indo-german tool room aurangabad- (maharashtra state… · 2015 indo-german tool room aurangabad-...

2015

INDO-GERMAN TOOL ROOM AURANGABAD- (MAHARASHTRA STATE) GOVT. OF INDIA

CURRICULUM DOCUMENT FOR CERTIFICATE COURSE IN MACHINE MAINTENANCE

TRADE

IGTR/DGET/CCMM/CURRICULUM

Page 1 of 34

INDEX

PART

PARTICULARS

PAGE NO.

I General Information 2

II Course information: Certificate

Course in Machine maintenance

3

III Curriculum Philosophy 4

IV Course Structure 9

V First Semester: Course Details 11

VI Second Semester: Course

Details

30


Page 2 of 34

GENERAL INFORMATION

1. Name of the Trade : CERTIFICATE COURSE IN

MACHINE MAITENANCE

2. NCO Code No. :

3. Duration of Craftsmen Training : One year (Two semesters each of six

Months duration)

4. Power Norms : 3.7 Kw.

5. Space Norms : 69 Sq. Mtrs [ 100 Sq. M. in actual]

6. Entry Qualification : Passed 10th

7.Trainees per unit : 20(Max. Supernumeraries seats :5)

8a. Qualification for Instructor : Degree in Mechanical Engineering from

Recognized university with one year

Post qualification experience in the

Relevant field.

OR

Diploma in Mechanical Engineering

from a recognized board of technical

education with two year post

qualification experience in the relevant

field.

Note:

Distribution of training on Hourly basis: Total hours

/week

Trade practical Trade

theory

Work shop

Cal. &Sc.

Employability

skills

Extra

curricular

activity

40 Hours 28Hours 6 Hours 2 Hours 2 Hours 2 Hours


Page 3 of 34

COURSE INFORMATION

1. Introduction:

This course is meant for the candidates who aspire to become a professional

Machine maintenance operator.

2. Terminal Competency/Deliverables:

After successful completion of this course the trainee shall be able to perform the following skills with proper sequence.

1. Trainees will work as a maintenance operator in industry 2. Preventive maintenance & breakdown maintenance 3. Knowledge of Conventional machines 4. Knowledge of Technical English terms used in industry.

3. Employment opportunities:

On successful completion of this course, the candidates shall be gainfully employed

in the following industries:

1. Production & Manufacturing industries.

2. Structural Fabrication like bridges, Roof structures, Building & construction.

3. Automobile and allied industries

4. Service industries like road transportation and Railways.

5. Ship building and repair

6. Infrastructure and defense organizations

7. In public sector industries like BHEL, BEML, NTPC, etc and private industries in

India & abroad.

8. Self-employment

4. Further learning pathways:

On successful completion of the course trainees can pursue Apprenticeship training in the reputed Industries / Organizations.

On successful completion of the course trainees can opt for IGTR Diploma course/or its equivalent.

On successful completion of the course trainees can opt for CITS course.


Page 4 of 34

CURRICULUM PHILOSOPHY

The Indo German Tool Room, Aurangabad has been introduced the rational process of

curriculum development. This rationale for the curriculum development is based on the

following basics:

1. The scientific principles embodied in Theories of Learning, Educational Technology,

curriculum development.

2. Social Surveys to identify the job description of a diploma holder in the Tool and Die

Making / using industry.

3. The contents design of the entire curriculum.

4. Resource requirement for implementing the curriculum.

While developing the curriculum, the following factors also taken into consideration to the

maximum extent possible.

- The vast experience obtained from

Centre Tool Room, Ludhiana

Indo-German Tool Rooms, Ahmedabad, Indore & Aurangabad.

- The expectations of Industries.

The overview of design of curriculum process followed is given below:

- Aims & objectives of course have been derived from the job description.

- The curriculum areas are identified on the basis of aims and objectives of the course.

- On identifying the curriculum areas, these are classified into discipline & non-

discipline subjects.

- Graphical structure of the contents of entire subjects is derived from the subjects

objectives and identifies its concepts, principles, procedures and problems to be

dealt with by the subject and its organisation designed to achieve subject objective.

- Identified units & chapters from the graphical structure and the subject is divided

semester wise.

- The detail contents of each chapter derived linking to the subject objective.

Accordingly the trainer Guide 1 (Curriculum documents for subject level) has been

designed for all the subject areas.


Page 5 of 34

In this syllabus, only the overall structure of the course with objectives, Horizontal &

Vertical organisation of subjects with time and the unit & chapter level of each subject

are given. The evolving approach to student’s evaluation is also derived.

