DIPLOMA IN AUTOMOBILE ENGINEERING

DIPLOMA IN AUTOMOBILE ENGINEERING

SCHEME OF INSTRUCTIONS AND EXAMINATIONS

(FIRST YEAR)

Subject Code
Name of the Subject
Instruction
period / week
Total Period / year

Scheme of Examination

Theory
Practical/Tutorial
Duration (hours)
Sessional Marks
End Exam Marks
Total
Marks
THEORY:

A-101

English

3
-
90
3
20
80
100

A-102

Engineering Mathematics - I
5
-
150
3
20
80
100

A-103

     Engineering Physics
4
-
120
3
20
80
100

A-104

         Engineering Chemistry
&Environmental
Studies
4
-
120
3
20
80
100

A-105

Engineering Mechanics
4
-
120
3
20
80
100

A-106

Workshop Technology
4
-
120
3
20
80
100
PRACTICAL:

A-107

Engineering Drawing practice

-
6
180
3
40
60
100

A-108

Basic Work shop practice
-
6
180
3
40
60
100

A-109

109-A Engineering Physics Lab practice
109-B Engineering Chemistry Lab practice
-
3
90
3
(1.5+1.5)
20+20
30+30
100
(50+50)

A-110

Computer fundamentals Lab practice
-
3
90
3
40
60
100
TOTAL
24
18
1260

280
720
1000















ENGINEERING MECHANICS

 

Subject Title                          :           Engineering Mechanics

Subject Code                         :           A-105

Periods/Week                        :           04

Periods per year                   :           120


TIME SCHEDULE

S No.
Major Topics
No. of  Periods
Weightage
of
Marks
Short
Answer Questions
Essay
Type
Questions
1
Statics
16
16
02
01
2
Friction
16
16
02
01
3
Dynamics
14
13
01
01
4
Simple machines
20
23
01
02
5
Basic Link Mechanisms
16
16
02
01
6
Transmission of power
28
26
02
02

Total
120
110
10
08

OBJECTIVES 
            Upon completion of the course the student shall be able to
           
1.0          Understand the concept of Statics
1.1       Explain the meaning of mechanics in engineering.
1.2       State the importance of mechanics in engineering.
1.3       Review the system of units used.
1.4       Explain the concept of force
1.5       List the types of forces
1.6       Explain the force system
            a) Co-planar and Non-Coplanar,
b) Parallel and Non-Parallel,
c) Like and Un like,
d) Concurrent and Non-concurrent
1.7       Explain the concept of equilibrium
1.8       State the parallelogram law of forces
1.9       State the triangle law of forces
1.10     State the polygon law of forces
1.11     State the Lami’s theorem.
1.12     Explain the concept of free body diagram
1.13     Solve the problems involving concurrent coplanar forces
1.14     Solve simple problems involving non-concurrent coplanar forces
1.15     Solve simple problems using Lami’s theorem
1.16     Define the term couple and moment of couple with legible sketch.
1.17     Explain the properties of a couple
1.18     State the condition of equilibrium of a body acted upon by co-planar
forces.

2.0          Understand the concept of Friction
2.1       Explain the concept of friction
2.2       State the laws of friction
2.3       Identify the machine members in which friction exists and desirable
2.4       Resolve the forces acting on bodies moving on horizontal plane.
2.5       Resolve the forces acting on bodies moving along the inclined planes.
2.6       Solve the related numerical problems

3.0       Understand the concept of Dynamics
3.1       Define the terms Kinematics and Kinetics    
3.2       Classify the motion types
3.3       Define the terms displacement, velocity and acceleration
3.4       State the Newton’s Laws of motion (without derivation)
3.5       Solve the problems related to the rectilinear motion of a particle
3.6       Explain the Motion of projectile
3.7       Solve the numerical problems
3.8       State the D’Alembert’s principle
3.9       Define the Law of conservation of energy
3.10     Explain the Work-Energy principle
3.11     Define the Law of conservation of momentum
3.12     Explain the Impulse –Momentum equation
3.13     Solve the problems using the above principles
3.14     Explain the Rotary motion of particle
3.15     Define Centripetal force.
3.16     Define Centrifugal force.
3.17     Differentiate Centripetal and Centrifugal forces
3.18     Describe simple harmonic motion.
3.19     Explain the application of simple harmonic motion in engineering.

4.0       Comprehend the Principles involved in Simple Machines
4.1       Define the important terms of simple machines
a) Machine, b) Mechanical Advantage, c) Velocity Ratio, d) Efficiency.
4.2       Illustrate the use of three classes of simple lever.
4.3       Show that an inclined plane is a simple machine to reduce the effort in lifting loads.
4.4       Derive expression for Velocity Ratio in cases of Wheel & Axle, Weston Differential pulley blocks, Pulleys, Worm & Worm wheel, Winch crabs, Screw jack, Rack & Pinion.
4.5       Compute the efficiency of a given machine.
4.6       Compute effort required to raise or lower the load under given conditions.
4.7       Interpret the law of machine.
4.8       State the conditions for self-locking and reversibility.
4.9       Calculate effort lost in friction and load equivalent of friction.          
4.10     Evaluate the conditions for maximum Mechanical Advantage & Maximum
            efficiency.

