DPT SYLLABUS STRUCTURE

SEMESTER II
THEORY CODE GE 201 GE 202 GE 203 GE 204 PT 201 PT 202 SUBJECT Communication English-II Applied Mathematics Fundamentals of Electrical and Electronics Engineering Engineering Drawing-II Fundamentals of Polymer Science Plastics Materials - I Total (20 weeks - 24 hours per week) CH 72 72 52 40 72 72 480 TH 08 08 08 60 08 08 EH 3 3 3 3 3 3 18 INT 40 40 40 40 40 40 240 MARKS EXT TOTAL 60 100 60 100 60 60 60 60 360 100 100 100 100 600

PRACTICAL Code GEL 205

Name of Laboratory

Exc. Hrs 40 80 160 40 320

EH 4 4 8 16

INT 50 50 100 200

Marks EXT Total 50 50 100 200 100 100 200 400

Electrical and Electronics Engineering Lab PTL 203 Utilities & Service Equipments Lab PTL 204 Workshop Practices - II *ISAP / Library Total (20 weeks - 16 hours per week) CH- Contact Hours TH-Tutorial Hours

EH- Examination Hours

1 DPT / 2010

SEMESTER II GE 201 COMMUNICATION ENGLISH II

Unit I (80 Hours) (20 Hours)

Grammar - Changing a sentence into negative without changing the meaning; Changing words from one form to another; Degrees of Comparison; Simple, Compound & Complex sentences; Rewriting a sentence with 'It' / 'There' in the initial position; Answering the verbal questions in affirmative and negative; Synonyms and Antonyms; forming meaningful sentences for the words given; phrases / structures indicating use and purpose; concord; Modal Verbs; Definitions; Spelling and Punctuations, sequencing of Jumbled sentences. Unit II (40 Hours)

Composition - Conversion of Graphics (pie-chart, bar-chart, table ) ; Letter writing - Business and Official letters (Letter of Quotation, Letter of Clarification, Letter of Complaint, Letter Placing orders, Letter for Seeking Permission for Industrial visit , Letter to editor, Letter of request for Leave / Bonafide Certificate / Testimonials, Letter of Application for a job with Bio-data / Curriculum vitae); Unit III (20 Hours)

Technical Report writing (Analytical Report, Accident Report, Project report, Inspection Report, Production Report, Investigation Report, Field Report); Check list. Text / References Books 1. A.S. Homby . 'The Advanced Learners Dictionary of Current English' Oxford University Press: 1973. 2. Wren & Martin, 'High School English Grammar and Composition. S.Chand & Co., Ltd. 3. Glennis Pye, 'Vocabulary in Practice - Part 1 to 4', Cambridge University Press, 2004. 4. Shiv.K.Kumar & Hemalatha Nagarajan, 'Learn Correct English', Pearson Longman. 5. Raymond Murphy, 'Essential English Grammar', Cambridge University Press, 1990. 6. M.Thomas, 'Common Errors in English', Lotus Press, New Delhi, 2006. 7. Michael Swanm 'Basic English Usage,' E,BS/OUP, 1989.

GE 202 - APPLIED MATHEMATICS

2

(80 Hours)

DPT / 2010

Unit I Vector Algebra 1.1

(15 Hours)

Introduction Definitions - Types - Addition and Subtraction of Vectors - Properties - Position Vector, Resolution of Vector in two and three dimensions, Direction Cosines and Direction Ratios of Vectors, Simple problems. Product of Vectors Scalar and Vector product of two vectors - Geometrical meaning - Angle between two vectors Unit vector perpendicular to two vectors. Applications of Vectors Work done - Moment - Scalar and vector triple product - Geometrical interpretation of scalar triple product - Coplanar Vectors, Scalar and Vector product of four vectors, Simple problems. (15 Hours)

1.2

1.3

Unit II Integral Calculus 2.1

Integration Definition - Integral values using reverse process of differentiation - Integration using decomposition method - Integration by substitution - Integrals of the form [f(x)]n f'(x) dx, n # - 1. f'(x)/f(x) dx, [f(x)] f'(x) dx Standard Integrals Integral of the form dx/ (a2 x2), dx/x2 - a2, dx/ a2 - x2, dx /(x+a) (x+b), (Ax+ B) dx / ax2 + bx +c - simple problems. Integration by parts Integration by parts and Bernoull's form to evaluate x sin nx dx, x cos nx dx, x2dax, xn log x dx, log x dx. (15 Hours)

2.2

2.3

Unit III Applications of Differentiation 3.1 3.2 3.3

Velocity and Acceleration, Tangents and Normals - Simple problems. Maxima and Minima of Single variable - Simple Problems. Partial differentiation of two variables upto second order - Euler's Theorem - Simple problems.

