Documente Academic
Documente Profesional
Documente Cultură
( SEMESTER PATTERN )
UNDER
Designed in – 2013
By
Government of India
Ministry of Labour & Employment (DGE&T)
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
Block - EN - 81 SECTOR – V, SALT LAKE CITY,
KOLKATA – 700 091
1
List of the trade committee members approved the syllabus of Semester System
for the trade of “Mechanic Machine Tools Maintenance” under Craftsman
Training Scheme (CTS) held on 27.09.2011 at ATI, Mumbai – 22, Maharashtra.
GENERAL INFORMATION
2. N. C. O. code No : 845.50
5. Power Norms : 17 KW
OR
OR
10th Class Pass + NTC/NAC in the Trade of Mechanic
Machine Tool Maintenance With 3 years post qualification
experience in the relevant field.
8b. Desirable qualification : Preference will be given to a candidate with CIC (Craft
Instructor Certificate)
4
SYLLABUS FOR THE TRADE OF
“MECHANIC MACHINE TOOL MAINTENANCE”
UNDER CRAFTSMAN TRAINING SCHEME
First Semester
(Semester Code no. MTM - 01)
Duration : Six Month
5
Electrical safety.
3-4 Marking practice: Basic Fitting Skill Introduction about Properties and use of
Marking - straight, parallel and curved Classification, constructional lines - its types, their non-ferrous materials
lines with odd leg calipers, steel rule, and functional details of thickness and and its alloy.
dividers, Scriber. Cut metals pieces of different type of vices (bench & applications in the
different profiles & sections by hack- machine), Care of vices, drawing as per BIS-
sawing (straight, inclined & curved hacksaw, its classification, saw 696.
line) to accuracy of 0.5 mm. setting, selection of hacksaw
blades.
Bench work safety- related
hazards, risk and precautions.
5. Breaking of new file teeth (on Brass). Classification, construction, Introduction about -do-
Marking of flat job as per drawing and material and functional detail of Lettering – its
parallel filing practice with in the Files. Specification of files & practice – types of
accuracy of 0.5mm. Filing technique. lettering (single
Marking media, Prussian blue, stroke & gothic
red lead, chalk and their special letters)
application and description
6&7 Filing- flat, square and steps surfaces to Linear measurements & its units -do- Solving problems of
an accuracy of 0.4mm. Classification, construction, percentage, ratio and
(Measurement by caliper and steel materials and functional detail of proportions.
rule). following basic measuring and
marking tools : -
Steel Rule
Calipers,
Divider, Trammel
Try Square
Marking Punch
8. Checking and setting of Vernier Vernier calipers, vernier height Dimensioning – its
calipers vernier height gauge & vernier gauge & vernier bevel protector types, terms, -do-
bevel protector. - principle, construction, notations, placing of
Filing flat, square, steps and contour calculation of least count and its
dimensions, unit of
surfaces to an accuracy of 0.4mm use and care. dimensioning and its
general rules..
9. Checking and setting of micrometer. Precision Measuring -do-
Filing flat, square and steps to an Instruments: -do-
6
accuracy of 0.3mm Concept of precision & accuracy
(Measurement by Precision Micrometer (outside, inside and
Instrument). depth) – working principle,
construction, use & care,
calculation of least count.
10. Transfer of dimensions from drawing Classification, construction and Scales - its Definition of Various
to work pieces. Finding center of a functional detail of following introduction, types heat treatment
round bar with the help of ‘V’ block marking devices- and application in processes of Steel
and marking block. Surface plate, angle plate, drawing. and its alloy.
Filing flat, square, steps and contour marking block and V-Block.
surfaces to an accuracy of 0.2mm.
11 Fixing of hammer handle. Classification, construction, -do- -do-
& Chipping practice on flat surface, slots materials and functional detail of
12 & oils grooves, and chamfer at Chisels & Hammers.
different angle on MS plate. Chipping technique.
Scraping practice on flat & curved Related hazards, risk and
surfaces precautions, while working.
Scrapers: Its types, material and
its use.