5.0       Understand the concept of Basic Link mechanism
5.1       Define important terms of basic link mechanism
a) Link, b) Kinematics pair, c) Kinematic chain, d) Mechanism & e) Machine
5.2       Explain kinematic pair and kinematic chain with the help of legible sketch
5.2       List examples for Lower and Higher pairs.
5.3       List examples of inversion.

6.0       Understand the concept of transmission of power in Engineering.
6.1    Identify various power transmitting media like belt, chain, rope, gears.
6.2    Select suitable material for belt.
6.3    Explain the belt fasteners
6.4    Derive the expression for velocity ratio of a belt drive.
6.5    Explain the term slip in belt and its effect on velocity ratio.
6.6    Explain the combined effect of belt thickness and slip on velocity ratio.
6.7    Explain the use of jockey pulley.
6.8    Distinguish between open belt drive and cross belt drive.
6.9    Explain the tensions in tight and slack sides of a belt.
6.10  Calculate velocity ratio and power in belt drive.
6.11  Explain the rope drive state the advantages and limitations.
6.12  Explain the chain drive state the advantages and limitations.
6.13  Explain the types of chain.
6.14  Explain the principle of gear drive state the advantages and limitations.
6.15  Classify the gears.
6.16  Explain nomenclature of gear
6.17  Discuss the simple and compound gear train.
6.18  Explain the applications of the above drives in engineering.
.

COURSE CONTENT
1.0          Statics
1.1          The meaning of word mechanics.
1.2          Application of Mechanics in Engineering.
1.3          System of Units.
1.4          Definition and specification of force
1.5          System of  forces
1.6          Resolution of force
1.7          Equilibrium and Equilibrant.
1.8          Statement of Parallelogram law of forces, Triangle law of forces, Polygon law of forces and Lami’s theorem
1.9          Drawing the free body diagram
1.10       Numerical problems related to concurrent coplanar forces
1.11       Couple and moment of a couple
1.12       Condition for equilibrium of a rigid body subjected to number of coplanar non-concurrent forces.
1.13       Related numerical problems

2.0       Friction
2.1       Definition of static friction, dynamic friction and impending friction
2.2       Laws of solid and liquid friction
2.3       Derivation of limiting angle of friction and angle of repose
2.4       Resolution of forces considering friction when a body moves on horizontal plane.
2.5       Resolution of forces considering friction when a body moves on  inclined plane.
2.6       Numerical examples on the above cases

3.0       Dynamics
3.1       Definition of Kinematics and Kinetics
3.2       Classification of motion
3.3       Definition of displacement, velocity and acceleration
3.4       Laws of motion (without derivation)
3.5       Solving the problems related to the rectilinear motion of a particle
3.6       Motion of projectile and solving the numerical problems
3.7       Newton’s laws of motion.
3.8       D’Alembert’s principle
3.9       Definition Law of conservation of energy
3.10     Work - Energy principle
3.11     Law of conservation of momentum
3.12     Impulse – Momentum equation
3.13     Solving the kinetic problems using the above principles
3.14     Rotary motion of particle and laws of rotary motion
3.15     Definition and Differentiate Centripetal and Centrifugal forces.
3.16     Simple Harmonic Motion (SHM).
3.17     Definition of the terms frequency, time period, amplitude and circular frequency
3.18     SHM equation, natural frequency
3.19     Simple problems on SHM

4.0       Simple Machines
4.1       Definition of Simple machine, and uses of simple machine, levers 
and inclined plane.
4.2       Fundamental terms like mechanical advantage, velocity ratio and efficiency.
4.3       Expressions for VR in case of Simple/Differential pulley/pulleys of 3 systems, Worms and Worm wheel, Rack and pinion, Winch crabs, & Screw jack.
4.4       Conditions for reversibility and self locking.
4.5       Law of Simple Machine.
4.6       Effort lost in friction, Load equivalent of friction, Maximum Mechanical Advantage, and Maximum efficiency.

5.0       Basic Link Mechanism
5.1       Definition of terms: Link, Kinematic pair, Kinematic chain,     
Mechanism, Structure and Machine.
5.2       Quadric cycle chain and its inversions.
5.3       Slider Crank chain and its inversion.