THEORY AND PRACTICAL HOURS

TOTAL NO. OF HRS IN 2 SEMESTERS = 1920 Hrs

TOTAL NO. OF HRS THEORY = 220 Hrs

TOTAL NO. OF HRS PRACTICE & LABS = 1700 Hrs


Page 6 of 34

EDUCATIONAL OBJECTIVES

I. To Design & manufacture indicate Tools like Press Tools, Plastic Moulds, Die

Casting Dies, Jigs Fixtures & Gauges etc. independently by using conventional,

CAD/CAM & CNC Technologies.

II. To work as competent employee in industry and business

III. To set up an own enterprise

IV. The apply knowledge, skills & attitudes (core) through the relevant Theoretical

subjects needed to perform the above task effectively & efficiently.

V. The individual development with sspecial emphasis on cultural values &

personality development.


Page 7 of 34

NO. OF HRS CATEGORY WISE FOR CERTIFICATE COURSE IN MACHINE

MAINTENANCE

INDO GERMAN TOOL ROOM, AURANGABAD


Page 8 of 34

SYSTEMS APPROACH CHART

SKILLS VALUES

Liaison

Designing

Estimating

Production Planning

Independent skill in

operation of machines

Independent skills

Formative Evaluation

Summative Evaluation

Maintenance

Entrepreneurial

Social Skill

Personal Development

System Orientation

Customer Needs

Productivity

Employee welfare

Precise Communication

Quality

Safety

Environmental

protection

Inquisitiveness

Initiative

Innovativeness

Society needs

Personal development

STRUCTURING OF BROAD CATEGORIES OF SUBJECTS DERIVED FROM CURRICULUM

OBJECTIVES

ENGINEERING SCIENCE. CORE TECHNOLOGY TECHNOLOGY

SUBJECT /

COURSE

MAPPING

Material Technology Workshop Technology

Engg. Drawing

Engg. Metrology

Basics of mechanical

maintenance

Workshop practice

Maintenance practice

Communication skill

Sociology

Entrepreneurship through blended

learning

Primarily – (social/person

context)

Independent operation of

machines

Supervision of production

Production Planning

Also

Design of Tools

Orientation towards system

up gradation

Capable on the job learning

Later

Overall supervision of Tool

Room

-Career

development:

Higher

Qualification

Start own

Business

Move to Medium

& large industries

Move within the

organization

CURRICULIM OBJECTIVES


Page 9 of 34

COURSE STRUCTURE

ADVANCE CERTIFICATE COURSE IN CNC MACHINING

IST Semester

Sr.

No.

Subject

code Subject Name

Teaching

Scheme/ No. of

Hours

Examination Scheme

Theory Practice

Theory Practice

Total

Marks

Sessional Semester

Exam

Sessional Semester

Exam

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

1 WORK SHOP

PRACTICE (PR) 280 0 0 0 0 160 80 240 120 400

2

ENGINEERING

DRAWING (TH

& PR)

80 80 40 20 60 30 0 0 0 0 100

3 ENGNEERING

METROLOGY 20 20 40 20 60 30 0 0 0 0 100

4 MATERIAL

TECHNOLOGY 40 - 40 20 60 30 0 0 0 0 100

5 WORKSHOP

TECHNOLOGY 80 - 40 20 60 30 40 20 60 30 100

6

BASICS OF

MECHANICAL

MAINTENANCE

40 - 40 20 60 30 0 0 0 0 100

7 MAINTENANCE

PRACTICE - 320 0 0 0 0 400 200 0 0 400

260 700 1300

1


Page 10 of 34

CERTIFICATE COURSE IN MACHINE MAINTENANCE

IIND Semester

Sr.

No.

Subject

code Subject Name

Teaching

Scheme/ No. of

Hours

Examination Scheme

Theory Practice

Theory Practice

Total

Marks

Sessional Semester

Exam

Sessional Semester

Exam

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

Max.

Marks

Min

to

pass

1

INPLANT

TRAINING

(LIVE

PROJECTS) ON

MAINTENANCE

PRACTICE

- 960 0 0 0 0 0 0 600 300 600

600


Page 11 of 34

FIRST SEMESTER: COURSE DETAILS



Page 12 of 34

Syllabus for the Trade of CCMM

First Semester

Duration: Six Month

Workshop Practice

Week

No.

Trade Practical Trade Theory

1.

Introduction & visit to training workshop of

organization

Introduction To Workshop Technology

2.