13 Truing of pedestal grinding wheel. Introduction and care of pedestal Geometrical Algebra – addition,
& Grinding/Repair and maintenance grinding machine, procedure of Construction of subtraction,
14. ordinary fitters’ tools such chisel, wheel mounting & wheel figures- triangles, multiplication and
Hammer, Screw driver, Scriber, Centre dressing. Related hazards, risk square, hexagon, division.
punches, dividers, trammel and and precautions, while working. Octagon, circles,
scrapers. Drill & Reamer- its ellipses etc. &
classification, construction, dividing of lines,
materials and functional detail. angles into equal
parts, tangent to a
curve -using drawing
instruments.
7
flat. Drilling on cylindrical surface. cutting speed, feed & drilling involutes, helix –
Reaming of drilled hole by hand time. using French curves.
reamer. Related hazards, risk and
Making internal & external thread by precautions.
Taps & Dies. Study of drill chuck, drill chuck
Prepare studs, nut and bolt. key, drill sockets, sleeves – its
construction, materials, its
specifications and use.
Taps & Dies: Classification,
construction, material and
functional detail of Taps & Dies.
17 Filing & fitting of mating components Surface finish - importance, Free hand sketching -do-
within an accuracy of ± 0.15 mm. symbol, measuring techniques. of standard elements
Lapping & honing process. like - spanners,
Gauges: Classification and uses
hammers, chisels,
of Sine bar, Slip gauge, Limit
gauge, Feeler gauge, thread punches, O/S caliper,
gauge, screw pitch gauge, taper I/S caliper, Odd Leg
gauge. Caliper. Draw
different types of
bolts, nuts, screws,
dowels, rivets etc.
18 Filing & fitting mating components by Brief introduction to ferrous -do- -do-
& filling within an accuracy of ± 0.15 mm metals used for hand tools.
19 & angular 30 minutes Difference between ferrous &
non- ferrous metal. Concept of
Heat treatment of ferrous metals-
normalizing, annealing,
tempering, hardening, case
hardening etc.
Related hazards, risk and
precautions, while working..
20 Fitting of mating components by Interchangeability-Definition Free hand sketching - do -
filling and scrapping within an and its necessity, basic size, of Vice, File,
8
accuracy of ± 0.10 mm & angular actual size, limits, deviation, Hacksaw, parallel
within 30 minutes Tolerance, allowance, clearance, shank twist drill, drill
interference, Fits- definition, chuck, micrometer,
types, description with sketches. vernier, etc.
Method of expressing Tolerance
as per BIS, Hole and Shaft basis
(BIS standard).
Related calculation on Limit, Fit
and Tolerance.
21 Practice on dovetail fitting mating Fasteners: -do- Algebra - solving of
& components by filling and scrapping Introduction to fasteners, screw simple equations,
22 within an accuracy of ± 0.10 mm & threads, related terminology and quadratic equations
angular within 30 minutes for specification. & simultaneous
cylindrical surfaces. Keys- types & use, (parallel, equation.
sunk, tangential, gib head,
woodruff, key ways.)
Related hazards, risk and
precautions, while working.
23 Preparation of flat surfaces and Types of nuts, bolts, studs, Projection – -do-
& scraping practice on flat surface taking locking devices for nut, wrench introduction,
24 impressin face high spots using and spanner, pliers, screw principle, method of
prussian blue sharpening mond wheel drivers, Circlip, split pin, projection.
& lapping stone. washers, spring washer. Difference between
Concept of torque & torque third angle & first
wrench. angle projection.
Different types of rivets and Draw the projection
their applications. view in 1st & 3rd
method for the same
component
25. (i) Project Work (ii) Industrial Visit (Optional)
26. Examination
Achievements:
On completion of first semester the trainee will be able to do:
Basic filling & fitting work, drilling, proper grinding of drill chipping, scrapping, reaming and making thread
(internal & external) using Taps & Dies.