 

6.0       Transmission of power:
6.1       Belt drive, Materials for the belt drive and belt fasteners.
6.2    (a) Explanation of the terms.
                                    i)Velocity ratio, in terms of diameters of pulleys.
                                    ii)Slip, percentage of slip and its effect on velocity ratio.
        iii)Thickness of belt and its effect on velocity ratio.
        iv)Tight side and Slack side of the belt.
                     (b) Open belt and Cross belt drive.
                     (c) Effective tension (T1 – T2).
                     (d) Velocity of the belt and Power transmitted by belt 
                     (e) Problems –Velocity ratio, Slip and Power transmitted in a belt drive.
            6.3      Rope drive – Advantages and limitations over a belt drive.
            6.4      Chain drive – Advantages and limitations over a belt drive.
            6.5       Types of chains.
            6.6       Gears and Gear trains
                     a) Nomenclature of gear
                     b) Types of gears – spur, helical, bevel, and spiral.
                     c) Simple and compound gear trains.
                     d) Velocity ratio in gear drive processes and problems.
                     e) Advantages and limitations gear drive over a belt drive.
REFERENCE BOOKS:

1          Basic Mechanical Engineering           by        V.N Kumar
2          Elements of Mechanical engineering by        Roy & Choudary
3          Engineering Mechanics          by        Singer                          B.S.Publications
4          Engineering Mechanics          by        Basudeb Bhattacharya – Oxford Publishers
5          Engineering Mechanics          by        A Nelson         Mc Graw Hill Publishers
6          Engineering Mechanics          by        I.B.Prasad
7          Engineering Mechanics          by        R.S.Khurmi                 S.Chand & Comp      
8          Theory of Machines                by        S.S.Rathan                 TMH P
9          Theory of Machines                by        R.S. Khurmi
10        Theory of Mechanisms and Machines by   Malik & Ghoshe



















WORKSHOP TECHNOLOGY


Subject Title                          :           Workshop Technology
Subject Code                         :           A-106
Periods per Week                 :           04
Periods per Year                   :           120

TIME SCHEDULE
S. No.
Major Topics
No. of Periods
Weightage
of
Marks
Short
Answer Questions
Essay type

Questions

1
Basic Workshop tools & operations





(1) Carpentry                         
20
16
2
1

(2) Fitting
25
26
2
2

(3) Forging      
15
13
1
1

(4) Sheet metal                                                        
12
13
1
1
2
Drilling
10
13
1
1
3
Foundry
22
16
2
1
4
Mechanical working of metals
16
13
1
1

Total
120
110
10
08

OBJECTIVES :
Upon completion of the course the student shall be able to

1.0          Comprehend the use of Basic workshop tools and its operation
a.    State the importance of workshop processes.
b.    List the various workshop processes and explain briefly about each.

1.1          Carpentry
a.    Identify various carpentry tools.
b.    Distinguish between marking tools, measuring tools and cutting tools.
c.    List work holding devices.
d.    Explain wood working processes viz., sawing, chiselling and planing.
e.Explain the use of carpentry joints such as lap joint, dovetail   
 joint, mortise and tenon joint with legible sketch
f.     Explain the working of wood working machines.      

1.2  Fitting
a.    List various fitting tools.
b.    Distinguish between marking and measuring tools.
c.    List cutting tools.
d.    List various work holding devices.
e.    List various checking and measuring instruments.
f.     Explain fitting operations such as marking, sawing, chipping, filing, grinding, drilling and tapping with legible sketch
1.3          Forging
a.    List various tools used in black-smithy.
b.    List equipment used in a forging shop.
c.    Explain the important smithy operations
d.    Explain the working principle of machine forging
e.    Explain machine forging operations such as upsetting, drawing down and punching with legible sketch
f.     Explain the working principle of forging press with legible sketch.
g.    List the forging defects
                    
1.4          Sheet Metal
a.    List various marking tools in sheet metal work
b.    List various stakes
c.    List various measuring tools used in sheet metal work
d.    List various sheet metal joints.
e.    Describe sheet metal operations such as shearing, bending,
drawing and squeezing
f.     Differentiate between riveting, soldering & brazing  
.
2.0          Understand the concept of drilling
2.1 State the working principle of drilling.
2.2 List out different types of drilling machines.
2.3 Draw the line diagrams of the sensitive and radial drilling machines.
2.4 Identify the parts of sensitive and radial drilling machines
2.5 Describe the functions of each part of sensitive and radial drilling machines
2.6 Write the Specications of drilling machines.
2.7 Write the nomenclature of the drill bit.
2.8 Write the geometry of twist drill.
2.9 List the functions of twist drill elements.
2.10 List the different operations on drilling machine.

3.0       Understand the concept of Foundry
3.1 Acquaint with foundry as a manufacturing process.
3.2 State the advantages of casting over other process.
3.3 State the limitations of the process.
3.4 List the various hand moulding tools.
3.5 State the properties of good moulding sand.
3.6 State the types of moulding sands.
3.7 List the ingredients in foundry sand.
3.8 List the various types of patterns.
3.9 State the sequence of pattern making operations.
3.10 Identify the colour codes.
3.11 List the various moulding processes.
3.12 State the need and types of cores.
3.13 Describe the casting processes.
3.14 Identify the defects in casting.
3.15 Describe special casting processes.

4.0       Mechanical working of metals
            4.1 Define mechanical working of metals.
            4.2 Differentiate between cold working and hot working.
            4.3 Illustrate the working principle of hot rolling, piercing, spinning, extrusion and
                 drawing.
            4.4 State advantages and limitations of hot working.
            4.5 Identify various cold working processes such as rolling, bending and
                  squeezing.
            4.6 State advantages and limitations of cold working.

