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SYLLABUS FOR THE TRADE OF MECHANIC MACHINE TOOL MAINTENANCE UNDER

CRAFTSMEN TRAINING SCHEME

PERIOD OF TRAINING – 2YEARS Week No.

Trade Theory Trade Practical Engineering Drawing

Workshop Calculation &

Science 1. Familiarization with the Institute.

Machinery used in the trade and type of work done by the trainees in the trade. Importance of safety, general safety precautions observed in the Institute and in the section. Occupational safety hazards and its prevention. Importance to safe working habits importance of good house keeping cleanliness & personal hygiene. Importance of the trade & trade training in the event of Economy of the conintry.

INTRODUCTION Importance of the trade trainning, types of the work done by the Trainee & role of Machine Tool Maintenance Mechanic in an industry. Rules & regulatance of the Institute. Importance of cleanliness, orderliness at the work place. Introductions to First Aid Box - it’s procedure of use and maintenance. Use of Personal Protective Equipment. Familiariasation with verios hand tools used in the trade. Issue of the Tool Box & Essinatail Tools & Alloction of work place.

Introduction to Engineering drawing, drawing board, T- square, set- squares, scales, French curves and its uses.

Introduction to Iron & Steel – its properties & uses. Difference between Iron & Steel.

2. Introduction of first aid. Causes and type of fires, fire precautions, precautions against outbreak of fire, different type of fire extinguishers and their

Usage of First aid box and practice of Cardiopulmonary Resuscitation (CPR)

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uses. Precautions while working at height. Gas safety Electrical safety

Usage of - Fire extinguishers - Safety appliances-

personal protective equipment (PPEs).

3-4 Basic Fitting Skill Classification, constructional and functional details of different type of vices (bench & machine), Care of vices, hacksaw, its classification, saw setting, selection of blades. Bench work safety- related hazards, risk and precautions.

Marking practice: Marking - straight, parallel and curved lines with odd leg calipers, steel rule, dividers, Scriber. Cut metals pieces of different profiles & sections by hack-sawing (straight, inclined & curved line) to accuracy of 0.5 mm.

Introduction about lines - its types, their thickness and applications in the drawing as per BIS-696.

Properties and use of non-ferrous materials and its alloy.

5. Classification, construction, material and functional detail of Files. Specification of files & Filing technique.

Breaking of new file teeth(on Brass) Parallel filing practice on flat surface.

Introduction about Lettering – its practice – types of lettering (single stroke & gothic letters)

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6. Linear measurements & its units Classification, construction, materials and functional detail of following basic measuring and marking tools : -

• Steel Rule • Calipers, • Divider, Trammel • Try Square • Marking Punch

Filing- flat, square and steps surfaces to an accuracy of 1.00mm. (Measurement by caliper and steel rule).

-do- Solving problems of percentage, ratio and proportions.

7. Precision Measuring Instruments: Concept of precision & accuracy Micrometer (outside, inside and depth) – working principle, construction, use & care,

Checking and setting of micrometer. Filing flat, square and steps to an accuracy of 0.5mm

Dimensioning – its types, terms, notations, placing of dimensions, unit of

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calculation of least count. (Measurement by Precision Instrument).

dimensioning and its general rules.

8 - 9. Vernier calipers, vernier height gauge & vernier bevel protector - principle, construction, calculation of least count, use and care.

Checking and setting of Vernier calipers vernier height gauge & vernier bevel protector. Filing flat, square, steps and contour surfaces to an accuracy of 0.4mm

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10. Classification, construction and functional detail of following marking devices- Surface plate, angle plate, marking block and V-Block.

Transfer of dimensions from drawing to work pieces. Finding center of a round bar with the help of ‘V’ block and marking block. Filing flat, square, steps and contour surfaces to an accuracy of 0.3mm.

Scales - its introduction, types.

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11. Classification, construction, materials and functional detail of Chisels & Hammers. Chipping technique Related hazards, risk and precautions.

Fixing of hammer handle. Chipping practice on flat surface, slots & oils grooves, and chamfer at different angle on MS plate.

-do- Definition of Various heat treatment processes of Steel and its alloy.

12. Introduction and care of pedestal grinding machine, wheel mounting & wheel dressing procedure. Related hazards, risk and precautions.

Truing of pedestal grinding wheel. Grinding/Repair and maintenance ordinary fitters’ tools such chisel, Hammer, Screw driver, Scriber, Centre punches, dividers, trammel and scrapers

Geometrical Construction of figures- triangles, square, hexagon, Octagon, circles, ellipses etc. & dividing of lines, angles into equal parts, tangent to a curve -using drawing instruments.

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13. Scrapers: Types and use. Marking media, Prussian blue, red lead, chalk and their special application and description.

Filing flat, square, steps and contour surfaces to an accuracy of 0.2mm. Scraping practice on flat & curved surfaces.