Giving the information of safety in

organization

Giving information about personal protective

equipment’s

Introduction To Hand Tools (Hand Cutting

Tools), Measuring Tool, Equipments & Their

Uses & Applications.

Safety Precautions

3.

Demo & practice on Hand Tools (Hand

Cutting Tools), Measuring Tool, Equipments

& Their Uses & Applications.

Metal Working Technique Using Hand Tools

4. Demo & practice on Basic Metal Cutting

Operations Using Hand Tools, Sheet Metal

Work, Manufacturing Useful Products.

Metal Working Technique - Joining

5. Demo & practical on Basic Metal Cutting

Operations Using Hand Tools, Sheet Metal

Work, Manufacturing Useful Products.

Metal Working Technique - Hot Forming

6 Demo & practice on Drilling Machines

(Bench, Pedastal, Portable)

Drilling Operations & Drilling Machines


7 Demo & practice on Drilling Machines


Drilling Operations & Drilling Machines


8 Demo & practice on Column And Radial

Drilling Machines

Drilling Operations And Drilling Machines

9 Demo & practice on column & radial drilling

machine

Column And Radial Drilling Machines

Parts of Column And Radial Drilling

Machines

Accessories of Column And Radial Drilling

Machines


Page 13 of 34

10 Demo & practice on all types of accessories

used on drilling machines.

Drilling Operations And Drilling Machines

Basic Knowledge Of Working Principle Of

drilling Machine, Various Parts Of Machine &

Their Functioning, Use Of Various

Accessories & Attachments For Work Holding

& Tool Holding.

Knowledge Of Calculating Metal Cutting

Parameters.

11 Demo & practice on Gang Drilling & Special

Drilling Machines using different cutting

parameters

(Gang Drills & Special Drilling Machines)


Lathe Machine, Various Parts Of Machine &



& Tool Holding.

Knowledge & Basic Skills For Various Turning

Operations.


Parameters.

12 Demo & practice on shaper machine using

different cutting parameters

Shaping Operations And Shaper


shaper Machine, Various Parts Of Machine &



& Tool Holding.

Knowledge & Basic Skills For Various

shaping Operations.


Parameters.

13 Demo & practice sawing and power hack saw

machines using different cutting parameters

Sawing Operation And Power Hacksaw


sawing Machine, Various Parts Of Machine &



& Tool Holding.

Knowledge & Basic Skills For Various


Page 14 of 34

14 Demo & practice band saw machines using

different cutting parameters

Sawing Operation And Bandsaw


bandsaw Machine, Various Parts Of Machine

& Their Functioning, Use Of Various


& Tool Holding.


Parameters.

15 Demo & practice on tool sharpening on hand

grinding & pedestal grinding

Hand Grinding Operations And Pedestal

Grinder


Milling Machine, Various Parts Of Machine &


Accessories & Attachments For Work

Holding & Tool Holding. Knowledge & Basic

Skills For Various Milling Operations.


Parameters.

16 Demo & practice on lathe machine for

different operations

Turning Operation And Lathe


lathe Machine, Various Parts Of Machine &



& Tool Holding. Knowledge & Basic Skills For

Various Milling Operations.


Parameters.

17 Demo & practice on milling machine for

different operations

Milling Operations And Milling Machine








Parameters.


Page 15 of 34

EXAMINATION SCHEME:

SESSIONAL MARKS

(160 Marks)

SEMESTER MARKS

(240 Marks)

TOTAL MARKS

(400 Marks)

Minimum Pass Marks

Product / practical

Exercises

(100Marks)

Planning Processes Documents

(30 Marks)

Viva- Voce/ Presentation

(20 Marks)

Work book assignment and Behavior (10 Marks )

Semester Examination

(240 Marks – 10 Hrs Duration)

Sessional

Semester

50% 50%

Evaluations of any one parts of the tool of each group

One Process Planning Sheet of any one parts of the tool

Viva-Voce at regular interval during Practical work

Average of semesters Total Viva-Voce marks

One assessment weekly 10 marks each.

Total obtain weekly assessment marks to be converted into out of 10 Marks for final sessional marks.

Examination at the end of Semester covers entire skills as per syllabus.

eligible to write in final exam only after obtaining minimum Sessional

80 Marks 120

Marks

18 Demo & practice on milling machine for

different operations.

Milling Operations And Milling Machine








Parameters.

19 Demo & practice on Column Knee Type

[Vertical And Horizontal] Milling Machine

Column Knee Type [Vertical And Horizontal]

Milling Machine

Parts of Column Knee Type [Vertical And

Horizontal] Milling Machine

20 Preventive Maintenance & Care Of Bench

Tools & Machine Tools.