COURSE CONTENT

1              Introduction : Basic workshop tools and its operation
Methods of manufacturing processes - casting, forming, metal removal processes, joining processes, surface finishing processes, basic workshop processes -  carpentry, fitting, hand forging, machine forging, sheet metal work, cold and hot working of metals.
1.1          Carpentry

1.1.1      Marking & measuring tools: scales, rules, fourfold wooden rule, flexible measuring rule (tape), straight edge, try square, bevel square, combination square, marking knife, marking gauge, mortise gauge, cutting gauge, wing compass, trammel, divider, outside calliper, inside calliper, odd leg calliper, spirit level, plum bob, specifications- uses.

1.1.2      Cutting Tools

 Saws: ripsaw, cross cut saw (hand saw), panel saw, tenon or     
 back saw, dovetail saw, bow saw, coping saw,  compass saw,   
 pad or keyhole saw, specifications & uses.
 Chisels: Firmer chisel, bevelled edge firmer chisel, parting    
 chisel, mortise chisel, inside and outside gauges, specifications   
 and uses.
 Planes: Jack plane (wooden jack plane, metal jack plane),   
 rough plane, smoothing plane, rebate  plane, plough plane, 
 router, spoke shave, special planes and their specifications  
 and uses.
             Boring Tools:
 Gimlet, braces- wheel brace, ratchet brace, bit-shell bit, twist bit  
 (auger bit), expansive bit, centre bit, router bit, countersink bit,   
 drill, reamer their specifications & uses.
1.1.3   Striking tools:
           Hammers - Warrington hammer, claw hammer, mallet,   
           specifications & uses.  
1.1.4   Holding devices
                        Bench vice, bench stop, bench hold fast, sash cramp (bar 
                        cramp) G- cramp, Hand screw, specifications & uses.
1.1.5  Miscellaneous tools
                        Rasps and files, scraper, oilstone, glass paper, pincer, screw
                        driver,  cabinet screw driver, ratchet-screw driver, saw set, oil
                        stone slip. specifications and uses.
1.1.6   Carpentry Processes
                        Marking, measuring, sawing, chiselling, planing, boring, grooving,
                        rebating & moulding.

1.1.7   Carpentry joints
                          Halving Joint, mortise and tenon joint, bridle joint, butt joint.
                          dowel joint, tongue & groove joint, screw & slot joint,
                          dovetail joint, corner joint.

1.1.8 Wood working machines
                        Wood working lathe (wood turning lathe), circular saw, band
                        saw, wood planer, sanding machine, belt sander, spindle
                        sander, disc sander and grinder, specifications and uses.

1.2          Fitting
1.2.1      Cutting tools
Chisels: Flat chisel, cross cut chisel, half round chisel, diamond point chisel, side chisel, specifications and uses.
Files: Different parts of a file – sizes and shapes - flat file, hand file, square file ,piller file ,round file, triangular file, half round files, knife edge file, needle file – specifications and uses.
Scrapers: Flat, triangular, half round scrapers, specifications &
uses.
Saws: Hand hacksaw - solid frame, adjustable frame, specifications & uses, hand hacksaw blades. Power hack saw – description (horizontal reciprocating type), power hacksaw blade, specifications and uses, teeth set - saw material.
Drill bits: Flat drill, straight fluted drill, twist drill, parallel shank, tapered shank, specifications & uses.
Reamer:  Hand reamer, machine reamer, straight and spiral flutes reamers, specifications and uses.
Taps:  Hand taps - taper tap, plug tap and bottoming tap, specifications and uses.
Dies & Sockets: Dies- solid, adjustable - specifications and
uses.
1.2.2      Striking Tools
Hammers: Parts, ball peen, cross peen, straight peen hammers, soft hammer, sizes, specifications and uses.
1.2.3      Holding Devices
Vices: Bench vice, leg-vice, hand vice, pin vice, tool maker’s vice, pipe vice, care of vices, specifications and uses.
1.2.4      Marking Tools
Surface plate, V-block, angle plate, try square, scriber, punch - prick punch, centre punch, number punch, letter punch, specifications and uses.

1.2.5      Miscellaneous Tools
Screw drivers, spanners, single ended & double ended, box type, adjustable spanners, cutting pliers, nose pliers, allen keys, specifications and uses.

1.2.6      Checking and measuring instruments
Checking instruments :
Callipers: Outside & Inside callipers, hermaphrodite (odd leg) calliper with firm joint, spring callipers, transfer calliper sizes & uses, dividers - sizes & uses.

Measuring instruments :
Combination square, bevel protractor, universal bevel protractor, sine bar, universal surface gauge, engineer’s parallels, slip gauges, plane gauge, feeler gauge, angle gauge, radius & template gauge, screw pitch gauge, telescopic gauges, plate & wire gauge, ring and plug gauges, snap gauges specifications & uses, vernier callipers, vernier height gauge, vernier depth gauge, micrometer - outside & inside, stick micrometer, depth micrometer, vernier micrometer, screw thread micrometer- specifications and uses.