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14. Classification, construction, materials and functional detail of Drill & Reamer.

- do- -do- Algebra – addition, subtraction, multiplication and division.

15-16 Drilling machines: -Bench, pillar & radial types. Drilling operation, Cutting speed, feed & depth of cut. Related hazards, risk and precautions.

Use of drilling machine for drilling through & blind holes, counter boring and counter sinking on mild steel (MS) flat. Drilling on cylindrical surface. Reaming of drilled hole by hand reamer. Grinding practice of Drill.

Construction of Ellipse, cycloid, epicycloids, hypocycloid, involutes, helix – using French curves.

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17. Study of drill chuck, drill chuck key, drill sockets, sleeves – its construction, materials, its specifications and use.

Internal & external threading by Taps & Die. Making internal threads with taps (through holes and blind holes). Making external threads with dies. Prepare studs, nut and bolt. Prepare nuts and match with bolts.

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18. Taps & Dies: Classification, construction, material and functional detail of Taps & Dies.

Making square, Triangular, hexagon on MS flat to an accuracy of 0.2mm.

-do- Algebra – factors & factorization, fractions.

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19 Gauges: Classification and uses of Sine bar, Slip gauge, Limit gauge, Feeler gauge, thread gauge, screw pitch gauge, taper gauge.

Filing & fitting mating components within an accuracy of ± 0.15 mm & angular 45 minutes

Free hand sketching of standard elements like bolts, nuts, screws, dowels, rivets, spanners, hammers, chisels, punches, O/S caliper, I/S caliper, Odd Leg Caliper etc.

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20-21 Brief Introduction to ferrous metals used for hand tools. 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.

Filing & fitting mating components by filling within an accuracy of ± 0.13 mm & angular 30 minutes

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22-23 Interchangeability-Definition and its necessity, basic size, actual size, limits, deviation, Tolerance, allowance, clearance, interference, Fits-Definition, types, description with sketches. Method of expressing Tolerance as per BIS, Hole and Shaft basis (BIS standard). Related calculation on Limit, Fit and Tolerance.

Fitting of mating components by filling and scrapping within an accuracy of ± 0.12 mm & angular within 30 minutes

Free hand sketching of Vice, File, Hacksaw, parallel shank twist drill, drill chuck, micrometer, vernier, etc.

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24. Surface finish - importance, symbol, measuring techniques. Lapping & honing process.

-do- -do- Algebra - solving of simple equations, quadratic equations & simultaneous equation.

25. Fasteners: Introduction to fasteners, screw threads, related terminology and specification.

Practice on dovetail fitting mating components by filling and scrapping within an

Projection – introduction, principle, method of

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Keys- types & use, (parallel, sunk, tangential, gib head, woodruff, key ways.) Related hazards, risk and precautions

accuracy of ± 0.10 mm & angular within 30 minutes for cylindrical surfaces.

projection. Difference between third angle & first angle projection. Draw the projection view in 1st & 3rd method for the same component

26. Types of nuts, bolts, studs, locking devices for nut, wrench and spanner, pliers, screw drivers, Circlip, split pin, washers, spring washer. Concept of torque & torque wrench.

-do- Removal of broken studs from an assembly. Tightening of nut with the help of torque wrench.

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27. -do- Preparation of flat surfaces and scraping practice on flat surface taking impressin face high spots using prussian blue sharpening mond wheel & lapping stone.

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28. Revision & Test 29. Different types of rivets and their application Preparation of cylindrical

surfaces and scraping practice on cylindrical internal/external surface taking impressin face high spots using prussian blue sharpening mond wheel & lapping stone.

Orthographic projections I & III angle (simple figure to complex figure).

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30. Mechanical Assembly and Maintenance Practice Elements of mechanical power transmission, type of spindles and shafts (Universal spindle, Plain shaft, Hollow shaft, crank

-do- -do- Logarithm – its applications in multiplication, division, powers, roots (by using log

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shaft, cam shaft). Positive and Non-positive drive, Friction drive, Gear drive, Belt drive, Chain drive and Rope drive.

table).

31. Clutches Function of Clutches, its types and use in power transmission system. Function of electromagnetic system in clutch mechanism.

Identification and study of various components of mechanical power transmission system - Shafts, couplings, keys, gears, bearings, belts, chains, pulley, rope.

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32. Couplings: Concept of coupling and its type viz. Rigid coupling- Muff coupling, Flange coupling, Flexible coupling, Pin-bush coupling, Chain coupling, Gear coupling, Spider coupling, Tyre coupling, Grid coupling, Oldham-coupling, Fluid coupling, Universal coupling.

Identification of various types of clutches, clutch arrangements in power transmission system (machine tools), maintenance of clutch mechanism in machine tool.