9
SYLLABUS FOR THE TRADE OF
“MECHANIC MACHINE TOOL MAINTENANCE”
UNDER CRAFTSMAN TRAINING SCHEME
Second Semester
(Semester Code no. MTM - 02)
Duration : Six Month
06. Identification of various types of Type of Rolling contact -do- Definition of mass &
bearing and bearing mounting bearings- Ball bearings- single weight – their units and
arrangements in machine tools. row & double row, Deep groove differences.
11
Tackles used for mounting and ball bearing, Angular contact,
dismounting of bearing. Self aligning and Thrust bearing.
Inspection and mounting of ball Roller bearing- Cylindrical,
bearing on shaft with proper fit by Needle roller, Taper roller,
i) Impact sleeve Spherical roller, self aligning and
ii) Hydraulic or Spherical roller thrust bearing.
iii) Mechanical Press Use of ISO bearing designation
Mounting of ball & roller bearing in code to generate market survey
gear box housing. and purchase.
Dismounting of rolling contact bearing Checking and adjustment of
by using bearing clearance.
i) Hydraulic puller
ii) Hydraulic press and
iii) Mechanical pullers.
07. Inspection of bearing for its smooth Methods of Mounting and -do- - do -
roiling, allowable-side play, noises. dismounting of rolling contact
Practice of Mounting and dismounting bearing & taper roller bearing.
of bearings. (Back to back, Face to face
tandem)
Mounting-dismounting and
adjustment of
Taper bore bearings with adopter
and withdrawal sleeve.
Handling and storage of
bearings.
Related hazards, risk and
precautions.
12
08. Use of gear roll tester for smooth Gear: -do- Definition of speed,
rolling- impression testing of gear mesh velocity & acceleration
Type, description and function of
with Prussian blue. their units. Difference
gears-
PCD checking by Cylindrical Pin. between speed &
Spur, Helical, Spiral, Bevel,
Checking of gear tooth thickness, velocity.
Straight and Spiral bevel, Worm
clearance, concentricity etc.
gears, Rack and pinion.
Gear meshing: Checking of backlash
Gear Terminology.
and root clearances with Feeler Gauge,
Gear train- simple, compound,
Dial Test Indicator and Lead Wire.
reverted and epicyclic.
Types of Gear box
Gear meshing: Checking of
backlash and root clearances
with Feeler Gauge, Dial Test
Indicator and lead wire.
Impression testing of gear mesh
with Prussian blue.
Running maintenance
Related hazards, risk and
precautions
09 Overhauling procedure of gear box (Pre -do- -do- - do -
& cleaning, dismantling, cleaning,
10. inspection, repair/ replacement,
assembly).
Preparation of inspection sheet/ report.
Preparation of action plan.
11 Identification of lubricators. Lubrication (Oil and Grease) Drawing of Isometric Forces – definition - its
& Working on (on models) centralized views from unit, compressive,
Concept of lubrication
12. lubrication system, various lubrication orthographic views. tensile and shear force.
Types and properties of Oil and
fittings. Newton’s laws of
Grease.
Cleaning procedure of oil filters, motion. Laws of
Methods of oil lubrication-
lubricating line. gravitation
Once through and centralized
Identification & Fitting of different
system.
type of seals and oil ring.
Methods of grease lubrication
Preparation & Fitting gasket for
system- grease guns, centralized
different joint surfaces.
system.
Identification of elements for pressure
13
switch, temperature gauge, level Warning & protective devices
indicator and relief valve and their assy. used in centralized lubrication
procedure. system (Pressure switch,
temperature gauge, level
indicator and relief valve.)
Lubrication fittings. Storage and
handling,
Contamination control,
Leakage prevention- Shaft seals,
sealing devices and “O” rings.
13 -do- Cutting Fluids And Coolants -do- -do-
Properties – its types and users ,
cooling, system type-soluble
oils- soups, sudsparfin, soda
water etc.
Effect of cutting fluids in metal
cutting.
Difference between coolant and
lubricants.