1.2.7      Fitting Operations :
Marking, sawing, chipping, filing, scrapping, grinding, drilling, reaming, tapping and dieing.

1.3          Forging

1.3.1      Hand forging tools: Anvil, swage block, hand hammers - types; sledge hammer, specifications and uses, tongs - types, specifications & uses, chisel - hot & cold chisels specifications & uses. swages - types and sizes, fullers, flatters, set hammer, punch and drift -  sizes and uses.
1.3.2      Equipment: Open and closed hearth heating furnaces, hand and power driven blowers, open and stock fire, fuels-charcoal, coal, oil and gaseous fuels.
1.3.3      Smith Operations: Upsetting, drawing down, setting down, punching, drifting, bending, welding, cutting, swaging, fullering and flattering.
1.3.4      Machine Forging: Need of machine forging, forging hammers -  spring hammer, pneumatic hammer, drop hammer, forging press, hydraulic press - line diagram, machine forging operations - drawing, upsetting, punching, tools used in machine forging.
1.3.5      Forging defects: Types and remedies.

1.4          Sheet Metal Work
1.4.1      Metals used for sheet metal work.
1.4.2      Sheet metal hand tools:
Measuring tools - steel rule, circumference rule, thickness gauge, sheet metal gauge, straight edge, scriber, divider, trammel points, punches, chisels, hammers, snips or shears, straight snip, double cutting shear, squaring shear, circular shear, bench & block shears.
Stakes: Double seaming stake, beak horn stake, bevel edged square stake, Hatches stake, needle stake, blow Horn stake, hollow mandrel stake, pliers (flat nose and round nose), grocers and rivet sets, soldering iron, specifications & uses.

1.4.3      Sheet Metal Operations

                                    Shearing: Cutting off, parting, blanking, punching, piercing,
                                    notching, slitting, lancing, nibbling and trimming.                                                                               Bending: Single bend, double bend, straight flange, edge hem,
                                    Embossing, beading, double hem or lock seam.
                                    Drawing:  Deep drawing, shallow or box drawing.
                        Squeezing: Sizing, coining, hobbing, ironing, riveting.


1.4.4      Sheet Metal Joints
Hem Joint: single hem, double hem & wired edge, seam joint -lap seam, grooved seam, single seam, double seam, dovetail seam, burred bottom seam or flanged seam.
1.4.5      Fastening Methods
                        Rivetting, soldering, brazing & spot welding.

                                                                                                                                                                                                                              
2              Drilling
2.1          Type of drilling machines: sensitive & radial and their constructional details and specifications.
2.2          Drill bits: Terminology - geometry of twist drill - functions of drill elements.
2.3          Operations: Drilling, reaming, boring, counter boring, counter sinking, tapping, spot facing and trepanning.

3              Foundry.
3.1          Introduction: Development of foundry as a manufacturing process, advantages and limitations of casting over other manufacturing processes.
3.2          Foundry equipment:
            Hand moulding tools:  shovel, riddle, rammers, trowels, slicks, lifter, strike - off bar, spruepin bellow, swab, gate cutter, mallet, vent rod, draw spike, rapping plate or lifting plate, pouring weight, gagger, clamps, spirit level, moulding boxes, snap box & flash box.
3.3          Sands: Properties of moulding sand - porosity, flowability, collapsibility, adhesiveness, cohesiveness and refractoriness.
3.4          Types of moulding sand : green sand, dry sand, loam sand, facing sand, backing sand, parting sand, core sand, system sand their ingredients and uses.
3.5          Pattern making: Materials such as wood, cast Iron, aluminium, brass, plastics their uses and relative advantages, classification of patterns such as solid (one piece), two piece and three pieces, split patterns, gate patterns and shell patterns, sequence in pattern making, pattern allowances and colour codes.
3.6          Cores:  Need of cores, types of cores.
3.7          Casting: green sand and dry sand moulding, cement bonded moulding, shell moulding, ceramic moulding,  defects in castings and their remedies.
3.8          Special casting processes: (Principles and applications only) die casting – hot chamber and cold chamber, centrifugal casting, CO2 process, investment casting.      
                          
4              Mechanical working of metals
4.1          Introduction: Hot working and cold working
4.2          Hot working processes: rolling - types of rolling, two high mill, three high mills, four high mills, piercing or seamless tubing, drawing or cupping, spinning, extrusion - direct or forward extrusion, indirect or backward extrusion, tube extrusion, Impact extrusion.
4.3          Effects of hot working of metals, advantages & limitations of hot working of metals.
4.4          Cold working process:
Rolling, drawing - wire drawing, tube drawing, bending, roll forming, angle bending, spinning, extrusion, squeezing, cold heading, thread rolling, peening.    
4.5          Effects of cold working of metals, advantages & limitations of cold working.

