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TSLC in Mechanical Engineering, Pre SLC intake

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1. S Duties and Tasks Time hrs No A Milling Machine Operation Demo Practical 1 Set Up Machine 1 1 Set up machine controls 1 2 1 2 Set up milling vice on machine table 2 2 1 3 Set up workpiece on machine table 2 2 1 4 Mount milling cutter on long arbor and in horizontal spindle 1 2 1 5 Mount milling cutter on short arbor in vertical spindle 1 1 1 6 Set up milling cutter in collets chuck 1 1 1 7 Grind single tip tool for fly cutter 2 4 2 Mill Plain Surface 2 1 Mill plain surface on horizontal milling 3 12 2 2 Mill plain surface on vertical milling 3 12 3 Mill Shoulders 3 1 Mill step surface in vertical milling with shell end mill cutter 2 12 4 Mill Angular Surface 4 1 Produce angular surface tilting vertical head 3 12 4 2 Perform angular surface with angular cutter 1 7 4 3 Perform angular surface setting the workpiece on machine table 2 8 or vice 5 Drill and Bore 5 1 Perform drilling amp boring in milling machine 2 16 6 Mill Grooves 6 1 End Milling a slot 2 8 6 2 Mill V groove 2 8 6 3 Mill blind groove through groove 3 12 7 Mill Key Ways 7 1 Mill key way through the length in a round workpiece 1 5 7 2 Mill blind key way in a round workpiece 1 5 8 Index Milling 8 1 Mill hexagonal shape around the periphery of round workpiece 2 8 9 Perform Project 9 1 Manufacture a Clamp 18 9 2 Manufacture Slide Rule 24 9 3 Manufacture
2. SN Name Author Publication l Welding Engineering and Dr R S Parmar Khanna Publishers Technology 2 Principal of Welding L M Gourd Viva Books Private Ltd Technology 3 Welding Principles and Larry Jeffus Thomsom Delmar Applications Learning 4 AWS D1 1 D1 1M 2004 Structural Welding Code Steel ANEAN e OE Di oes Ta William H Minnick The Good heart Willcox Handbook Company 152 Workshop Technology I Total 117 hrs Class week 3 hrs Unit sub unit Areas and Topics Time hrs 1 General Safety Theory 4 1 1 Safety introduction 1 3 General workshop safety 1 4 Occupational health surveillance 1 5 Electrical safety 1 6 Identifying shop hazards 1 7 Fire hazards and fighting safety 2 Bench work Theory 30 2 1 File 2 1 1 Filing safety 21 2 Introduction of File and its elements 2 1 3 Size of files 2 1 4 Types of file Cuts of files 2 1 4 1 Profiles 2 1 4 2 Cut of teeth 2 1 4 3 Grades of cut 24 3 Methods of filling 2 1 5 1 Transverse filing cross filing 2 1 3 2 Diagonal filing 21 53 Draw filing 2 2 Bench work hand tools Zak Introduction 2 2 1 1 Hacksaws and sawing 2 DA Safety precaution 2 2 1 3 Types of Frame 2 2 1 4 Hacksaw blades D22 Hammers 2 2 2 1 Introduction
3. Obtain sample or drawing of object to draw oblique view Determine the position in which draw oblique view to be able to show all the details A type of drawing represents Pictorial views Oblique projections and Fully equipped Classroom with Drawing board T set and drawing instrument Draw a horizontal base line their applications Mark a point on the base line Task Concept of trimetric Draw projection lines in one direction of projection 180 angle and other direction is 30 or 45 or Draw oblique projection 60 angle from marked point Draw a vertical line from the base point Mark the divisional points towards width Standards up to end point Mark the divisional points towards length up to end point Draw parallel vertical lines on all division points 10 Mark the divisional points on vertical line up to total height 11 Draw other lines to figure out on the layout 12 Erase projection lines 13 Give darkness for necessary lines Line should be uniform and joint should be crossed Neatness and cleanliness is maintained Safety Precautions 74 Duty 5 DRAW ORTHOGRAPHIC PROJECTION Time 18 0 hrs 5 1 Draw Three View Drawings in First Angle Projection Exercise 16 0 hrs Demo 2 0 hrs Objective Knowledge Obtain sample or drawing of object to draw Condition three view Prepare a drawing sheet Determine the front side and top view in first angle Calculate the space from dr
4. 2 2 2 2 Safety precaution LAA Types and use of Hammer 22259 Chisels and chippings 2 2 3 1 Introduction 22 32 Safety precaution 2223 Types and use of Chisels 2 2 4 Punch and punches ADAM Introduction DIAZ Safety precaution 2 2 4 3 Types and use of Punches 2 2 3 Pliers and Cutters 2 231 Introduction 222 Safety precaution D203 Types and use of Pliers 2 2 6 Taps and dies 2 2 6 1 Introduction 153 2 2 6 2 Safety precaution 2 2 6 3 Types of Taps and Dies 2 2 6 4 Tap handles and Die stocks 2 2 6 5 Size of Tap drills tapping drills 2 2 6 6 Screw extractor 22 Wrench and spanners 2 2 fal Introduction 221 2 Safety precaution 2 2 1 3 Types and use of Wrenches and Spanners 2 3 Work clamping devices 2 31 Vices 23A Introduction 2 3 1 2 Types of vices 2 3 1 3 Main parts of the vices 2 3 1 4 Uses of vices 2 3 2 C clamps 2d Introduction 2 3 2 2 Types and Use of C clamps 233 V Block with bridges 2 3 3 1 Introduction 2 3 3 2 Types and use of V Blocks and Clamping Measuring Instruments and Gauges 12 3 1 Scales and meters 3 1 1 Introduction 3 1 2 Types of Scale and rules 3 2 Calipers 3 2 1 Intro