14. Demonstration for location & MACHINE FOUNDATION -do- - do -
excavation of foundation bolts, method Method employed for
employed for installation & eraction of installation & eraction of
precision & heavy duty machines. precision & heavy duty
machines.
Location & excavation of
foundation. Different types of
foundations – foundation bolts,
structural, reinforced, wooden,
isolated foundations.
15. Checking for soft foot, checking for Leveling -do- Calculation of areas of
leveling, calculation of required Definition and importance of plane figures formed by
amount of packing and shim for 4 leveling, Concept of Soft foot, the combination of
legged bed, putting shim and do final Methods of checking and standard figures.
check. correcting soft foot.
Types of levels- Spirit level,
14
Water level, Dumpy level,
Method of leveling.
Preparation of packing and shim.
16. Alignment: -do- -do-
Shaft alignment, Pre-check: coupling Definition and importance of
fit, eccentricity, perpendicularity, alignment, Types of
finding soft-foot with feeler, dial gauge misalignment, Planes of
and corrections methods. misalignment, Shaft vs. coupling
Checking misalignment with the help alignment, Actions to be taken
of Taper gauge, Feeler gauge and Dial before alignment, Concept of
test indicator for Soft foot, Methods of checking
i) Rim and Face readings on and correcting soft foot, Concept
stationary machine (SM) of axial float, Concept of
ii)Rim and Face reading on machine Indicator sag, Dial Test
to be seamed (MTBS) Indicator, Methods of alignment
Checking and correcting alignment - Rim and Face readings on
with straight edge and thread: Stationary Machine, Rim and
V-pulley and sprocket. Face reading on machine to be
Geometrical Alignment of Machine. seamed.
Geometrical Alignment of
Machine.
17. Balancing Missing lines and -do-
Locating static unbalance in a rotor, views.
Understanding importance of
finding the correction weight.
balancing and reasons of
unbalance.
Type of unbalance.
Method of static balancing and
its correction
-Adding and removing mass
-Mass centering.
18. Practice of Lathe tool grinding, tool Machine Tool Operation & -do- -do-
setting. Maintenance
Lathe operations – plain turning, Lathe Machine
facing, step turning, undercut, Introduction to lathe machines
chamfering, grooving, fillet radius parts, constructional details and
within the accuracy of ±0.1mm and its lathe operations.
15
checking of square ness, diameter, Speed, feed & depth of cut
length, chamfer, fillets radius using Lathe accessories and
micrometer, vernier caliper and attachments. Chuck – its types,
gauges. face plates, lathe dogs, lathe
centers - its types, and lathe
steady. Coolants and lubricants .
Related hazards, risk and
precautions.
19. Lathe operations – drilling, boring, Nomenclature of cutting tool. -do- Calculation of volumes
counter boring, thread making using Lathe cutting tools angles for of standard solids
die and tap. different lathe operations. prisms, cylinder,
Recommended cutting tool spheres, cone, pyramid,
materials for lathe operations. Frustum of cone and
pyramids.
20 Practice of different taper turning Different simple lathe -do- -do-
& methods on lathe. operations – parallel/straight
21 turning, step turning, grooving,
radius forming, drilling and
boring, counter boring.
Calculation of cutting speed,
feed and turning time.
22 Practice screw thread cutting - whit Different taper turning methods Sectional views – -do-
& worth/metric (Internal & external) and its calculations. introduction,
23 Definition of screw thread, application, section
types, forms and its line, full sections,
applications. Calculation of gear Half sections,
train for screw thread cutting on aligned, revolve and
lathe. Change gear and its remove section and
calculation. different exercises.
24. Holding the job on shaping machine Shaper: -do- -do-
vice, setting of length of ram stroke. Introduction to Shaper machine
Making square block and “V” block. parts & constructional details its
function and operations.
Quick return mechanism of
shaper.
16
Calculation of cutting Speed,
feed & depth of cut.