(Column Knee Type [Vertical And Horizontal]

Milling Machine)

21 Revision


Page 16 of 34

Engineering Drawing

Week

No.


1.

Demo & practice of required engineering

drawing instruments

Introduction

Introduction And Observation Of Engineering

Drawing Practices In The Tool Room

Environment And Manufacturing Industry.

Introduction To Engineering Drawing & Its

Importance

Introduction To Iso & Bis

2.

Practice Exercises by showing drawing sheet

size & how to draw the layout of drawing

Std. Drawing Sheets & Sizes

Different Std. Sizes Of Drawing Sheets

Layout Of Drawing Sheets

3.

Practice Exercises layout Of Drawing Sheets

Std. Drawing Sheets & Sizes

Different Std. Sizes Of Drawing Sheets

4. Practice Exercises Of Lettering & Sentence

Writing

Lettering & Numbering

Introduction To Lettering.

Types Of Lettering

Relationship Between Size Of Letter And

Space Between Letters

Factors For Selection Type And Size Of

Letters

5. Practice Exercises Of Lettering & Sentence

Writing



Types Of Lettering




Letters

6 Practice Exercises Of Lettering & Sentence

Writing



Types Of Lettering





Page 17 of 34

Letters

7 Practice Exercises

Types Of Lines

Lines

Introduction To Lines.

Types Of Lines

Application Of Lines

Factors For Selecting Types Of Line

8 Practice Exercises



Lines Introduction To Lines.

Types Of Lines



Practice Exercises

9 Practice Exercises (Linear, Circular, Angular)

Principles Of Dimensioning

Methods Of Dimensioning

Indication Of Dimensioning

Rules Of Dimensioning

Procedure Of Dimensioning

Dimensioning

Introduction Of Dimension

Definition Of Dimension

Functional Dimensions

Nonfunctional Dimensions

Auxiliary Dimensions






Practice Exercises (Linear, Circular, Angular)

10 Practice Exercises on (Linear, Circular,

Angular)






Dimensioning

Introduction Of Dimension

Definition Of Dimension

Functional Dimensions

Nonfunctional Dimensions

Auxiliary Dimensions





Page 18 of 34

11 Practice Exercises on Scales

Full

Reduced

Enlarged

Scales

Introduction

Definition Of Drawing To Scale

Full

Reduced

Enlarged

Factors For Choice Of Scale

Purpose, Actual Size, Size Of Sheet

Bis Norms

Procedure For Drawing To Scale

12 Practice Exercises on Scales



Bis Norms


Scales

Introduction

Definition Of Drawing To Scale

Full

Reduced

Enlarged



Bis Norms


13 Practice Exercises On

Straight Lines Angles Polygons Circles / Arcs

Definition, Principle, Procedures

Geometrical Construction

Introduction To Simple & Advanced


Definition, Principle, Procedures, Exercise Of

Simple Geometrical Construction



Advanced Geometrical Construction Conic

Section - Ellipse, Parabola, Hyperbola

Other Curves - Helix, Cycloid, Involutes

14 Practice Exercises On





Introduction To Simple & Advanced



Simple Geometrical Construction



Page 19 of 34





15 Practice Exercises on

Exercises On Oorthographic Projection Of 1st

& 3rd Quadrants Points Lines In Different

Positions To Planes Planes In Different

Positions To Planes Solids In Different

Positions To Planes

Principle Of Projections & Orthographic

Projections

Introduction To Orthographic Projection.

Definition Of Orthographic Projections Points,

Lines, Planes & Solids Principles Of

Quadrants & Planes Principles Of Different

Views

Procedure For Drawing Different Views Of

Points, Lines, Planes & Solids (1st & 3rd

Quadrants)

16 Practice Exercises on

Exercises On Oorthographic Projection Of 1st

& 3rd Quadrants Points Lines In Different

Positions To Planes Planes In Different

Positions To Planes Solids In Different

Positions To Planes

Principle Of Projections & Orthographic

Projections

Introduction To Orthographic Projection.