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33. Belts- Belt types (v belt), specification(Flat and V ) Pulleys used for belt drive. Installation, Alignments of belts. Problems related to belts(Creep and slip) Belt maintenance. Sheave alignment, Chain drive- Roller chain, Silent chain, alignment of sprockets, maintenance of chain drive.

Measuring shaft and coupling bore for finding out taper & ovality to determine the type of fit. Find out the size of key for a given set of shaft & bore. Key making, mounting of coupling on shaft with key. Application of fits on assy. of key, hub & shaft. Installing drive belts, Measuring and adjusting the belt tension.

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34. Bearing:

Description and function of bearing, its types - sliding, rolling, solid bush, split bush, Collar and Pivot bearing. Plummer block bearing. Mounting of sliding contact bearings, measurement and adjustment of clearances in bearings.

Identification of various types of bearings. Checking dimensions of solid bush bearing, split bush bearing, journal and housing comparing of fits with its mating component as per BIS. Checking split bush bearing for proper contact on journal and housing by impression testing. Mounting of split bush bearing with proper clearance, measuring clearance with the help of lead wires.

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35. Type of Rolling contact bearings- Ball bearings- single row & double row, Deep groove ball bearing, Angular contact, Self aligning and Thrust bearing. Roller bearing- Cylindrical, Needle roller, Taper roller, Spherical roller, self aligning and Spherical roller thrust bearing. Use of ISO bearing designation code to generate market survey and purchase. Checking and adjustment of bearing clearance.

Identification of various types of bearing and bearing mounting arrangements in machine tools Tools- tackles used for mounting and dismounting. Inspection and mounting of ball bearing on shaft with proper fit by i) Impact sleeve ii) hydraulic or mechanical press iii)heating – in oil bath & induction heater. Mounting of ball & roller bearing in gear box housing. Dismounting of rolling contact bearing by using

-do- Definition of mass & weight – their units and differences.

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i) Hydraulic puller ii) Hydraulic press and iii) Mechanical pullers.

36. Methods of Mounting and dismounting of rolling contact bearing & taper roller bearing. (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.

Inspection of bearing for its smooth roiling, allowable-side play, noises, using bear test rig.

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37. Gear:

Type, description and function of gears- Spur, Single helical, and Double helical, Spiral, Bevel, Straight and Spiral bevel, Worm gears, Rack and pinion. Gear terminology. Gear train- simple, compound, 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

Use of gear roll tester for smooth rolling, PCD checking by cylindrical pin (Roll tester rig manufactured by the institute. Adjustable centre distance type). Checking of gear tooth thickness, clearance, concentricity etc.

-do- Definition of speed, velocity & acceleration their units. Difference between speed & velocity.

38. -do- Overhauling procedure of gear box (Pre cleaning, dismantling, cleaning, inspection, repair/ replacement, assembly). Preparation of inspection

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sheet/ report. Preparation of action plan.

39- 40.

Lubrication (Oil and Grease)

Concept of lubrication Types and properties of Oil and Grease. Methods of oil lubrication- Once through and centralized system. Methods of grease lubrication system- grease guns, centralized system. Warning & protective devices used in centralized lubrication 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.

Identification of lubricators. Working on (on models) centralized lubrication system, various lubrication fittings. Cleaning procedure of oil filters, lubricating line. Identification & Fitting of different type of seals and oil ring. Preparation & Fitting gasket for different joint surfaces. Identification of elements for pressure switch, temperature gauge, level indicator and relief valve and their assy. procedure.

Drawing of Isometric views from orthographic views.

Forces – definition - its unit, compressive, tensile and shear force. Newton’s laws of motion. Laws of gravitation

41. Cutting Fluids And Coolants 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.

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42. MACHINE FOUNDATION Method employed for installation & eraction of precision & heavy duty machines. Location & excavation of foundation. Different types of foundations – foundation bolts, structural, reinforced, wooden, isolated foundations.

Demonstration for location & excavation of foundation bolts, method employed for installation & eraction of precision & heavy duty machines.

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43. Leveling Definition and importance of leveling, Concept of Soft foot, Methods of checking and correcting soft foot. Types of levels- Spirit level, Water level, Dumpy level, Method of leveling. Preparation of packing and shim.

Checking for soft foot, checking for leveling, calculation of required amount of packing and shim for 4 legged bed, putting shim and do final check.

-do- Calculation of areas of plane figures formed by the combination of standard figures.

44. Alignment: Definition and importance of alignment, Types of misalignment, Planes of misalignment, Shaft vs. coupling alignment, Actions to be taken before alignment, Concept of Soft foot, Methods of checking and correcting soft foot, Concept of axial float, Concept of Indicator sag, Dial Test Indicator, Methods of alignment - Rim and Face readings on Stationary Machine, Rim and Face reading on machine to be seamed. Geometrical Alignment of Machine.