25 (i) Project Work(ii) Industrial Visit (Optional)
26 Examination
Achievements:
On completion of Second Semester the trainee will be able to do:
a). Setting of Power Transmission system viz. Clutches, Flanges, Belts, Gears.
b). Foundation, Leveling, Alignment, Balancing, Lubrication techniques used in Machine Tool
Commissioning/Installation.
c). Performed different Lathe & Shaping Machine Operations.
Third Semester
(Semester Code no. MTM - 03)
Duration : Six Month
04 Practical Demo CNC machine Introduction to CNC Machines, Drawing of different -do-
& operation – its effected parts. constructional details, study of bolt heads, screw
05 Functioning of each part. (Training hydraulic diagram, hydraulics heads, nuts, rivet
through related CDs) valves etc. heads, dowels and
Industrial visit to CNC based keys.
Workshop/factory.
06. Setting of milling cutters, machine Milling: -do- Elementary
vice (job holding device), cutting Introduction to milling machine, trigonometry – ratios,
speed, feed, setting of table movement. parts & constructional details, use of trigonometric
Preparation of rectangular block by types. Safety precaution tables. Sine & Cosine
milling with in an accuracy of ± 0.2 followed during milling rule.
mm. operation. Milling machine
attachments.
07. Step milling (external) operation Different types of milling -do- -do-
within the accuracy of ± 0.2mm cutters and its materials.
Nomenclature of milling cutters.
08 Angular milling (external) Milling cutter holding devices, Draw different types -do-
work holding devices, Milling of Screw threads
machine operations, Up milling forms and their
and Down milling. applications.
09 Concave and convex radius milling. Calculation of cutting speed, -do- -do-
feed, machining time for milling
19
machine. Indexing methods and
its calculations.
10 Gear Cutting (spur, helical) Gears – types, calculation for -do- Friction – definitions,
spar, helical and bevel gears. its effect, types. Laws
Holding of gear blanks. Setting of friction, angle of
of cutters and gear blanks on friction and its
m/c. related calculations.
11 -do- -do- Free hand drawing of -do-
different types of
Flanges, Coupling.
12. Procedure for holding of job, setting of Grinding: -do- -do-
machine – stroke length. Practice of Grinding machine –
wheel balancing. Grinding of parallel introduction, parts &
and perpendicular surfaces with in the constructional details, types –
accuracy of ±0.02mm, using magnetic surface grinding and cylindrical
chucks and C-clamp. grinding machines. Safety
precaution followed while
working on grinding machines.
13. Grinding angular surfaces within an Grinding wheels – abrasives, Cotter & Cotter joints -do-
accuracy of ±0.02 minutes using bond and bonding process, grit, (Socket & Spigot)
universal vice. grade, and structure of grinding
wheels and its marking system.
14. Setting of machine for cylindrical Procedure for mounting of Strap joint with jib & Centre of
grinding for internal & external grinding wheels, balancing of cotter. gravity(CG) –
surfaces within an accuracy of grinding wheels, dressing and definitions,
±0.01mm. truing of grinding wheels, calculation of CG of
glazing and loading in grinding regular & irregular
wheel. shape body. Effect of
(CG) centre of
gravity in the trade
work.
15. Grinding steps on cylindrical surfaces Calculation for cutting speed and -do- -do-
within ±0.02mm accuracy. Grinding work speed, feed, depth of cut
taper holes on cylindrical grinding and machining time.
machine within ±0.02mm accuracy.
20
16. Cutting & Threading of pipe. Pipe Fitting and Valves Pin & knuckle joints. -do-
Fitting of pipes as per sketch. Types of pipe, tubes and
different fittings.
Tools used in pipe work.
17. Bending of pipes as per drawing. Pipe bending and jointing Types of keys – its Definition of specific
Making pipe joint (flaring and ferrule). methods. types, fittings in gravity, density and
Different types of expansions machine tools. relative density.
joints and their applications. Difference between
specific gravity &
density. Calculation
of density of a body.
18 Use of different type of valve like: Pipe colour code. Circlips - its types, -do-
& Gate, Globe, butterfly, Diaphragm. Safety precautions to be applications &
19 Assembly and disassembly of valves. observed while working at fittings in machine
Making and replacement of gaskets. pipeline. tools.