Unit IV Applications of Integration 3

(15 Hours)

DPT / 2010

4.1 4.2 4.3

Definite Integral, Area and volume - Area of circle, Volume of Sphere and Cone - Simple problems. Solution of Differential Equations - Variable Seperable - Linear type Differential Equations Simple problems. Second order differential equation with constant coefficients ad2y/dx2 + bdy/dx + cy = e ax where f (a) # 0. (20 Hours)

Unit V Probability & Statistics 5.1 5.2

Definitions - Axioms - Addition Formula, Mutually exclusive event, Addition Theorem on Probability, conditional probability - Multiplication Theorem Random Variable Types of random variable- Definition of Discrete Random Variable, probability mass function, continuous random variable and probability density function - simple problems. Mathematical expectation of discrete random variable, simple problems. Discrete Distributions (a) Binomial Distributions p(X = x) = nCxpxqn - x x = 0,1,2...........n 0 otherwise Expression for mean, variance and standard deviation - simple problems (b) Poisson Distribution Definition of Poisson distribution p(X = x) = e- x / x! x = 0,1,2........ 0 otherwise Expression for mean, variance and standard deviation - Simple problems

5.3

5.4

Continuous Distribution Normal distribution: Definition of normal and standard normal distribution - Constants of normal distribution - Properties of normal distribution - Simple problems using the table for standard normal distribution.

Text / Reference Books 1. Applied Mathematics for Polytechnic Colleges (Second Semester) - P.Krishnamurthy, N.Thangasamy. 4 DPT / 2010

2. Higher Secondary - First Year - Tamil Nadu Text Book Cooperation. 3. Engineering Mathematics - Dr.M.K.Venkatraman, Natinal Publishing Co, Chennai. 4. Engineering Mathematics - Dr.P. Kandasamy & Others, Schand & Co Ltd., New Delhi.

GE 203 - FUNDAMENTALS OF ELECTRICAL AND ELECTRONICS ENGINEERING

Unit I 5

(60 Hours) (12 Hours)

DPT / 2010

DC & AC Circuits and Batteries Definitions Electric current, Voltage and Resistance Ohms Law and Kirchoffs Laws Resistance in series, parallel and series parallel Simple problems Electromagnetism, Magnetic flux, Flux density, Magnetic field Intensity, MMF, Permeability, Reluctance, Faradays Laws of Electromagnetic Induction. Fundamentals of AC voltage and current Peak, average, RMS value of sine wave, Frequency, time period, amplitude, power, power factor, Ac circuits RLC in series star, Delta Connections - relationship between phase and line voltages, current in star and Delta connections. Batteries classification of cells construction of ni iron and cadmium cell concept of recharging cells lead acid cell construction - indication of full charged cells defects, and remedies, applications. Unit II (12 Hours)

DC Generator, DC Motor, Transformer and Alternator DC Generator Construction Principles of Operation, Types and Applications, DC Motor construction Principles of Operation, Types and Applications, Necessity for starter three point, four point starter, Transformer Principle of Operation and Construction EMF Equation Losses in a Transformer Efficiency Autotransformer Three Phase Transformer Applications, Alternator Construction Principle of Operation Types and Applications. Unit III (12 Hours)

AC Motors and Electrical Safety Principle of Operation of single phase capacitor start induction motor applications three phase induction motors squirrel cage and slip ring IM (construction and working principle) applications speed control of three phase induction motor necessity of starter DOL and star delta starter. Special Motor: PMDC, Stepper motor Construction, Working Principle and Application. Electrical Safety Importance of Earthing Electric shock First aid for electric shock Precautions against shock Cause of Accidents and their preventive measures Energy conservation. Unit IV (12 Hours)

Basic Electronics and Logic Gates Semiconductor materials N type and P type PN Junction forward and reverse bias, characteristics of PN junction diode Half wave rectifier, full wave rectifier, bridge rectifier, zener diode and avalanche break down, characteristics of zener diode application of zener diode. Transistor construction of NPN and PNP types basic bias requirements (common emitter configuration), Thyristors principle and working of SCR characteristics applications, Introduction of integrated circuits classification and packages applications, Logic Gates positive and negative logic, definition, symbol, truth table, Boolean expression for OR, AND, NOT, NOR, NAND, EXOR and EXNOR gates.