Shaft alignment, Doing the pre-check: coupling fit, eccentricity, perpendicularity, finding soft-foot with feeler, dial gauge and making corrections. Checking misalignment with the help of Taper gauge, Feeler gauge and Dial test indicator for i) Rim and Face readings on stationary machine (SM) ii)-Rim and Face reading on machine to be seamed (MTBS) Doing the related calculations to find out the rectification value adjusting for indicator sag. Preparing the appropriate shims, Correcting misalignment in vertical plane by providing calculated thickness of shim and in horizontal plane by shifting to required distance.

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Checking and correcting alignment with straight edge and thread: V-pulley and sprocket. Geometrical Alignment of Machine.

45. Balancing

Understanding importance of balancing and reasons of unbalance. Type of unbalance. Method of static balancing. Method of correction -Adding and removing mass -Mass centering.

Locating static unbalance in a rotor, finding the correction weight.

Missing lines and views.

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46. Lathe Machine Introduction to lathe machines and lathe operations. Speed, feed & depth of cut Lathe accessories and attachments. Chuck – its types, face plates, lathe dogs, lathe centers - its types, and lathe steady. Coolants and lubricants. Related hazards, risk and precautions.

Practice of Lathe tool grinding, tool setting. Lathe operations – plain turning, facing, step turning, undercut, chamfering, grooving, fillet radius within the accuracy of ±0.1mm and its checking of squareness, diameter, length, chamfer, fillets radius using micrometer, vernier caliper and gauges.

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47. Nomenclature of cutting tool. Lathe cutting tools angles for different lathe operations. Recommended cutting tool materials for lathe operations.

Lathe operations – drilling, boring, counter boring, thread making using die and tap.

-do- Calculation of volumes of standard solids prisms, cylinder, spheres, cone, pyramid, Frustum of cone and

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pyramids. 48. Different simple lathe operations –

parallel/straight turning, step turning, grooving, radius forming, drilling and boring, counter boring. Calculation of cutting speed, feed and turning time.

Practice of different taper turning methods on lathe.

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49. Different taper turning methods and its calculations.

Practice screw thread cutting - whit worth/metric (Internal & external)

Sectional views – introduction, application, section line, full sections, Half sections, aligned, revolve and remove section and different exercises.

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50. Definition of screw thread, types, forms and its applications. Calculation of gear train for screw thread cutting on lathe. Change gear and its calculation.

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51. Revision 52. Test 53. Shaper:

Introduction to Shaper machine its function and shaper operations.

Holding the job on shaping machine vice, setting of length of ram stroke. Making square block.

-do- Definition of work, Power & energy – their units’. Calculations of work, Power & energy.

54. Quick return mechanism of shaper. Calculation of cutting Speed, feed & depth of cut.

Making a “V” block -do- -do-

55. Welding & Gas Cutting Metal Joining Methods & its advantages, Welding types (Fusion, Non-fusion & Pressure), Common tools used in welding. Classification of welding processes, Arc

Setting up of an arc welding machine, Straight bead practice. Edge preparation for same thickness of plate for arc

Drawing of different bolt heads, screw heads, nuts, rivet heads, dowels and keys.

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Welding accessories. Basic Electricity as applied to Welding Arc Length & its effects Electric Arc Welding – Manual Metal Arc Welding – effect of variations in welding procedure on weldments during manual metal Arc Welding. Basic Welding Joints & Positions: - Purpose of root gap, tacking & key hole in the job pieces during welding. Arc Welding Machines: - AC & DC Arc Welding Machine advantages & disadvantages of AC & DC Welding. Safety Precautions: Related to Arc welding m/c & accessories.

welding.

56. Manual Metal Arc Welding Electrodes: - Sizes & Coding. Edge Preparation: - Necessity of edge preparation, Nomenclature of butt & fillet weld. Welding Symbols. Weld defects.

Laying straight-line bead on 12mm M.S. Plate in flat position and Horizontal position. Making butt , lap, tee and corner joint by arc on 12 mm M.S. Plate in Flat, Horizontal position.

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57. Explanation of gas welding and arc welding techniques. High Pressure Oxy-Acetylene Welding equipments & Accessories Safety precautions in handling Oxy-Acetylene Gas welding set. Systems of Oxy-Acetylene Welding- Flashback & backfire Types of Oxy-Acetylene flames: - Gases used in welding & Gas flame combination. Filler Rods for Gas Welding

Setting up of a gas welding set. Making different types of flames with gas welding equipment. Making straight beads with and without filler rod. Making square butt joint using plates / sheets of up to 3 mm thickness.

-do- Elementary trigonometry - ratios, use of trigonometric tables. Sine & Cosine rule.

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Safety in gas cutting process. 58. Description of welding equipment, types of

welding joints. Knowledge about flux, filler rod material. Principle of gas cutting. Oxy-Acetylene- Oxy L.P.G. cutting equipments. Name and application of other metal joining methods.