Definition Of Orthographic Projections Points,

Lines, Planes & Solids Principles Of

Quadrants & Planes Principles Of Different

Views

Procedure For Drawing Different Views Of

Points, Lines, Planes & Solids (1st & 3rd

Quadrants)

17 Practice Exercise

Method Of Drawing The Conventional

Representation Of Different Materials

Conventional Representation Of Materials



18 Practice Exercise on







Page 20 of 34

EXAMINATION SCHEME: SESSIONAL MARKS SEMESTER

MARKS

TOTAL MARKS

(100 Marks)

Minimum Pass Marks

(40 Marks) (60 Marks)

Internal Assessment (30 Marks – 1 Hour Duration)

Internal Assignments & Attendance & Discipline

(10 Marks)



Sessional

50%

Semester

50%

Three Assessments at regular intervals as specified in syllabus detailed Programme.

Average of best of two assessments to be considered for final Sessional marks

Class work books & home assignment books checked before the each Assessments.

Attendance & Discipline of the student evaluated by the Teacher before each Assessment.

Average of best of two assignments to be considered for final Sessional marks.

Final Examination at the end of Semester covering entire syllabus of the

Semester. Student is eligible to write in final exam only after

obtaining minimum Sessional Marks.

20 Marks

30 Marks













21 Revision

22 Examination

SESSIONAL THEORY: 40; END-TERM (TH): 60;


Page 21 of 34

Engineering Metrology

Week

No.


1.

Visit of igtr & giving information about all

measuring instruments used in industries

Introduction To Engineering Metrology

Scope & Need Of Metrology.

Objectives Of Metrology.

General Care Of Equipment.

2.

Demo on international system of units used

for measuring instruments

Terminology Used In Metrology.

Measuring Range.

International System Of Units.

3.

Showing different measuring instruments for

repeatability & sensitivity

Readability.

Sensitivity.

Repeatability.

4. Demo & practice on Steel Rule Accuracy.

Precision.

Uncertinity Of Measurement : Calibration.

Steel Rule

5. Demo & practice on Types Of Calipers. Concept : Application & Procedure.

Calipers

6 Demo & practice on Vernier Caliper

Description Application & Procedure.

Vernier Caliper

Reading The Vernier Scale.

7 Demo & practice on Reading The Vernier

Scale.

Least Count.

Errors Observed In Vernier

Precautions In The Case Of V.C. &

Procedure.

8 Demo & practice on Vernier Height Gauge.

Reading Height Gauge

Precautions In The Case Of V.C. &

Procedure.

Description Of Parts & Requirements.

Precautions In The Use Of Height Gauge.


Page 22 of 34

9 Demo & practice on outside Micrometer.

Test For Accuracy & Procedure.

Micrometer.

Description Of Parts, Reading Of Micrometer.

10 Demo & practice on inside Micrometer.

Ratchet Stop Mechanism, Possible Errors.

Precaution, Use Of Micrometer & Procedure.

Description Of Parts, Reading Of Micrometer

11 Demo & Practice On Surface Plate Surface Plate

Matl. Cast Iron & Graphite.

Sizes & Accurancy.

Care,Use Of S.P. & Procedure.

12 Demo & Practice On Surface Plate Care,Use Of S.P. & Procedure.

Sizes & Accurancy.

Application, Care,Use Of Angle Plate.

V' Block.

13 Demo & Practice On

Try Square/Engg.

Straight Edge.

Radius Gauge.

Feeler Gauge.

Try Square/Engg.

Straight Edge.

Radius Gauge.

Feeler Gauge.


Pitch Screw Gauge.

Bevel Protractor

Pitch Screw Gauge.

Bevel Protractor

Description Of Parts.

Application.


Combination Set.

Combination Set.

Application Care & Procedure.

16 Demo & Practice On different types of errors

in measuring instruments

Introduction To Errors.

Types Of Errors: Controllable Errors, Static

Errors, Random Errors.

Concept Of Precision & Accuracy.

Definition & Symbols.

17 Practice Of Gd & T Symbols Straightness, Flatness, Parallelism,

Circularity, Cylindricity, Concentricity,.Co-

Axiality, Ovality, Lobbing, Angularity,

Roundess.

Introduction To Limits & Fits.


Page 23 of 34

EXAMINATION SCHEME: SESSIONAL MARKS SEMESTER

MARKS

TOTAL MARKS

(100 Marks)

Minimum Pass Marks




(10 Marks)



Sessional

50%

Semester

50%









20 Marks

30 Marks

Interchangeability.

Limit Of Size(Min. & Max.).

Types Of Fit

Clearance Fit, Transition Fit, Interference Fit.

18 Practice On Limits Fits & Tolerances Terminology For Limits & Fits.

Shaft, Hole, Basic Nominal Size, Actual Size.

Deviation: Lower Deviation, Upper

Deviation.

Fundamental Deviation.

Basic Shaft, Basic Hole, Tolerance Zone.