Unit V

(12 Hours)

Programmable Logic Controller PLC Features and Benefits of PLC Systems and its elements Input and Output elements PLC Memory System PLC circuit verses hardwired circuits Sensors Types of Sensors Limit Switch, Reed Switch, Photo Electric Sensor, Inductive Proximity Sensor Types of contacts normally open (NO) contact, normally closed (NC) contact ladder logic symbol AND logic OR logic , truth table 6 DPT / 2010

steps involved in application circuits using a PLC PLC scan input Programme and output scan design ladder diagram for operation of motor using AND and OR logic. Design ladder logic diagram for ON delay control of a motor and OFF delay control of a motor. Text / Reference Books 1. B.L. Theraja, Fundamentals of Electrical and Electronics Engineering, S.Chand & Co. 2. T. Thiyagarajan, Fundamentals of Electrical and Electronics Engineering, Scitech Publicatiuons (India) Pvt.ltd. 3. Mikell P. Groover, Automation, Production System and Computer Integrated Manufacturing, Edn. 2 Published by Pearson Education (Singapore) Pte. Ltd., Indian Branch, 2842 F.I.E., Patparganj, Delhi 110 002, India. 4. KB Raina & S.K.Battachariya, Electrical Design Estimating and Costing, Edn. 6, Tata McGraw Hill Publishing Co., 7, West Patel Nagar, New Delhi 110 008. 5. Gary Dummy, Introduction to Programmable logic controls, Thomson Debnar learning second edition second reprint 2003. 6. B.L.Theraja & A.K. Theraja, Electrical Technology Vol. I & II, Edn. 23, published by S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055.

GE 204 ENGINEERING DRAWING II

Unit I 1.1

(100 Hours) (25 Hours)

Sectional views of objects Need for sectional drawing of an engineering object- Sectioning of solids in simple vertical position by cutting planes inclined to one reference plane and perpendicular to the other, obtaining true shape of section. 7 DPT / 2010

1.2 1.3

Auxiliary views Need of auxiliary views auxiliary views given engineering drawings. Development of surfaces Development of Lateral Surfaces of Simple and Truncated Solids- Prisms, Pyramids, Cylinders and Cones- Development of Lateral Surfaces of Solids with Cylindrical Cutouts, Perpendicular to the axis. (30 Hours)

Unit II 2.1

Pictorial drawings Principles of Isometric Projection, Construction of Isometric Scales- Isometric Projections of Simple Solids, Truncated Prisms, Pyramids, Cylinders and Cones -Isometric Projection of Simple Engineering. Perspective drawing Principle of Perspective Projection Type of Perspective Projection Perspective Projection of Prisms, Pyramids and Cylinders by Visual Ray Method. (15 Hours)

2.2

Unit III

Fastening Devices Basic Fastening Devices - Temporary and Permanent Fastenings Areas of Applications Bolts and Nuts Different types of bolted joints for different applications purpose of locking nuts Types of lock nuts. Exercises in drawing bolted connection using standard proportion. Exercises in the selection of appropriate fastening devices to meet the given working conditions. Unit IV (30 Hours)

Assembly and Detail Drawings of Machine Part Need and functions of assembly and detailed drawings selection of sheet sizes preparation of title block bill of materials and parts list Steps in preparing assembly and detailed drawings. Exercises in assembly and detailed drawings of sleeve & cotter joint, socket & spigot joint , knuckle joint, muff coupling, half lap muff coupling , protected flanged coupling, Plummer block, Tail stock and Screw jack.

Text / Reference Books 1. 2. 3. 4. 5. 6. 7. Engineering Graphics, Julyes Jaisingh. Engineering Drawing by N. D Bhutt. Engineering Graphics by P. I. Varghese. Machine Drawing by P.I. Varghese & K.C. John. Machine Drawing by N.D. Bhatt. A test book of Machine Drawing by V. Lakshmi Narayan. Machine Drawing by K.R. Gopalakrishna. 8 DPT / 2010

PT 201 FUNDAMENTALS OF POLYMER SCIENCE

Unit I

(80 Hours) (16 Hours)

Introduction to Polymer Science The science of large molecules Definitions Monomers & its requirement- Broad Classifications of Polymers - Types based on Structure Processing and Application - Molecular Force and Chemical Bonding in Polymers Polymer structure Homo Polymers and Copolymers Geometric Isomerism Tacticity Nomenclature Molecular Weight and Distribution and its effect on Properties and Processing of Polymers- Thermal Transition Tg & Tm. 9 DPT / 2010