REFERENCE BOOKS

1.         Production Technology                         by      Jain & Gupta   (Khanna Publishers)
2.         Elementary Workshop Technology      by      Hazra Chowdary & Bhattacharya
                                                                                                            (Media Promotors)
3.         Manufacturing Technology (Vol I )       by      P N Rao (Mc Graw Hill)
3.         Workshop Technology Vol I & II           by      Raghuvamshi








































BASIC WORKSHOP PRACTICE

Subject Title                          :           Workshop Practice

Subject Code                         :           A -108

Periods/Week                        :           06
Periods Per Year                   :           180

TIME SCHEDULE
S.No
Major Title
No of Periods
1.
Fitting shop
36
2.
Forging shop
39
3.
Carpentry shop
51
4.
Sheet metal work
51

Test
03

Total
180

OBJECTIVES

Upon completion of the course the student shall be able to

·         Practice the required operations in Fitting Shop

 

·         Practice the required operations in Forging Shop

·         Practice the required operations in Carpentry Shop

 

·         Practice the required operations in Sheet metal Shop



















Competencies and Key competencies to be achieved by the student.
Title of the Job
Competencies
Key Competencies
Fitting shop

1.Marking and Chipping on Mild steel flat of
12 mm thick (12)
-        Identify appropriate measuring tool
-        Handle appropriate marking tool
-        Handle appropriate chipping tool
-        Mark the dimensions
-        Remove the material by chipping from MS flats
·         Mark the dimensions
·         Remove the material by chipping from MS flats
2.Cutting with hack saw of MS flats of 6mm thick (06)
-        Check the raw material for size
-        Fix the work piece in vice
-        Mark the work as per given dimensions
-        Perform dot punching
-        Load and unload hack saw blade from its frame
-        Use the hack saw to perform cutting operation
·         Load and unload hack saw blade from its frame
·         cut the work as per marked dimensions using Hack saw
3.Drilling  and  chamfering on  MS flat of 12mm thick (06)
-        Check the raw material for size
-        Apply the chalk on the surface and on all sides of the flat
-        Layout the dimensions and mark the lines using dot punch
-        Chamfer the edges through filing
-        Locate the hole centres using odd leg callipers and centre punching
-        Identify appropriate drill bit
-        Load and unload drill bit from the machine
·         Load and unload drill bit from the machine









4.Tapping and Dieing  on a MS flat of 12mm thick (06)
-        Check the raw material for size
-        Identify appropriate tap and die
-        Secure the tap in the wrench 
-        Tap the hole
-        Hold the bar in bench vice
-        Fix the die in die stock
-        Cut external threads using a Die
-        Check the fit for accuracy
·         Identify appropriate tap
·         Secure the tap in the wrench 
·         Tap the hole
·         Fix the die in die stock
·         Cut external threads using a Die

5.Assembling of two pieces, matching by filing 6mm thick MS flat (06)
-        Cut the pieces to size using hack saw
-        File surface of flat for trueness
-        Mark the surfaces as per dimensions
-        Dot punch the marked lines
-        Cut with hack saw as per marked lines
-        Smoot the surfaces with file
-        Assemble the two pieces
·         Identify appropriate file
·         File the specimen
·         Assemble two pieces





















Title of the Job
Competencies
Key Competencies
Forging shop

6.Conversion of Round to Square (09)
-        Identify the holding and striking tools
-        Heat the specimen to the appropriate temperature
-        Remove the specimen and hold it on the anvil
-        Hammer the specimen to the required shape


·         Heat the specimen to the appropriate temperature
·         Hammer the specimen to the required shape
7.Conversion of Round to Hexagon (09)
-        Identify the holding and striking tools
-        Heat the specimen to the appropriate temperature
-        Remove the specimen and hold it on the anvil
-        Hammer the specimen to the required shape


·         Heat the specimen to the appropriate temperature
·         Hammer the specimen to the required shape

8.Preparation of a Chisel from round rod (09)
-        Identify the holding and striking tools
-        Heat the specimen to the appropriate temperature
-        Remove the specimen and hold it on the anvil
-        Hammer the specimen to the required shape

·         Heat the specimen to the appropriate temperature
·         Hammer the specimen to the required shape

9.Preparation of a ring and hook from M.S round (06)
-        Identify the holding and striking tools
-        Heat the specimen to the appropriate temperature
-        Remove the specimen and hold it on the anvil
-        Hammer the specimen to the required shape

·         Heat the specimen to the appropriate temperature
·         Hammer the specimen to the required shape

10.Preparation of a hexagonal bolt and nut (06)
-        Identify the holding and striking tools
-        Heat the specimen to the appropriate temperature
-        Remove the specimen and hold it on the anvil
-        Hammer the specimen to the required shape

·         Heat the specimen to the appropriate temperature
·         Hammer the specimen to the required shape



Title of the Job
Competencies
Key Competencies
Carpentry Shop

11.Cutting of wood with hand saw (06)
-        Identify the orientation of grains
-        Select appropriate saw for cutting in each of the directions viz. across and along the grains
-        Select appropriate work holding device
-        Handle appropriate measuring and marking tools(Steel rule, Try square, Marking gauge)
-        Mark dimensions on work using Marking gauge
-        Fix the work in the vice
-        Perform cutting along the grains using Rip saw
-        Change the position of work in the vice
-        Perform cutting perpendicular the grains using cross cut saw
·         Identify the orientation of grains
·         Mark dimensions on work using marking gauge
·         Perform cutting along and perpendicular the grains using appropriate saw