Setting up of gas cutting set. Setting up & adjustment of flame. Gas cut plates and sheets for the required dimensions – Straight cut, bevel cut, piercing hole and profile cutting.

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59 Milling: Introduction to milling machine, construction, types. Safety precaution followed during milling operation. Milling machine attachments.

Setting of milling cutters, machine vice (job holding device), cutting speed, feed, setting of table movement. Preparation of rectangular block by milling with in an accuracy of ± 0.2 mm.

Draw different types of Screw threads forms and their applications.

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60 Different types of milling cutters and its materials. Nomenclature of milling cutters.

Step milling (external) operation within the accuracy of ± 0.2mm

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61 Milling cutter holding devices, work holding devices, Milling machine operations, Up milling and Down milling.

Angular milling (external) -do- Friction – definitions, its effect, types. Laws of friction, angle of friction and its related calculations.

62 Calculation of cutting speed, feed, machining time for milling machine. Indexing methods and its calculations.

Concave and convex radius milling.

Free hand drawing of different types of Flanges, Coupling.

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63. Gears – types, calculation for spar, helical and bevel gears. Holding of gear blanks. Setting of cutters and gear blanks on m/c.

Milling key ways or spline. -do- -do-

64. Do Gear Cutting (spur/helical) Cotter & Cotter joints (Socket & Spigot)

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65. Grinding: Grinding machine - introduction, description, types - surface grinding and cylindrical grinding machines. Safety precaution followed while working on grinding machines.

Procedure for holding of job, setting of machine – stroke length. Practice of wheel balancing. Grinding of parallel and perpendicular surfaces with in the accuracy of ±0.02mm, using magnetic chucks and C-clamp.

Strap joint with jib & cotter.

Centre of gravity(CG) – definitions, calculation of CG of regular & irregular shape body. Effect of (CG) centre of gravity in the trade work.

66. Grinding wheels – abrasives, bond and bonding process, grit, grade, and structure of grinding wheels and its marking system.

Grinding angular surfaces within an accuracy of ±0.02 minutes using universal vice.

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67. Procedure for mounting of grinding wheels, balancing of grinding wheels, dressing and truing of grinding wheels, glazing and loading in grinding wheel.

Setting of machine for cylindrical grinding for internal & external surfaces within an accuracy of ±0.01mm.

Pin & knuckle joints. -do-

68. Calculation for cutting speed and work speed, feed, depth of cut and machining time.

Grinding steps on cylindrical surfaces within ±0.02mm accuracy. Grinding taper holes on cylindrical grinding machine within ±0.02mm accuracy.

Types of keys – its types, fittings in machine tools.

Definition of specific gravity, density and relative density. Difference between specific gravity & density. Calculation of density of a body.

69 Pipe Fitting and Valves Types of pipe, tubes and different fittings. Tools used in pipe work.

Cutting & Threading of pipe. Fitting of pipes as per sketch.

Circlips: its types, applications & fittings in machine tools.

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70 Pipe bending and jointing methods. Different types of expansions joints and their applications.

Bending of pipes as per drawing. Making pipe joint (flaring and ferrule).

Using method of felt, “O” ring, oil seal in machine tools.

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71 Pipe colour code. Use of different type of valve Bearing its drawing Levers – definitions,

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Safety precautions to be observed while working at pipeline. Constructional detail of different type of valve & their uses like: Gate, Globe, butterfly, Diaphragm.

like: Gate, Globe, butterfly, Diaphragm. Assembly and disassembly of valves. Making and replacement of gaskets. Overhauling of valves applicable to steel industry.

symbols, bearing retaining procedure in machine tools.

its types, working principle of levers.

72. Centrifugal Pump, Fan, Blower and Compressor Pump Function of pump. Types and working principle of centrifugal pump. Vertical turbine pump. Constructional detail of pump Starting and stopping Series & parallel operation of pump. Pump performance and characteristics. Capitation, & aeration Preventive & schedule maintenance of pumps. Gland packing changing procedure. Concept of Mechanical seal Trouble shooting in pump.

Identification of various types of centrifugal pumps, their parts. Overhauling of pump. Priming of pump, Fitting gland packing. Starting and stopping of pumps. Trouble shooting in pump operation.

Application of limits, fits, tolerance and different symbols used in manufactu-ring drawing.

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73. Fan & Blowers: Types and working principle Constructional detail of Fans & Blowers. Starting and stopping of Fans and Blowers Different parts of Fans & Blowers Concept of surge.

Identification of various type of fans, Blowers, their parts. Dismantling, cleaning and assembly of parts.

-do- Moment of a force. Problems with respect to levers of all the three orders.

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Preventive & scheduled maintenance.

74. Compressors:

Compression theory, Types of compressors Constructional detail of compressors, working mechanism Different parts and their function. Loading unloading system Concept of air dryer. Preventive & schedule maintenance.

Identification of various types of compressors, their parts. Starting and stopping of compressors Cleaning and changing of filters.