Unit II

(24 Hours)

Polymerisation Chain growth Polymerization Addition Polymerisation Reaction Mechanism - Free Radical Reaction Ionic Reaction Coordination Polymerization Ring Opening Polymerization - Condensation Polymerization Extend of Reaction and Degree of Polymerisation Polymerization Techniques Bulk, Solution, Suspension & Emulsion Polymerization Techniques and Co-polymerization. Unit III (20 Hours)

Polymer Structure and Properties Structure Property Relationship Molecular Weight and Poly Dispersity Index (PDI) - Effect of Polymerization on PDI Polymer solutions and solubility General Rules for Polymer solubility solubility Parameters, Properties of Dilute solutions - Solid state properties State of Polymer Crystalline, Amorphous, Semi-crystalline, Liquid crystalline Requirement of Crystallinity factors affecting crystallinity. Deformations in Polymer Mechanical properties - Stress Strain behavior Polymer Fracture and Toughness Cracking & Crazing Thermal & Electrical properties. Unit IV Degradation & Stabilization of Polymer Polymer Characterization Identification and Characterization of Polymers Simple Spectroscopic Methods Molecular Weight Determination Measuring Dilute Solution Viscosity Gas Chromatography Gel Permeation Chromatography Melt Flow Characteristics - Thermal Analysis DSC and TGA Dynamic Mechanical Analysis. Text / Reference Books 1. Polymer Science Gowariker V.R. & others. 2. Text book of Polymer Science Billmeyer F.W. (20 Hours)

PT 202 PLASTICS MATERIALS I

Unit I

(80 Hours) (08 Hours)

Natural Polymer Nomenclature of Polymers Sources of Raw Materials Methods of Manufacture General Characters & Properties, processing behaviour and applications of natural polymers such as Shellac Resin Natural Rubber Casein. Unit II Commodity Plastics 10 DPT / 2010 (24 Hours)

Olefinic & Styrenic Plastics: Sources of Raw Materials Method of Manufacture General Characters & Properties Processing Behaviour and end use applications of LDPE Low Density Polyethylene LLDPE Linear Low Density Polyethylene HDPE High Density Polyethylene HMHDPE High Molecular weight High Density Polyethylene PP Polypropylene (Homo & Copolymer) PS Polystyrene HIPS High Impact Polystyrene ABS - Acrylonitrile Butadiene Styrene SAN Styrene Acrylonitrile EPS Expanded Polystyrene Unit III Commodity Plastics Vinyl & Cellulosic Plastics: Sources of Raw Materials Method of Manufacture General characters & Properties Processing Behaviour and end use applications of PVC - Polyvinyl chloride & Chlorinated PVC. PVDC Polyvinylidene Chloride. PVAc - Polyvinyl Acetate. PVA Polyvinyl Alcohol. CN Cellulose Nitrate. CA Cellulose Acetate. CAB Cellulose Acetate Butyrate. Regenerated Cellulose. Acrylic Plastics (Polymethyl Methacrylate, Polyacrylonitrile). Thermoplastic Elastomers. (24 Hours)

Unit IV

(24 Hours)

Thermoset Plastics Source of Raw Materials Methods of Manufacture General Characters & Properties Processing Behaviour and Applications of Phenol Formaldehyde Urea Formaldehyde Melamine Formaldehyde Unsaturated Polyesters Alkyd Resins Epoxy Resin Polyurethane Silicones. Text / Reference Books 1. Plastic Materials J.A. Brydson. 2. Plastic Materials Hand Book A.S. Athalye.

11 DPT / 2010

GEL 205 - ELECTRICAL AND ELECTRONICS ENGINEERING LAB

1. Electrical Engineering Lab 1. Study of Measuring Instruments Ammeter Volt meter Watt meter etc. 2. Determination of unknown resistance by Ohms Law. 3. Energy Measurement in a single phase circuit using Lamp Load. 4. Power Measurement in a Single Phase Circuit. 5. Load test on a Single Phase Transformer. 12

(40 Hours) (20 Hours)

DPT / 2010

6. Load test on a Single Phase Induction Motor. 7. Verification of Series and Parallel Circuit. 8. Study of DC & AC Machine Starters.

2. Electronics Engineering Lab 1. Charactertics of PN Junction Diode. 2. Charactertics of Transistor. 3. Construction of Bridge Rectifier. 4. Verification of Logic Gates. 5. Charactertics of Photo Diode and Thermister. 6. Measurement using CRO and Megger. 7. Study of Microprocessor.