12.Planing of wood(06)
-        Identify the direction for planing wood stock
-        Select appropriate jack plane
-        Prepare the jack plane for planing
(Load and unload the blade of a jack plane
-        Select appropriate work holding device
-        Perform marking on work using appropriate tool
-        Fix the work in the vice
-        Plane the surfaces on all four sides using jack plane
·         Identify the direction for planing wood stock
·         Prepare the jack plane for planing
·         Plane the surfaces on all four sides using jack plane








Title of the Job
Competencies
Key Competencies

Contd.,,,

13.Chiselling of wood (06)
-        Select appropriate chisels and saw
-        Select appropriate work holding device
-        Select appropriate measuring and marking tools
-        Fix the work in the vice
-        Mark the position of grooves on work using marking gauge
-        Cut sides of grooves by hand saw
-        Chip the material using firmer chisel by applying pressure with mallet
-        Finish the grooves with rasp file
·         Select appropriate chisels and saw
·         Mark the position of grooves on work using marking gauge
·         Cut sides of grooves by hand saw
·         Chip the material using firmer chisel by applying pressure with mallet


14.Preparation of  a Dove tail joint (09)
-       Select the appropriate cutting tools and work holding devices
-       Plane the wooden pieces on all sides
-       Mark at an angle of 750 with bevel square
-       Trim the dovetail by chisel to exact size
-       Cut the dovetail groove on second piece
-       Finish the groove
-       Assemble the two pieces to prepare dovetail halving joint by using mallet
·         Trim the dovetail by chisel to exact size
·         Mark at an angle of 750 with bevel square
·         Cut the dovetail groove on second piece
·         Assemble the two pieces to prepare dovetail halving joint by using mallet

15.Preparation of Mortise and Tenon joint (09)
-       Select the appropriate cutting tools and work holding devices
-       Plane the two pieces to the required size using jack plane
-       Mark the dimensions to make tenon using mortise gauge
-       Cut tenon with tenon saw along the marked lines

·         Mark the dimensions to make tenon  and mortise on two pieces using mortise gauge
·         Cut tenon with tenon saw along the marked lines


Title of the Job
Competencies
Key Competencies
Contd.,,,
Preparation of Mortise and Tenon joint
-        Use firmer chisel to remove the excess material to set finished tenon
-        Mark the dimension to make mortise on the second piece with mortise gauge
-        Use mortise chisel to provide recess in the second piece to accommodate tenon
-        Assemble the two pieces by fitting the tenon into mortise
·         Use mortise chisel to provide recess in the second piece to accommodate tenon
·         Assemble the two pieces by fitting the tenon into mortise
16.Wood turning on lathe (06)
-        Select appropriate tools
-        Plane the four corners of the work piece using jack plane
-        Mark the centres of the work  on either side
-        Mount the work between head stock & tailstock centres
-        Fix the tool in the tool post & Position it in appropriate height
-        Start the lathe to make the work piece to revolve at desired speed
-        Feed the bevel gauge against the rotating work to get the required size and shape
-        Use outside callipers to check the diameter of the work piece
-        Use parting off tool to reduce the diameter on either ends of the work piece
-        Remove the work piece between centres and cut off excess material on either sides
·         Mark the centres of the work  on either side
·         Fix the tool in the tool post & Position it in appropriate height
·         Start the lathe to make the work piece to revolve at desired speed
·         Feed the bevel gauge against the rotating work to get the required size and shape



Title of the Job
Competencies
Key Competencies
Contd.,,,


17.Preparation of any household article (ex: stool)
                                  (09)
-        Prepare the drawings of a stool required for a particular drawing table
-        State the specifications of the wood stock required
-        Identify the type of joints to be made
-        Identify the operations to be made and their sequence
-        Perform operations to produce pieces of joint
-        Assemble all joints as per the drawing
·         Prepare the drawings of a stool required for a particular drawing table
·         Identify the operations to be made and their sequence
·         Perform operations to produce pieces of joint
·         Assemble all joints as per the drawing