Reading of blueprints drawing of various assemblies –Bench vice, Tailstock, Clapper Box, and Pedestal Grinder – free sketches of assembled parts with dimensions.

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75. Basic Electrical, Electronics, PLC & Instrumentation Safety in electrical shop Passive circuit elements – resistors, capacitors and inductors. Its identification and testing. Colour code. Ohm’ law and its applications. Energy sources. Series and parallel connections.

Electrical

Safety precautions to be

observed while working in

electrical shop.

Identification of electrical accessories. Making simple wiring circuits and measurement of current and voltage.

-do- Definition, difference and unit of heat and temperature. Sources of heat and its effect on bodies. Types of heat transfer methods and their differences.

76. Measurement current, voltage, resistance and power. Use of multimeters. Basic principle of DC generators and motors, alternators and AC motors and transformers. Various types of switches, breakers, fuses, lamps, proximity switches, relays and contactor in electrical circuits.

Testing of power supply (AC & DC) Demonstration of use of test lamp and megger. Connections of DC/AC motors and its speed control. (Demonstration only)

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77. BASIC ELECTRONICS Introduction to electronics and its industrial applications.

Identification of passive and active electronic components. Observation of waveforms in

Reading of blueprints drawing of shaping machine power

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Introduction to digital electronics – numbers system and logic gates.

a power supply using oscilloscope. Verification of logic gate operations.

transmission assembly. Free hand sketching of bull gear, pinion, sliding blocks and their assembly arrangements with dimensions.

78. Introduction to semiconductor theory Intrinsic & extrinsic semi-conductors. P & N type semiconductors & P-N-junction-diode. Use of a P-N junction as switch use of P-N junction for rectification, Half wava. Full wave and bridge rectifiers. Introduction to transistors.

Scope of industrial electronics with reference to its application in machine tools operation. Fdentification of basic components. Such as Resistor capacitors Inductors.etc,from their out look.Types specifications and general applications of these components Testing & measurement of their values using multimeter,use of Resistance colour codes.solddering and desoldering of component on and from printed circuit boards (PCB) precautions to be taken while soldering on pcb.

-do- Relation between thermometric scales and their calculations. Calculation of quantity of heat of a body.

79. P-N-P & N-P-N junction devices a transistor – three layer three terminal device. Use of transistor as a switch. Use of transistor for amplification low amplification taken place. Soldering

Study of rectifiancs available in different package –lead identification & testeting by multimeter. Study of rectifier circuits –half wave full wave

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technique as applied to PCB soldering Dos Dont’s.

& brige rectifiers. Use of oscilloscope for checking of input & output wave forms. Studi of solid state devices such as diodes trasnsisters, SCRS & ICS 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.

80. Introduction to industrial process control system and equipment - sensors, transmitters and final control elements. Measurement of displacement, pressure, temperature, flow, level and speed. Application of encoders. Programmable logic controller (PLC) – General concept of working, Relay Logic Control vs. PLC, Block diagram, applications.

Instrumentation Demonstration on various measuring devices Demonstration of PLC

Reading of blueprints drawing of lathe machine head stock gear box - its power transmission system. Study of mounting of bearing, gears, fork, clutch- it’s locking/ retaining procedures. Preparation of free hand drawing as per dimensions.

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81. Hydraulics & Pneumatics Basic principles of Hydraulic - Advantages & limitation of hydraulic system, hydrostatic transmission, Pascal’s law, Brahma’s press, pressure & flow, speed of an actuator. Control valves: Different type of control valves used in hydraulic System.

Identification and familiarisation of various types of hydraulic elements such as pumps, valves, actuators and oil filters. Overhauling of valves

-do- Stress and strain – definitions, types, Hook’s Law. Ultimate strength and factor of safety.

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Function of pressure control valve, directional control valve, check valve, flow control valve.

82. Function and construction of gear pump, vane pump and piston pump, cylinder & hydraulic motor.

Overhauling of - Hydraulic pumps - Hydraulic actuators.

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83. Auxiliary & fluid conditioner: Reservoir, filter, strainer, pressure gauge, pipe & pipe fitting, accumulator, seals & packing Simple hydraulic circuits : - Hydraulic symbols - Study of different hyd. Circuits Related hazards, risk and precautions.

Simulation of hydraulic circuits. - Simple hydraulic circuits.

Reading of blueprints drawing of milling machine head & feed gear box - its power transmission system. Study of mounting of bearing, gears, fork, clutch- it’s locking/ retaining procedures. Preparation of free hand drawing as per dimensions.

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84. Electro hydraulic circuit, Electrical components

- Switches - Solenoid - Relay

Practical on hydraulic circuits.

-do- Problems on ultimate stress and factors of safety – Poisson’s Ratio-Modules of rigidity.