(20 Hours)

PTL 203 UTILITIES & SERVICE EQUIPMENTS LAB

(20 Weeks 4 hours a week) 1. 2. Study of Air Compressor Elements, Safety Features, Drive Mechanism, Lubrication.

(80 Hours)

Study on Hydraulic Pumps , Motors Accumulators, Safety Features, Control Valves & Simple Hydraulic Circuits for Lifting Tackle, Manual Pump, Hydraulic Press, Hydraulic Valves Different Types, Hydraulic Accumulators, Hydraulic Pressure Control and Flow Control, Hydraulic Piping and Coupling, Safety and Trouble Shooting. Working of 4/2, 2/2 & 4/3 directional control valve in Single Acting & Double Acting Cylinder. Study of FRL unit and Air Dryer in the Pneumatic System & Hopper Drier. Study of heat exchanger in Moulding Machine. 13 DPT / 2010

3. 4. 5.

6. 7. 8. 9.

Study of Mould Heating using Hot Oil Circulator. Study of Chilling Plant/Cooling Tower. Study of Electrical safety Measures & Demonstration about use of protective devices. Study and Usage of Various Electrical Tools & Instruments like Voltmeter, Ammeter, Multimeter (Analogue 7 Digital), Wattmeter & Energy Meter & Megger

10. Study of Single Phase and Three Phase power supply. Identification of phase, Neutral and Earth pits. 11. Importance of three phase wiring and its effectiveness, laying out three-phase wiring for an Electric Motor or any other three phase machine. 12. Study, Demonstration and Identification of common Electrical materials such as Wires, Cables, Switches, Fuses, Plugs, Connectors, Sockets etc. 13. Calculation of power and energy consumption. 14. Various types of protective devices such as: Wire Fuse, Cartridge fuse, slow acting/fast acting fuse, HRC fuse, thermal fuse, single/multiple miniature circuit breakers, over and under current relays, contractors, and Different types of switches, MCCB. 15. Study of Fluorescent lamp and CFL. 16. Study of Servo Voltage Stabilizer. 17. Study of Half wave / Full wave rectifier. 18. Study of different types of heater used in plastics processing Machinery using Voltmeter & Ammeter find out the unknown wattage of heater.

PTL 204 - WORKSHOP PRACTICES II

Workshop Safety General shop safety, safety on fitting bench and safety on machines. 1. Pedestal Grinding

(160 Hours)

(20 Hours)

Sharpening of Cutting Tools - Single point and Knife tools, Form Tools, Parting and Grooving Tools, Thread Cutting Tools. 2. Practice on Drilling Machine 2.1 2.2 2.3 (20 Hours)

Familiarization with Drilling Machine - Principal parts, work holding device, Cutting Tools & Tool holding device. Marking and Punching the layout. Drilling and Tapping. 14 DPT / 2010

2.4 2.5

Drilling and Reaming. Counter boring and Counter sinking. (40 Hours) holding

3. Practice on Lathe 3.1 3.2 3.3 3.4 3.5 3.6

Familiarization with lathes- principal parts, work holding device, Cutting tools & tool device. Plain turning and Step turning. Taper turning. Drilling and Reaming. Boring and counter boring. Thread cutting and knurling.

4. Practice on Milling Machine 4.1 4.2 4.3 4.4

(30 Hours)

Familiarization with Milling Machine - Principal parts, work holding device, Cutting Tools & Tool holding device. Plain surface Milling. Slot Milling. Pocket Milling. (30 Hours)

5. Practice on Surface Grinding Machine 5.1 5.2 5.3 5.4

Familiarization with Grinding Machine - Principal parts, work holding device, grinding wheels. Plain Surface Grinding. Slot Grinding. Angular Surface Grinding.