Title of the Job
Competencies
Key Competency
Sheet metal Work
18.Practice on cutting of sheet (06)
-        Cut the required sheet from the stock using snip
-        Mark the dimensions on the sheet using scriber & steel rule
-        Draw the circular shapes using divider
-        Perform rough cutting of the curved shapes using chisel and finish cutting using snips
-        Cut the straight edges using straight snips
·         Identify the marking and cutting tools
·         Cut the sheet of different shapes using appropriate tools
19.Formation of joints like grooved joint, locked groove joint (06)
-        Cut the sheet in to two halves
-        Form the flange on the sheet by folding the sheet along scribed lines using mallet & stakes
-        Perform bending edges of sheets applying moderate pressure using mallet
-        Inter lock the bent edges and apply pressure with mallet to make required joint
·         Identify the marking and cutting tools
·         Cut the sheet
·         Perform bending along the marked lines.
Title of the Job
Competencies
Key Competency
20.Preparation of a rectangular open type tray (09)
-        Draw the development of the object to be made
-        Place the pattern on the sheet
-        Mark the dimensions using scriber
-        Shear the required piece from the stock using straight snips
-        Mark the lines on the sheet to form bends
-        Strengthen the sides of sheet by single hem using hatchet stake
-        Form the sheet in to desired shape using stakes
-        Seam the corners by inserting laps of the adjacent sides with single hem
·         Drawing development of objects
·         Cut the sheet
·         Seam the corners by inserting laps of the adjacent sides with single hem
21.Preparation of  hollow cylinder (06)
-        Draw the development of the object to be made
-        Place the pattern on the sheet
-        Mark the dimensions using scriber
-        Shear the required piece from the stock using straight snips
-        Mark the lines on the sheet to form bends
-        Strengthen the sides of sheet by single hem on top & bottom side using hatchet stake
-        Form the flat sheet into cylindrical shape by cylindrical stake and apply pressure using mallet
-        Prepare single hem on to longitudinal sides in opposite directions
-        Inter lock the sides and apply pressure to make a strong joint
·         Identify the marking and cutting tools
·         Drawing development of objects
·         Cut the sheet
·         Inter lock the sides and apply pressure using mallet to make a strong joint
Title of the Job
Competencies
Key Competency
22.Preparation of pipe elbow (09)
-        Draw the development of a cylindrical pipe truncated at an angle of 450 on one side
-        Scribe the lines on the sheet by placing the pattern on it
-        Cut the sheet over the marked dimensions using curved snips
-        Hem the straight side of the sheet and flange the curved side
-        Fold the edges of joining sides
-        Form the sheet into cylindrical shape using stakes
-        Seam the sides using mallet
-        Repeat the similar operation for making the second pipe
-        Butt the treated portions of the cylindrical pipes at rectangles
-        Seam the  two pipes
-         Solder the joint to make leak proof

·         Draw the development of a cylindrical pipe truncated at an angle of 450 on one side
·         Cut the sheet over the marked dimensions using curved snips
·         Form the sheet into cylindrical shape using stakes




















Title of the Job
Competencies
Key Competency
23.Preparation of funnel (09)
-        Draw the development of upper conical part
-        Place the pattern on the sheet and cut to required size
-        Hem the upper side of the sheet
-        Flange out the bottom side of the sheet
-        Fold the edges of the joining sides
-        form the sheet into conical shape using appropriate stake and mallet
-        Repeat the similar operation for making the bottom part
-        Seam the top conical part and bottom conical part to obtain required funnel

·         Draw the development of upper and bottom conical parts
·         Place the pattern on the sheet and cut to required size
·         form the sheet into conical shape using appropriate stake and mallet
·         Seam the top conical part and bottom conical part to obtain required funnel
24.Preparation of utility articles such as dust pan, kerosene hand pump (06)
-        Draw the development of given dust pan
-        Scribe the lines on the sheet and cut to required size
-        Hem all the four sides to strengthen the edges
-        Form the sheet into designed shape using suitable stakes and mallet
-        Solder the corner lap joints to make the required dust pan
·         Identify the marking and cutting tools
·         Drawing development of objects
·         Cut the sheet
·         Perform bending along the marked lines and to form the article













COURSE CONTENT

FITTING SHOP

1.    Marking and chipping on Mild – steel flat 12 mm thick.
2.    Cutting with hack saw, M.S. Flats of 6 mm thick.
3.    Marking, cutting, drilling, Chamfering and tapping on a M.S. Flat 12 mm thick.
4.    Assembling of two pieces, Matching by filing (6 mm thick M.S. Plate)

FORGING SHOP

1.    Conversion of round to square.
2.    Conversion of round to Hexagon.
3.    Preparation of chisel from round rod.
4.    Preparation of ring and hook from M.S. round.
5.    Preparation of a hexagonal bolt and nut.

CARPENTRY SHOP

1.    Cutting of wood with hand saw.
2.    Planing of wood.
3.    Planing and chiseling of wood.
4.    Orientation of wood grain.
5.    Preparation of dovetail joint.
6.    Mortise and tenon joint.
7.    Wood turning on a lathe.
8.    Preparation of one household article.

SHEET METAL WORK

1.    Practice on cutting of sheet
2.    Formation of joints like grooved joints, locked groove joint
3.    Preparation of a rectangular open type tray
4.    Preparation of hollow cylinder
5.    Preparation of pipe elbow
6.    Preparation of mug.
7.    Preparation of funnel
8.    Preparation of utility articles such as dustpan, kerosene hand pump.



REFERENCE BOOKS

1.         Manufacturing Technology (Vol I )       by      P N Rao (Mc Graw Hill)
2.         Principles of Foundry Technology         by     P L Jain (Mc Graw Hill)







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