Constructional detail of different Using method of felt,
type of valve & their uses like: ‘O’ ring, oil seal in
Gate, Globe, butterfly, machine tools.
Diaphragm.
21
Trouble shooting in pump.
26 Examination
Achievements:
On completion of Third Semester the trainee will be able to do:
a). Different types of Welding, Milling & Grinding Operations.
b). Dismantling/assembling, cleaning, identifying defective
components of Valves, Pumps, Fan, Blower, and compressors.
22
SYLLABUS FOR THE TRADE OF
“MECHANIC MACHINE TOOL MAINTENANCE”
UNDER CRAFTSMAN TRAINING SCHEME
Fourth Semester
(Semester Code no. MTM - 04)
Duration : Six Month
24
& brige rectifiers. Use of oscilloscope Use of transistor for
for checking of input & output wave amplification low amplification
forms. taken place. Soldering technique
Studi of solid state devices such as as applied to PCB soldering Dos
diodes trasnsisters, SCRS & ICS Dont’s.
available in different packages,type &
application. Identification leads &
tasting by multimeter.
Assembly of simple battery elimeter
circuit using bright rectifier & filter
capiciter. Measurment of input &
output voltages.
06. Instrumentation Introduction to industrial process Reading of assembly -do-
Demonstration on various measuring control system and equipment - drawing for - Lathe
devices sensors, transmitters and final Machine Head Stock
Demonstration of PLC control elements. Gear Box - its power
Measurement of displacement, transmission system.
pressure, temperature, flow, level Study of mounting of
and speed. Application of bearing, gears, fork,
encoders. clutch- it’s locking/
Programmable logic controller retaining procedures.
(PLC) – General concept of Preparation of free
working, Relay Logic Control hand drawing as per
vs. PLC, Block diagram, dimensions.
applications.
07 Identification and familiarisation of Hydraulics & Pneumatics -do- Stress and strain –
various types of hydraulic elements Basic principles of Hydraulic - definitions, types,
such as pumps, valves, actuators and Advantages & limitation of Hook’s Law.
oil filters. hydraulic system, hydrostatic Ultimate strength and
Overhauling of valves transmission, Pascal’s law, factor of safety.
Brahma’s press, pressure & flow,
speed of an actuator.
25
Control valves: Different type of
control valves used in hydraulic
System.
Function of pressure control
valve, directional control valve,
check valve, flow control valve.
08 Overhauling of Function and construction of -do- -do-
& - Hydraulic pumps gear pump, vane pump and
09. - Hydraulic actuators. piston pump, cylinder &
hydraulic motor.
10. Simulation of hydraulic circuits. Auxiliary & fluid conditioner: Reading of assembly -do-
- Simple hydraulic circuits. Reservoir, filter, strainer,
drawing for - Milling
pressure gauge, pipe & pipe Machine Head &
fitting, accumulator, seals & Feed Gear Box - its
packing power transmission
Simple hydraulic circuits : system. Study of
- Hydraulic symbols mounting of bearing,
- Study of different hyd. Circuits
gears, fork, clutch-
Related hazards, risk and it’s locking/ retaining
precautions. procedures.
Preparation of free
hand drawing as per
dimensions.
11. Practical on hydraulic circuits. Electro hydraulic circuit, -do- Problems on ultimate
Electrical components stress and factors of
- Switches safety – Poisson’s
- Solenoid Ratio-Modules of
- Relay rigidity.
12. Identification of various types of Basic principle of pneumatic -do- -do-
pneumatic elements such as: control system.
valves, actuators, filter, pressure Advantages & limitation.
regulator and lubricator. Air preparation.
Constructional & functional
26
details of pneumatic cylinder,
motor, control valves and FRL
unit.
13 Overhauling of pneumatic cylinders Introduction to Pneumatic -do- Electricity –
& - Practice on Pneumatic circuit actuators definitions, Ohm’s
14. Pneumatic Symbols Law, electrical
Pneumatic circuit power, energy and
Electrical control components units.