6. Plumbing 6.1 6.2 6.3 6.4 Pipe cutting and Thread cutting practice. Coupling joint. Elbow joint. Tee joint.

(20 Hours)

15 DPT / 2010

SEMESTER IV
THEORY Code PT 401 Subject CH 72 72 52 52 TH 08 08 08 08 280 EH 03 03 03 03 12 INT 40 40 40 40 160 Marks EXT Total 60 100 60 60 60 240 100 100 100 400

Fundamentals of Plastics Product & Mould Design PT 402 Plastics Processing Techniques - II PT 403 Plastics Testing Techniques - II PT 404 Polymer Composites and Applications Total Theory Hours (20 weeks - 14 hours a week) PRACTICAL Code PTL 405 PTL 406

Name of Laboratory
Plastics Processing Lab II (20 weeks 12 hours a week) Plastics Testing Lab -II (20 weeks 8 hours a week) 16

Exc. Hrs 240 160

EH 08 08

INT 100 100

Marks EXT Total 100 200 100 200

DPT / 2010

PTL 407

Design Practical by Auto CAD Lab (20 weeks - 4 hours a week) Library ( 20 weeks 2 hours a week) Total Hours CH- Contact Hours TH-Tutorial Hours

80 40 520

16

200

200

400

EH- Examination Hours

SEMESTER IV PT 401 FUNDAMENTALS OF PLASTICS PRODUCT AND MOULD DESIGN

Unit I Product Design Product Design Concepts size, shape, function, aesthetics, life, tooling aspects on product design process variables Vs product design - product design thumb rules for plastics - cost reduction through product design concepts - design of external, internal undercuts - side openings - hinges - fits of box and lid - assembly through resilience properties - case studies. Unit II Injection Mould Design Mould design concepts - Introduction - concept of design - design principles - parting line - mould elements - types of moulds - construction of core and cavities - position of gate - gate balancing ejection - types of ejections - mould cooling - mould alignment - ancillary parts of the mould. 17 DPT / 2010 (26 Hours) (80 Hours) (20 Hours)

Types of Injection Moulds - Two plate mould - Direct Sprue injection - Single Impression - Multi Impression - Side Gated Three Plate Moulds - Stack Moulds - Multi Day Light Moulds. Split moulds - external undercut - internal undercut - delayed action - cam track actuation - hydraulic core pulling devices - split cavities - split cores - threaded inserts - internal and external. Methodical approach to mould design - determination of economical number of cavities mould standards bolsters - standard mould parts - mould design check list. Unit III Compression Mould Design Types of compression mould, open flash, semi-positive type, positive, displacement moulds, types of loading chambers, bulk factor, flash thickness, pot design, projected area, compression pressure, clamping force, no. of impression by technological method, heating system, types of heaters, heat loss, heat requirement & heater capacity. Transfer Mould Design - Types of transfer moulds, integral pot transfer mould, auxiliary ram transfer mould, transfer pot design, projected area, transfer pressure, clamping force, pressure pad design, design of sprue runner and gate, advantages and disadvantages of transfer mould - design related calculations. Unit IV (14 Hours) (20 Hours)

Blow Mould Design Types of Blow Moulds - Extrusion - Injection and Stretch Blow Moulds - Blow Ratio - Parison Design pinch off design - Parting Line - Clamping Force - Mould venting, Mould Cooling - Mould Alignment. Extrusion Die Design -Principles of Extrusion - Die geometry - die swell - Die Land Design - Sizing die design - Construction of extrusion dies - blown film - pipe - profile - flat film - sheet - Wire Coating and Co-Extrusion Dies. Design of other Moulds-Thermoforming-vacumm forming-rotational mould Text / Reference Books 1. Technical Manual on Plastics Mould Design CIPET 2. Injection Mould Design for Thermoplastics Pye, R. G. W. 3. Plastics Product Design Engineering Dubois H.

18 DPT / 2010

PT 402 PLASTICS PROCESSING TECHNIQUES - II

Unit I Rotational Moulding

(80 Hours) (12 Hours)

Basic principle - Material selection & Estimation through trial analysis - Type of machine - Process variables - Charge size - wall thickness control - Heating and Cooling system Process requirement for the moulding of water tank - Dust Bin, etc. Application of Rotational Moulding - Ejection & Finishing Fault - Causes & Remedies - Merits & Demerits of Rotational Moulding Process. Unit II Thermoforming Basic principles Advantages - Material Selection - Thermoforming machine Single Stage - Multi Stage - Sheet fed m/c - Packaging Machine - Mould Material - Thickness Control - Types of Forming Vacuum Forming Free Forming - Plug-assist-forming - Drape forming - Matched die forming - Drape forming - Snap back forming - Dual sheet forming - Skin & Blister pack forming - Types of heating process variables - Forming of Disposal Cups & tumbler - Refrigerator Panel & Automobile Body Faults - Causes & Remedies. Unit III 19 DPT / 2010 (12 Hours) (24 Hours)