19 Practice On Limits Fits & Tolerances Hole Basis System

Shaft Basis System

Introduction To Gauges

Definition.

20 Practice On Limits Fits & Tolerances Classification Of Gauges.

According To Type, According To Purposes,

According To Form Of Tested Surfaces,

According To Design.

Advantages Of Gauges.

21 Revision


Page 24 of 34

Material Technology

Week

No.


1.

Demo & Discuss Practical Applications Of

Aluminum & Its Alloys

Introduction And Characteristics Of Aluminum

Properties Of Al Alloys Effect Of Alloying

Elements In Aluminum Uses Of Aluminum

And Its Alloys

2.


Aluminum & Its Alloys

Classification Of Aluminum Alloys Heat

Treatment Of Aluminum Properties Of

Magnesium

3.


Magnesium

Properties And Application Of Magnesium

Alloys

Various Type Of Magnesium Alloys

4. Demo & Discuss Practical Applications Of

Zinc

Properties Of Zinc Application Of Zinc Zinc

Alloys

5. Demo & Discuss Practical Applications Of

Lead

Properties Of Lead Use And Application Of

Lead

Available Form Of Lead Lead Alloys

6 Demo & Discuss Practical Applications Of

Copper

Main Grades Of Raw Copper Properties Of

Copper

Application Of Copper


Brass

Effects Of Alloying Elements In Copper,

Copper Alloys Classification Of Copper Alloys

Brass


Bronze

Bronze Gun Metal Bearing Material

9 Demo & Discuss Practical Applications Of Tin Properties Of Tin Tin Alloys


Nickel

Properties Of Nickel Use Of Nickel Various

Type Of Nickel Alloys

11 Identify The Ceramic Materials Available In

The Market

Properties Of Ceramic Materials Various

Type Of Ceramics And Their Properties

Introduction Of Refractories

12 Applications Of Refractories Properties Of Refractories Classification Of


Page 25 of 34

Refractories Consumer Of Refractories

13 Applications Of Different Types Of Polymers

In Day To Day Life

Characteristics Of Polymer Modification In

Properties Of Polymers By Addities

Polymerization

14 Identify The Plastic Product Material &

Applications

Classification Of Polymer Thermoplastics

Commercial Thermoplastics

15 Demo on thermosetting & thermoplastics Difference Between Thermosetting And

Thermoplastic. Thermosetting System

Commercial Thermosetting Plastics

Elastomers Special Polymeric Products

16 Discuss How Composite Materials Are

Finding Applications In Different Fields

Classification Different Type Of Composites

Protective Coatings

17 Corrosion Causes, Effects 7 Ticks To Avoid

It.

Factors Influencing Corrosion

Type Of Corrosion Mechanism Of Corrosion

Corrosion Testing Oxidation Corrosion And

Prevention

18 Demo on powder metallurgy Application Of Powder Metallurgy

Advantages Of Powder Metallurgy

Disadvantages And Limitation Of Powder

Metallurgy

19 Demo & discussion on powder metallurgy Process Description Secondary Operations

Powder Metallurgy And Fabrication

20 Demo & discuss on iron & steel scrap Introduction

Recycling Of Iron And Steel Scrap

21 Revision


Page 26 of 34

EXAMINATION SCHEME:

SESSIONAL MARKS SEMESTER MARKS

TOTAL MARKS

(100 Marks)

Minimum Pass Marks




(10 Marks)



Sessional

50%

Semester

50%









20 Marks

30 Marks


Page 27 of 34

Basics of mechanical Maintenance

Week Trade Practical Trade Theory

1.

Practical concept of maintenance. Mechanical Maintenance – Brief Concept &

Its Meaning.

2. Mechanical Maintenance Types & Its Adv. Mechanical Maintenance Types & Its Adv.

3.

Mechanical Maintenance – Brief Concept &

Its Meaning. Types & Its Advantages.



4. Assignment On: Wear In Machines & Their

Causes- Mechanical Wear & Corrosive Wear.

Defects Due To Wear In The Equipment



5. Assignment On: Wear In Machines & Their

Causes- Mechanical Wear & Corrosive Wear.

Defects Due To Wear In The Equipment

Wear In Machines & Their Causes-

Mechanical Wear & Corrosive Wear. Defects

Due To Wear In The Equipment.

6 Assignment On: Service Of Machine Parts By

Welding, Electroplating, Metal Spraying, Iron

Lining, Adhesive Bonding.