- Switches
- Solenoid
- Relay
15. Practice of different type of knots & Rigging Piping symbols and -do-
hitches used in material handling Knowledge of different tools & its application in
Raving sets of pulley block. tackles used in rigging. drawing.
Splicing of manila rope. Construction and capacity of
Inspection of wire rope. wire rope.
Capacity of ropes (other than
wire rope).
Application of knots and hitches.
Care and maintenance of wire
rope.
16. Use of mechanical & hydraulic jack, Different type of jacks, chain Draw the typical Magnetism –
rope puller, chain puller, chain block, block and pull lift. symbols used in introduction,
winch. Knowledge of different types of electrical circuits. magnetization and
Inspection of tools and tackles scaffolding. Graphical symbols magnetic materials.
Loading, unloading and shifting of Material movement by using used in electrical Use of magnets.
common and uncommon shapes of different rigging tools and technology, circuit Laws of attraction
material. techniques. elements, types of and repulsion.
Hand signal used in rigging. Safety appliances & precautions distribution system
in rigging. and method of
Maintenance of tools and connection. (As per
tackles. BIS code and IEEE,
IES rules)
17 Demonstration on Belt conveyor Bulk Material Handling -do- -do-
system, Vibratory screen & feeder (Conveyor belt, Vibratory
screen, Feeders)
27
Principle & mode of material
handling.
Various components used in belt
conveyor system & their
functions.
(Pulleys, idlers, scrapers, skirts,
belt, take up unit system and
safety devices)
18 -do- Vibratory screen- working Exercise on electrical Definition of
mechanism. drawing reading of machines mechanical
Feeders- types, working connections to advantages (MA),
mechanism. motors through velocity ratio (VR),
ammeter, voltmeter
and KW meters.
Exercise on reading
and tracing wiring
diagram of an
alternator and
reproducing it in
proper sequence.
19 Demonstration on belt jointing Maintenance practice- Graphic symbols for Basic principle of
Pulley lagging, belt sway control Rotating m/cs machines, its
belt joining methods. and efficiency. Relation
Transformers between friction and
Diagram of efficiency in case of
connection to a idle machines.
squirrel cage Relation between
induction motor. efficiency and load.
Sketching the
connection diagram
of controlling and
protective devices for
induction motor.
20 Dismantle, inspect and do minor Breakdown Maintenance & Study of electrical -do-
& repairs and assemble machine tools Preventive Maintenance circuit diagram used
21 such as drill, shaper, lathe and power Difference between breakdown in machine tools
28
saw machines. and preventive maintenance – Its (lathe, milling,
importance in productivity, shaping, grinding).
types.
Normal procedure followed for
maintenance of machine tool in
the shop floor.
22 Practice on accuracy testing of machine Accuracy testing of machine Draw the typical Efficiency of
tools. tools. symbols used in machines - winch,
Logging checklist for machine tools. Various maintenance practices. hydraulic elements. pulleys, wheel and
Graphical symbols axle, screw jack and
used in hydraulic its calculations.
circuit, types of
distribution system
and method of
connection in
machine tools.-do-
23 Preparing inspection check-list, taking Inspection & Condition -do- -do-
measurement with the help of industrial Monitoring
thermometer and temperature gun. Maintenance strategy – Reactive,
Use of vibration meter to take Preventive, Predictive and
measurement. proactive
Importance of inspection.
Type/methods of inspection-
shutdown inspection, Inspection
of running equipments and
inspection of spare parts.
Commonly used gadgets for
inspection.
Concept of inspection check-list.
Importance of condition
monitoring.
Various techniques used for
condition monitoring. (vibration,
temperature, sound and lubricant
condition)
24 -do- -do- Study of hydraulic Calculation speed of
29
circuit diagram used belt pulley drive,
in machine tools gear drive. Cutting
(hydraulic operated speed and feed for
shaping, grinding & lathe, milling and
CNC machines). shaping machines.