Calendering Process Description - Materials used - Advantages over extrusion - Types of Calender Rolls - Heating System - Roll Bending - Complete Description of Calendering line with their function Heating & Cooling System - Winding Type & Method - Finishing Trouble Shooting. Unit IV Fibre Reinforced Plastics (FRP) Introduction - FRP processing methods - contact moulding - hand lay up, spray up method - vacuum bag & pressure bag moulding, filament welding, centrifugal casting, pultrusion, matched die moulding. Unit - V Secondary Processes Powder coating, casting, machining & joining of plastics - Decoration of plastics - Metalizing - Printing & Painting etc - Post moulding operations. Text / Reference Books 1. 2. 3. 4. Compression Moulding Iyesaw, A.I. Technical Manual on Plastics Processing CIPET Plastics Engineering Hand Book Society of Plastics Industry Inc. Plastics Materials & Processing Strong A Brent. (16 Hours) (16 Hours)

PT 403 PLASTICS TESTING TECHNIQUES II

Unit I Electrical & Optical Properties

(60 Hours) (20 Hours)

Dielectric strength - Dielectric constant and Dissipation factor - Insulation resistance - Volume and Surface resistivity - Arc resistance - Antistatic tests. Refractive index - Luminous transmittance - Clarity and Haze - Photo-elastic properties - Colour measurements and Specular Gloss. Unit II Chemical Properties Introduction Immersion test Stain Resistance of Plastics Environmental Stress Cracking Resistance (ESCR). Flammability Introduction Flammability Test Ignition Properties Oxygen Index Test Flammability of Cellular Plastics Smoke Density Test UL90 Flammability Test. Unit III 20 DPT / 2010 (12 Hours) (16 Hours)

Weathering Properties Introduction environmental factors affecting plastics Accelerated weathering tests outdoor weathering of plastics Resistance of plastics to biological systems. Bio-degradability Testing Test methods and standards for bio-degradable plastics - Criteria used in evaluation of bio-degradable plastics - Description of current test methods. Unit IV Product Testing Plastics Pipes Films Wovensacks Water Tanks Containers & Plastic Foams. Failure Analysis Introduction Types of failure Analyzing Failures Non Destructive Testing (NDT) Ultrasonic methods & its application in plastics, Gamma & Beta Transmission Laser X-ray Fluorescence. Text / Reference Books 1. Text Book on Fundamentals of Plastics Testing - Prof. (Dr.) S.K. Nayak 2. Plastics Testing Technology Hand Book Shah Vishu (12 Hours)

PT 404 POLYMER COMPOSITES AND APPLICATIONS

Unit I Introduction to Composites

(60 Hours) (16 Hours)

Definition Advantages Raw Material Matrix Reinforcements Properties of Polymer Matrix Thermoplastics Materials such as Polypropylene, Nylon-6, 66, 610, 11 & 12 Polybutylene Terephthalate (PBT) Polycarbonate (PC) Polyoxymethylene (POM) Polyphenylene Sulphide (PPS) Vinyl Plastics & Thermoset Plastics such as PF, UF, MF Unsaturated Polyester Resin Alkyd Resin Epoxy Resin Polyimide Resin Polyurethane & Silicon. Unit II Reinforcement Materials & Other Ingredients Fillers & Reinforcement for composites Natural & Synthetic Fibers Natural Fiber Cellulose, Jute, Coir, Linen, Vegetable Fiber Synthetic Fiber Glass Fiber Types Properties & Applications Carbon Fiber Properties & Applications Aramide Fiber Properties & Applications Polymeric Fiber Properties, Applications & Metallic Fiber Properties & Applications Coupling Agent Curing Agents Lubricants Plasticizer Nano Filler. Unit III Composite Processing Methods 21 DPT / 2010 (20 Hours) (16 Hours)

Processing Fundamentals Requirement Dough Moulding Compound (DMC) / Bulk Moulding Compound (BMC) / Sheet Moulding Compound (SMC) Open Mould Process Hand Layup, Sprayup, Bag Moulding, Filament Winding Closed Mould Process Centrifugal Casting, Resin Injection, Continuous Process High Pressure laminate Pultrusion Process. Unit IV Applications of Composites Application of Composites in Aerospace Automobiles Building & Construction Wind Power Generation Electrical & Electronics Applications of Nano Composites. Text / Reference Books 1. 2. 3. 4. 5. FRP Manufacturing Process Philip Ball. Composite Polymeric Materials Sheldon. FRP Technology Weathehead. Advanced Polymer Composites Borz Jang. Technical Manual on Plastic Processing CIPET. (8 Hours)