Increasing Service Life Of Equipment

Surface Roughness Vs Long Life

7 Assignment On: Functions Of Maintenance

Departments. Maintenance Organization.

A Brief Concept Of Important Process Applied

For Increasing Service Life Of Equipment

Such As Riling, Heat Treatment, Electro

Machining Methods, Use Of Compensating

Elements.

8 Assignment: Tool Room Preventive

Maintenance – Advantages, Inspection &

Scheduling, Routine

Proper Lubrication And Use Of Corrosive

Resistance Coatings. Brief Description Of

Service Of Machine Parts By Welding,

Electroplating, Metal Spraying, Iron Lining,

Adhesive Bonding. Consideration While

Selecting A Method Of Recovery.

9 Assignment: Hydraulic Devices Used In

Machine Tools.

Need Of Organization. Functions Of

Maintenance Departments. Maintenance

10 Practical On : Maintenance & Reconditioning

Of A Few Hand Tools Such As Marking

Tools, Chisel, Lathe Tool Drills Files Etc

Tool Room Preventive Maintenance –

Advantages, Inspection & Scheduling,

Routine Servicing & And Schedule Repair.

11 Assignment: Types Of Lubricants And Their

Specifications.

Types Of Maintenance Servicing Concept.

Periodic Maintenance Checks.

12 Assignment: Types Of Lubricants And Their Hydraulic Devices Used In Machine Tools.


Page 28 of 34

Specifications. Standard Tests For Fault Finding In Surfaces.

Restoring Different Parts Of A Lathe

13 Assignment: Working Of Gravity Feed, Force

Feed, and Lubrication Practices For Machine

Tools.

Schedule Of Maintenance Of Machine Tools

Such As Lathes, Drilling Machines, Milling

Machines & Presses.

14 Assignment: Working Of Gravity Feed, Force

Feed, and Lubrication Practices For Machine

Tools.

Maintenance & Reconditioning Of A Few

Hand Tools Such As Marking Tools, Chisel,

Lathe Tool Drills Files Etc.

15 Safety On Power Hacksaw, Band Saw,

Drilling Machine, Lathe, Shaper, Milling

Machine, Surface & Cylindrical Grinders.

Lubrication Principle,Types Of Lubricants And

Their Specifications.

16 Safety On Power Hacksaw, Band Saw,

Drilling Machine, Lathe, Shaper, Milling

Machine, Surface & Cylindrical Grinders.

Principles Of Working Of Gravity Feed, Force

Feed, Lubrication Practices For Machine

Tools.

17 Assignment On: Hygiene – Industrial

Hygiene, Personal Hygiene.

Definition And Importance, Analysis Of

Accident. Prevention Rules Of Accidents

18 Assignment On: Hygiene – Industrial


General Safety Devices Used On Machines

Safety On Tool Room Machines Such Power

Hacksaw, Band Saw, Drilling Machine, Lathe,

Shaper, Milling Machine, Surface &

Cylindrical Grinders.

19 Assignment On : General Safety Rules And

Precautions To Be Followed In Material

Handling & First Aid

Guarding If Machines- Introduction, Basic

Requirements, Types Of Guards, Principle Of

Safe Machine Design. Hygiene – Industrial


20 Assignment On : General Safety Rules And Precautions To Be Followed In Material Handling & First Aid

General Safety Rules And Precautions To Be Filled In Material Handling, Working Of Machine. Knowledge Of First Aid.

21 Revision


Page 29 of 34

EXAMINATION SCHEME:

SESSIONAL MARKS SEMESTER MARKS

TOTAL MARKS

(100 Marks)

Minimum Pass Marks




(10 Marks)



Sessional

50%

Semester

50%









20 Marks

30 Marks


Page 30 of 34

SECOND SEMESTER: COURSE DETAILS


TRADE


Page 31 of 34

Syllabus for the Trade of CCMM

Second Semester

Duration: Six Month

LIVE PROJECT ON MAINTENANCE

Week Trade Practical Trade Theory

1. Introduction to Maintenance Department. Introduction about Maintenance.

Safety instruction taken while working.

2. Introduction to Types of Maintenance Different types of Maintenance

Preventive Maintenance, Breakdown

maintenance etc.

3. Practical Preventive Maintenance work on

Conventional Machines like

Lathe, Milling, Drilling, Grinding, etc.

Instruction of Safety Precaution

Preventive Maintenance work on

Conventional Machines

Instruction of Safety Precaution while

working.





Preventive Maintenance work on




5. Practical Breakdown Maintenance work on




working.

Breakdown Maintenance work on




working.





working.