25 Revision
26 Examination
Achievements:
On completion of Third Semester the trainee will be able to:
a). Study & work on Basic Electrical & Electronics circuits used in machine Tools.
b). Basic knowledge of PLC Instrumentations & its function in machine control.
c). Know the functions of hydraulic pumps, valves, actuators, filter, pressure regulator, lubricator and its parts.
Knowledge about hydraulic & pneumatic circuits.
d). Working on Bulk Material Handling equipment, Breakdown & Preventive Maintenance of machine tools.
32
23 Hand keyway breacher As required
24 C.I. Surface plate 400 x 400 mm with wooden stand and cover As required
25 Head lamp 1 no.
26 Bearing and gear tester As required
27 Master test bars (Different sizes) 1 no.
28 Spirit Level 150 mm 2 nos.
29 3 Cells Torch 2 nos,
30 Gasket Hollow punches 5, 6, 8, 10, 12, 19, 25 mm dia. 1 each
31 Bar type Torque Wrench 1 no
32 Cam lock type Screw Driver 1 no
33 Flaring tools 2 no
34 Tube Expander up to 62 mm 2 set
35 Circlip Pliers (inside, outside and straight) 1 each
36 Sledge hammers 5 Kgs. 1 no
37 Viscometer 1 no.
38 Vernier height gauge 300 mm 1 no.
39 Maintenance tool kit trolley of 1200 x 800 x1200 mm (L x W x H) As required
40 Steel lockers for 16 trainees 2 nos.
41 Steel cupboard 180 cm x 60 cm x 45 cm 6 nos.
42 Workbench 240 cm x 120 cm x 75 cm (Each bench fitted with 4 vices) 4 nos.
43 Bench Vice with 100 mm jaw 16 nos.
44 Letter punch 5 mm set 1 set
45 Number punch 5mm set 1 set
46 Deep cutting hacksaw frame 300 mm 1 no.
C. PRECISION INSTRUMENTS:
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8 Combination set with 300 mm blade centre head, square head and 1 no.
protector head.
9 Sine bar 200 mm 1 no.
10 Slip Gauge Box (workshop grade) -87 pieces per set 1 no.
11 Inside micrometer 50 mm to 200mm, 0.01 mm least count with six 1 no.
extension rod.
12 Gear tooth Micrometer ( metric ) 1 no.
13 Bevel gauge 200 1 no.
14 Dial test indicator – Plunger type-Range 0-10 mm , Graduation 0.01 1 no.
mm, Reading 0-100 with revolution counter ( complete with
clamping devices and stand )
15 Feeler gauge 1 no.
16 Radius gauge 1 to 25 mm radius 1 no.
17 Screw pitch gauge for metric pitches ( 0.25 to 6 mm ) 1 no.
18 Center gauge 55º x 47½º 1 no.
19 Center gauge 60º 1 no.
20 Plug gauge Morse taper No.1, 2, 3, 4, 1 set
21 Ring gauge Morse taper No.1, 2, 3, 4, 1 set
22 Ring gauge Ø20mm (Go and No Go ) 1 no.
23 Limit plug gauges Ø20mm 1 no.
24 Wire gauges 1 no.
25 Bore gauge with dial indicator (1 mm range, 0-0.01 mm graduation)- 1 no.
Range of bore gauge 18-150 mm)
26 Dial test indicator – Plunger type-Range 0-10 mm, Graduation 0.01 1 no.
mm, Reading 0-100 with revolution counter.
27 Dial Test indicator holding stand with magnetic base of 60 x 47.5 1 no.
mm, universal swivel clamp and dial holding rod of 150 mm long
scriber.
28 Straight edge 485 mm to 1445 mm 1 set
D. LATHE TOOLS :
E. MACHINIST TOOLS :
F. GENERAL MACHINERIES :
H. WELDING WORK:
(If welding trade is available in the institute may be used-otherwise to be provided as per list given below)
1. GAS WELDING -
2. ARC WELDING -
(If welding trade is available in the institute may be used-otherwise to be provided as per list given below)
I. ERECTION TOOLS :
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