PTL 405 PLASTICS PROCESSING LAB II

(20 weeks 12 Hours a week) Sl. No. 1 Name of M/c Description of practical exercise to be Equipment/ done* Mould Injection (i) Study of semi automatic Injection moulding Moulding Semi machines of all types in IRO. Comparative Automatic study of Pneumatic type & Hydraulic type of machines operating principles of machines with nomenclature of parts, machines specifications. (ii) Operation of Pneumatic & Hydraulic type of Semi automatic Injection moulding machines, to produce components in different moulds. Cycle-time analysis, observations of process parameters & Procedure to be recorded. Exercise Code No. PP-09

(240 Hours) No. of Hours 40

PP-10

30

22 DPT / 2010

Extrusion Processes

(i) Study of extruders in IRO, Free sketch of machines, their parts and parts-function, List of products manufactured by Extrusion process. Study of different types of extrusion process. (ii) Procedure for setting up of processparameters eg. Temperature on different zones, screw speed, Nip-roller speed, Winder speed, Blow ratio, Control of cooling-Air on bubble, Methodology & Practice by trainees to fix the Blown film die on M/c. Familiarization of Dieparts & their function, technical specification of machines, defects, causes & remedies, Practice of operating machine to produce different sizes of blown film. Study of the machine parts & function from screw drive to the caterpillar. Practice of Die setting on the machine, Procedure for setting up of parameters & operation practice in running the machine to produce Pipe/tube/Film. Parameter setting, operation-practice on different Compression & Transfer Moulds, observation & procedure of startup & shut down of machine. Setting up procedure for operation of machine, Safety precautions, type of mould clamping arrangement available on Machine-Platen, Mould clamping procedure on machine, Operation of machine by setting the optimum temperature, curing time, clamping force, ejector-stroke etc. on continuous basis, Analysis of product defects & remedies, Analysis of cycle-time, Practice on operation of compression & Transfer moulds with thermoset materials.

PP-11 PP-12

30 40

Compression & Transfer moulding-Semi auto & Automatic

PP-13

40

Blow-Moulding Technical specification of machine, Mould Semi Auto & clamping on machines. Familiarisation with Automatic control-switches/valves on the machine, & procedure of operation of machine. Machine-setting Procedure, Parameter Setting Procedure, Method of mould fixing & Parisondie setting on the machine, Practice by trainees to remove & fix the Parison die to produce an appropriate Parison for blowing, type of blowing systems, operation-practice on different moulds, cycle-time analysis, process-faults & remedies. Two practical test on Plastic Processing Lab VIVA-VOCE

PP-14

40

8 Hours Per Test 4 Hours 240

23 DPT / 2010

* Practical Exercises on operation of machines shall be done as per the operating-manual instruction of the respective M/cs. *One test may be conducted in the middle of the Semester and the other one at the end of the Semester followed by Viva-Voce.

PTL 406 PLASTICS TESTING LAB II

(20 weeks 8 Hours a week) S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Name of Exercise Specimen Preparation by Injection Moulding Specimen Preparation by Compression Moulding Specimen Preparation by Cutting Specimen Preparation by Punching Hot Roll Milling for Melt Mixing Determination of Tensile Properties Determination of Flexural Properties Determination of Compressive Properties Determination of Izod & Charpy Impact Strength Determination of Dart Impact Resistance of Plastic Films & Sheets Determination of Hardness (Shore A & D, Rockwell Hardness, Barcol Hardness) 24

(160 Hours)

No. of Hours 10 10 10 10 10 10 10 10 10 10

DPT / 2010

12. 13. 14. 15. 16. 17. 18. 19. 20.

Determination of Melt Flow Index Determination of Heat Distortion Temperature Determination of Vicat Softening Temperature Determination of Rate of Burning Determination of Limiting Oxygen Index Determination of Volume Resistivity & Surface Resistivity Determination of Arc Resistance Determination of Dielectric Strength Determination of Clarity &Haze

10 20 10 10 10

PTL 407 DESIGN PRACTICAL BY AUTO CAD LAB

(80 Hours)

S. No.

Name of the Exercise

No. of Hours

1.

Hand Injection Mould Design

04

2.

Design of Mould Elements / Standard Mould Base

08

3.

Single Impression Two Plate Mould

08

4.

Multi-impression Two Plate Mould

08

5.

Three Plate Mould (Multi-impression)

16

6.

Split Mould Design

16

7.

Mould Design for Internal Undercuts

16

8.

Mid Term Test

04

Total

80

25 DPT / 2010

26 DPT / 2010