Breakdown Maintenance work on




working.


CNC Machines like

CNC lathe, CNC Milling, CNC EDM, etc.

Preventive Maintenance work on CNC

Machines like

CNC Lathe, CNC Milling, CNC EDM, etc...


Page 32 of 34


working.


working.


CNC Machines like

CNC Lathe, CNC Milling, CNC EDM, etc.


working

Breakdown Maintenance work on CNC

Machines like

CNC Lathe, CNC Milling, CNC EDM, etc.


working.

9. To handle Practical Equipment like Air

compressor,

DG set,Pumps,Centralised A.C Plant,

Power Distribution,

Pumps Cylinders, Valves, etc...

Introduction to Utility Maintenance & safety

of Additional Equipment’s


working.

10. Practical on Air compressor,

DG set,Pumps,Centralised A.C Plant

Utility Maintenance like Air compressor,

DG set,Pumps,Centralised A.C Plant

11. Practical on Power Distribution,


Utility Maintenance like Power Distribution,


12. To handle Equipment like Panel Filter,

Panel A.C,Lubrications, Suction Filters,

Evaporator’s

Introduction to Periodic Maintenance &

safety of Additional Equipment’s

13. Practical on Panel Filter,

Panel A.C,Lubrications

Periodic Maintenance like Panel Filter,

Panel A.C,Lubrications

14. Practical on Suction Filters,

Evaporator’s

Periodic Maintenance like Suction Filters,

Evaporator’s

15. Demo & Practical on Machine

Reconditioning Process

Introduction to Machine Reconditioning

process

16. Demo & Practical on how to install new

Purchase Machines.

Introduction to Machine Installation

process

17. Demo & Practical on Machine

Commissioning Process

Introduction to Machine Commissioning

process.

18. Practical on shop floor Preparation & sequence of Dismantling

Dismantling of main & then sub parts

Placing of parts

Information of all the parts


Page 33 of 34

FINAL EVALUATION

SESSIONAL MARKS

Total Marks Evaluation of On-Job Training &

Live Projects Project Report

Project Presentation

325 200 75 600

19. Safety taken while working on shop floor Assignment On : General Safety Rules

And Precautions To Be Followed while

working.

Rules for safety precautions

20. Safety taken while working on shop floor General Safety Rules And Precautions To

Be Filled In Material Handling, Working Of

Machine. Knowledge Of First Aid.

21 Revision


Page 34 of 34

LIST OF MACHINES AND EQUIPMENTS

Sr..No. NAME OF THE MACHINE TYPE OF MACHINE QTY.

01 Vertical Machining Centre (VMC) CNC Milling 10

02 CNC Turning Centre CNC Turning 11

03 Wire cut Machines Wire Cut 8

04 EDM EDM 13

05 Jig Boring Machine B3-DR JB 1

06 Vertical Milling Machine Conv. Milling 20

07 Universal Milling Machine Conv. Milling 6

08 Horizontal Milling Machine Conv. Milling 6

09 Lathe Machine Conv Turning 29

10 Cylindrical Grinding CG 5

11 Surface Grinding Machine SG 19

12 Tool and Cutter Grinder (SAACKE) SG 1

13 Engraving Machine Kibra TG 1

14 Injection Mouldig Machine Inj Moulding 4

15 Mechanical Press (125T) Eccentric Press Press 2

16 Hydraulic Press (63T) Dunkes Press 1

17 St.Press Dunkes Press 1

18 HMT Make Radial Drilling Machine Drilling 3

19 Colum type drilling machine (Floatt) Drilling 3

20 Bench type drilling machine (Floatt and Other) Drilling 13

21 Single Chamber Furnace (Nolzen) HT 2

22 Tempering Furnace(Nolzen) Electric Hot Air Furnace HT 1

23 Heat Treatment Furnance (Fluidtherm) HT 1

24 Tempering Furnace (Fluidtherm) HT 1

25 Vertical Band Saw Mossener Steel & Metal Saw Machine

Saw 1

26 Power Hack saw (Beheringer & other) saw 2

27 Indo tech Double column semi-auto Bandsaw Machine

Saw 1

28 Flame Cuttinig Machine FC 1

29 CNC CMM(Hexagon) CMM 1

30 CNC CMM (Carl Zeiss) CMM 1

31 Pofile Projector Batty SM-20 PP 1

32 Tool Maker Micro Scope Large TMMS 1

33 Chamfering Machine Hkf 125 Assfalg Jitamitra Make

CM 1

34 Tool Presetor ( Elbo Controli) TP 1