85. Basic principle of pneumatic system. Advantages & limitation. Air preparation. Constructional & functional details of pneumatic cylinder, motor, control valves and FRL unit.

Identification of various types of pneumatic elements such as: control valves, actuators, filter, pressure regulator and lubricator.

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86. Introduction to Pneumatic actuators Pneumatic Symbols Pneumatic circuit

Overhauling of pneumatic cylinders

- Practice on Pneumatic

-do- Electricity – definitions, Ohm’s Law, electrical

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Electrical control components - Switches - Solenoid - Relay

circuit

power, energy and units.

87. Rigging Knowledge of different tools & tackles used in rigging. Construction and capacity of wire rope. Capacity of ropes (other than wire rope). Application of knots and hitches. Care and maintenance of wire rope.

Practice of different type of knots & hitches used in material handling Raving sets of pulley block. Splicing of manila rope. Inspection of wire rope.

Piping symbols and its application in drawing.

-do-

88. Different type of jacks, chain block and pull lift. Knowledge of different types of scaffolding. Material movement by using different rigging tools and techniques. Safety appliances & precautions in rigging. Maintenance of tools and tackles.

Use of mechanical & hydraulic jack, rope puller, chain puller, chain block, winch Inspection of tools and tackles Loading, unloading and shifting of common and uncommon shapes of material. Hand signal used in rigging.

Draw the typical symbols used in electrical circuits. Graphical symbols used in electrical technology, circuit elements, types of distribution system and method of connection. (As per BIS code and IEEE, IES rules)

Magnetism – introduction, magnetization and magnetic materials. Use of magnets. Laws of attraction and repulsion.

89 Bulk Material Handling (Conveyor belt, Vibratory screen, Feeders) 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)

Demonstration on Belt conveyor system, Vibratory screen & feeder

-do- -do-

90 Vibratory screen- working mechanism. Feeders- types, working mechanism.

-do- Exercise on electrical drawing reading of connections to

Definition of machines mechanical advantages (MA),

26

motors through ammeter, voltmeter and KW meters. Exercise on reading and tracing wiring diagram of an alternator and reproducing it in proper sequence.

velocity ratio (VR),

91 Maintenance practice- Pulley lagging, belt sway control belt joining methods.

Demonstration on belt jointing

-do- -do-

92 Machine Tool Maintenance Introduction, parts & constructional details of Drill, Shaper, Lathe, Powershaw, Milling and Grinding Machines. Power transmission and lubrication system in machine tools.

Identification of different components of machine tools. Inspection of machine tool components. Demo on maintenance tools.

Graphic symbols for Rotating m/cs and Transformers Diagram of connection to a squirrel cage induction motor. Sketching the connection diagram of controlling and protective devices for induction motor.

Basic principle of machines, its efficiency. Relation between friction and efficiency in case of idle machines. Relation between efficiency and load.

93 - do - do - -do- -do- 94 Breakdown Maintenance & Preventive

Maintenance Difference between breakdown and preventive maintenance – Its importance in productivity, types. Normal procedure followed for maintenance of machine tool in the shop floor.

Dismantle, inspect and do minor repairs and assemble machine tools such as drill, shaper, lathe and power saw machines.

Study of electrical circuit diagram used in machine tools (lathe, milling, shaping, grinding).

-do-

95 Accuracy testing of machine tools. Practice on accuracy testing -do- Efficiency of

27

of machine tools.

machines - winch, pulleys, wheel and axle, screw jack and its calculations.

96. Various maintenance practices.

Logging checklist for machine tools. Revision & Test ( Practical)

Draw the typical symbols used in hydraulic elements. Graphical symbols used in hydraulic circuit, types of distribution system and method of connection in machine tools.

-do-

97 Inspection & Condition Monitoring Maintenance strategy – Reactive, Preventive, Predictive and 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.

Preparing inspection check-list, taking measurement with the help of industrial thermometer and temperature gun.

-do- -do-

98 Importance of condition monitoring. Various techniques used for condition monitoring. (vibration, temperature, sound and lubricant condition)

Use of vibration meter to take measurement.

Study of hydraulic circuit diagram used in machine tools (hydraulic operated shaping, grinding & CNC machines).

Calculation speed of belt pulley drive, gear drive. Cutting speed and feed for lathe, milling and shaping machines.

99 - 101

Introduction to CNC Machines, constructional details, study of hydraulic diagram, hydraulics valves etc.

Practical Demo CNC machine operation – its effected parts. Functioning of each parts. (Training through related

-do- -do-

28

CDs) Industrial visit to CNC based Workshop/factory.

102 - 103

Revision

104. Test

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SYLLABUS FOR THE TRADE OF MACHINE TOOL MAINTENANCE UNDER

APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING – 3 YEARS

FIRST & SECOND YEAR : SAME AS TWO YEAR CRAFTSMAN TRAINING SCHEME THIRD YEAR OF TRAINING: TRADE PRACTICAL

WEEK PRACTICAL 105-106

HOISTS AND CRANES Use of hoists and cranes for lifting purpose. Constructional feature and working principle. Methods of lifting jobs of various shapes, sizes and weights. Use of appropriate length of chains. Inspection of chain links.

