objectives
determinant of a By the end of the sub-
3x3 matrix module unit, unit the
c) determine the trainee should be able
inverse of a 3x3 to:
matrix a) define
d) solve linear interpolation and
simultaneous extrapolation
equations in 3 b) apply interpolation
unknowns extrapolation
e) apply knowledge of c) apply interactive
matrices in solving methods to solve
problems

425
 d) apply interactive b) use multiple
methods to areas integrals to find
and volumes areas and volume
c) consider double
30.3.03C Competence integrals in polar
The trainee should and cylindrical
have the ability to coordinates
apply knowledge of d) use triple integrals
Numerical methods in solving problems
to engineering
30.3.04C Competence
Content The trainee should have
30.3.03T1 Definition of the ability to apply
interpolation and knowledge of integrals
extrapolation to engineering
30.3.03T2 Application of
interpolation and Content
extrapolation 30.3.04T1 Definition of double
30.3.03T3 Application of and triple integrals
interactive methods to 30.3.04T2 Use of multiple
solve equations integrals to find areas
30.3.03T4 Application of and volume
interactive methods to 30.3.04T3 Consideration of double
areas and volumes integrals in polar and
cylindrical coordinates
Suggested Learning 30.3.04T4 Use of triple integrals
Resources in solving problems
- Graphs
- Calculators Suggested Learning
Resources
30.3.04 DOUBLE AND - Calculators
TRIPLE
INTEGRALS 30.3.05 DIFFERENTIAL
EQUATIONS
Theory
Theory
30.3.04T0 Specific Objectives
By the end of the topic, 30.3.05T0 Specific Objectives
unit the trainee should By the end of the
be able to: topic, unit the trainee
a) define double and should be able to:
triple integrals a) distinguish
different types of
first order

426
 differential 30.3.05T6 Solution of second
equations order differential
b) form first order equations
differential 30.3.05T7 Application of second
equation order differential
c) solve first order equations
differential
equations Suggested Learning
d) apply first order Resources
differential - Calculators
equations
e) form the second
order differential
equations
f) solve second order
differential
equations 30.3.06 LAPLACE
g) apply second order TRANSFORMS
differential
equations in Theory
different systems
30.3.06T0 Specific Objectives
30.3.05C Competence By the end of the
The trainee should topic, unit the trainee
have the ability to should be able to:
apply knowledge of a) define the laplace
differential equations transforms
to engineering b) derive the
transforms of
Content simple functions
30.3.05T1 Types of first order c) state the properties
differential equations of laplace
30.3.05T2 Formation of first transforms
order differential d) determine the
equations inverse of lt of
30.3.05T3 Solutions of first order simple forms and
differential equations partial fractions
30.3.05T4 Application of first e) solve differential
order differential equation by lt
equations f) solve simultaneous
30.3.05T5 Formation of the differential
second order equations by LT
differential equations given initial
for various systems conditions

427
 b) Determine the
30.3.06C Competence fourier series for a
The trainee should have non-periodic
the ability to apply function of the
Laplace transforms to range of 2π to π
engineering c) Determine fourier
series for even and
Content odd functions and
30.3.06T1 Definition of laplace half-range series
transforms for a given
30.3.06T2 Deriving laplace function
transforms from first
principles 30.3.07C Competence
30.3.06T3 State properties of The trainee should
laplace transform have the ability to
30.3.06T4 Determination of apply fourier series to
inverse LT of simple engineering
transforms
and partial fractions Content
30.3.06T5 Solution of differential 30.3.07T1 Determination of the
equations by LT fourier series as a
30.3.06T6 Solution of periodic function of
simultaneous period2π and
differential equations extended to π
by given initial 30.3.07T2 Determination of
conditions fourier series of non-
perodic functions
Suggested Learning over given range
Resources 30.3.07T3 Determination of
- Laplace tables fourier series for
even and odd
30.3.07 FOURIER SERIES functions and the
half-range series for a
Theory given function

30.3.07T0 Specific Objectives 30.3.08 LOCI

By the end of the
topic, unit the trainee Theory
should be able to:
a) Determine the 30.3.08T0 Specific Objectives
fourier series of a By the end of the
periodic function topic, unit the trainee
of period 2π and should be able to:
extended to π

428
 a) define the locus of Content
a point 30.3.08T1 Definition of a point
b) determine the locus 30.3.08T2 Locus of a point in
of a point in relation to a circle
relation to a circle 30.3.08T3 Loci of points for
c) calculate loci of given mechanism
parts for given
mechanisms
Suggested Learning
30.3.08C Competence Resources
The trainee should - Charts
have the ability to - Scientific
apply loci to calculators
engineering

31.3.0 TRADE PROJECT

31.3.1 Introduction
This module unit is intended to equip the trainee with knowledge,
skills and attitudes to enable him/her research, design, develop,
produce a component and write a report on the project.

31.3.2 General Objectives

By the end of the module unit, the trainee should be able to:
a) state the scope of the project
b) outline the design procedure and provide possible solutions to the
task

429