107-108

PAINTING Use of painting / protective coating for rust prevention. Surface preparation, use of primers and surfaces. Brush & spray painting- painting metallic & wooden articles. Lacquering practice.

109-110

HEAT TREATMENT Introduction to various furnaces and tools. Hardening and tempering of hand tools. Annealing of hardened components (jobs) & normalizing. Hardening of common forged bench tools such as centre punch, Chisels screw drivers etc. Case hardening of shafts, pins, bushes spacers, couplings, gears etc.

36

111-115

OVERHAULING OF MACHINES TOOLS & ACCESSORIES Dismantling machine tools - Cleaning & oiling of dismantled parts, Assemble & Testing for operation. Dismantling of machine tools such as Bench Grinder, Pedestal Grinder, Sensitive Drilling machines tools. Cleaning & oiling of parts & assembly & testing.

116-118

SPINDLE ELEMENTS Study of various spindle drive mechanism used on bench grinder, drilling, milling, lathe & grinding machines. Checking for spindle run out axial & radial play. Setting of play as per standard chart. Checking of bearings for its performance-repairs & replacement as needed.

119-121

CNC MACHINES Introduction to CNC Technology. Special constructional & operational features with reference to driving mechanism machine tools design, lubrication systems. Familiarizations with Co-ordinate system, use of CNC Codes & programming practice. Manufacturing of simple job on CNC Trainer after programming. Care & maintenance of CNC machines.

122-123

ADVANCED HYDRAULICS Circuit building practice-regenerative (Sequencing) circuit with speed & pressure (Clamping) control. Counter balance circuits with speed control Traverse & feed circuits. Differential control circuits. Circuits using pilot controlled check valve, pressure regulator valve, pressure relief valve etc. Study of machine tools applications of the hydraulic drives for Rotary, Reciprocating, speed changing, clamping, unclamping & feed motions. Trouble shooting in hydraulic drive circuit for low pressure, noisy system reduced speed of the table, jamming of piston rod at the end of the stroke pressure increase in the system etc. Repairs & maintenance of pumps-gear, vane & radial piston. Repairs & maintenance of values-pressure control, direction control & flow control. Adjustment of values. Repairs & maintenance of actuators- single & double acting cylinders, Hydraulic motors etc. Piping practice with metallic & hose pipes. Use of Various types of pipe joints and fittings. Precautions to be taken in storage & handling of oils. Study of pressure gauge, pressure selectors & filter units. Setting of various hydraulic elements for proper functioning. Repairs of hydraulic presses & various hydraulically operated equipments. Fault finding by simulation.

124-130 SLIEDS AND GUIDEWAYS Inspection of machine guide ways & slides. Checking for straightness, flatness, Scoring/ scuffing marks & conditions of gibs, wedges for setting the gap. Use of filles gauges and dial indicator. Study of feed mechanism-removing, dismantling, cleaning & oiling of its machine elements assembly & fitting back to its position. Testing for its operation. Mechanism to be studied-Lathe machine-carriage, apron, feed box, head stock etc. milling machine-feed box (column, knee, saddle), rapid traverse gear box, intermediate gear box etc.

131-136 REPAIRS OF MACHINE ELEMENTS Application of skills involved in repairing in machine elements. Repairs of worn-out parts, worn-out gears.

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Replacement / repairing of bolts. Removal of broken studs from machine parts. Removal & mounting of pulleys, gears in the shaft after removing run out. Sleeving worn out holes & reboring to desired accuracy. Checking & repairing of broken & worn out gears, shafts, Pulleys, clutches, flanges etc. Putting back in the position. Rectification of key ways & replacing worn out keys. Replacement of damaged glands & seals. Removal & mounting of antifriction bearings. Scraping of machine slides, beds plain bearings. Placing/lapping/ adjusting plates for smooth operation.

137-143 PREVENTIVE MAINTENANCE Preparing check list for preventive maintenance of all types of machines-general purpose machines, special purpose machines, material handling equipment, heat treatment furnaces, CNC machines, hydraulic presses etc. Attending machines for preventive maintenance.

144-145 BREAKDOWN MAINTENACE Basic of breakdown maintenance. Practicing diagnosis of faults. Breakdown maintenance of machines & equipments available in the workshop.

146-155.

RECORDITIONING Re-conditioning of small machine tools such as bench Drilling machine, pillar type drilling machine, bench grinder, pedestal grinder, tool & cutter, coolant pumps etc. Reconditioning of General purpose & special purpose machines. Air compressors etc. Attending misalignment problems. Alignment of different units of machine tools as per Schlesinger’s standards

156 Test