5. Machine Elements 9 1 Introduction to thread 9 2 Thread types and applications 9 3 Thread Repair 9 4 tools used for nut bolts and screws 9 5 Introduction of shaft and axle 9 6 Application of shaft and axle 9 7 Shaft and axle repair 9 8 Introduction of gear and its types 9 9 Introduction of belt and pulleys 9 10 Types of belt and pulley 9 11 Application of belt and pulleys 9 11 Pulleys and Belts 9 12 Introduction of bearing pins and keys 9 12 Types of bearing pins and keys 10 Repair and Maintenance 10 1 Mechanical Repair and Maintenance 10 1 1 Introduction 10 1 2 Types of maintenance 10 1 4 Types of repairs 10 2 Electrical Repair and Maintenance 339 10 2 1 Introduction 10 2 2 Safety 10 2 3 Symbols 10 2 4 Wiring concept 10 2 5 Wiring diagram 10 2 6 Electrical hand tools and equipment 10 2 7 Electrical components 11 Structural Fabrication 10 11 1 Steel structural fabrication 11 1 1 Introduction 11 1 2 Types of joints welding riveted nut and bolts 11 1 3 Steel profiles used in steel structures 11 1 3 4 Members of light and heavy structures 11 1 3 5 Safety 11 2 Paints and Painting 11 3 Introduction of Drill jig and fixture
6. Ni PA 10 11 12 13 14 Obtain work shop drawing Read drawing thoroughly Obtain pre machined work piece material Obtain Bevel protractor Set the angle that has to be measure Hold the work piece in one hand and place the bevel of the protractor against the adjacent surface Slide the bevel down the vertical surface until the protractor blade touches the angular surface Position the work so that a bright light such as a window or an electric light is behind the work piece Look at between work piece and protractor to see if any light shows between the blade and the work piece If no light can be seen the surfaces of the work piece are at required angle Wipe the Bevel protractor clean and put it in its storing place Clean any oil and chips from the work piece Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Take Angular Measurements Using Bevel Protractor Standard How well e No light should pass between the blade of protractor and the surface e Work piece should be match with given drawing e Introduction of Bevel protractor e Features of bevel protractor e Uses of Bevel protractor e Importance of measuring angular surface e Procedure of taking angula
7. Obtain work piece Material iu to Workpiece clamping Refer and follow the steps of surface IS I P LA a weld from 3 to 9 except 4 dan Wave of welding in a transformer weldin i iti Use back plate at first time welding i 5 vertical position i accessories and different ae vertical position Penetration of welding in electrodes Place the work piece on the welding Vertical position stand with clamps and supports in a Vertical position parallel to nose Task e Tipeeaute Refer and follow the steps of vertical welding from 6 to 11 Perform Square butt in Vertical position Standards Maintain joining of two metals Maintain welding distortion Maintain welding penetration Follow welding procedure of Vertical position welding Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 145 Duty PERFORM OVERHEAD POSITION WELDING Time 9 0 hrs 4 1 Perform surface weld Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition Obtain w
8. Calculate the Scale of drawing to be drawn Draw the supporting lines Draw Steel Stairs Darken all objective lines 2 Represent the dimensions with symbol Draw the supporting lines require 13 Give darkness for necessary lines 14 Clean up the drawing sheet 6 7 8 Erase all projection lines Standards 9 1 Projected representative lines Design the view Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions 181 DUTY 4 DRAW STEEL FABRICATION Time 7 0 hrs 4 3 Draw Steel Roof Truss Exercise 6 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Fully equipped Classroom Measurement obtain Determine the length breadth and height of with Drawing board T set Basic configuration of the box to be develop DI i Steel Stairs Truss and drawing instrument Draw a reference vertical line leaving the left border margin and horizontal line on bottom information column Task Sketch out the rough design of steel Truss with dimensions in extra sheet Calculate the Scale of drawing to be drawn Draw the supporting lines Draw Steel Truss Darken all objective lines 2 Represent the dimensions with symbol Draw the supporting lines require 13 Give darkness for necessary lines 14 Clean up
9. Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 250 Duty 2 BREAKDOWN MAINTENANCE Time 3 0 hrs 2 1 Diagnose Finds Faults Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional manual Condition Read the pages of machine errors and Introduction of bad remedies instructions Fully equipped Machining shop power supply Check the electrical power supply with maintenance tools and Introduction and Noted all remarks seen and observed materials characteristics of Check the power transmissions bad power Noted all the remarks and observed Task transmission Check all the machine faults Introduction and Noted all the remarks and observed characteristic of bad machine components Diagnose Find Faults Standards Diagnosed and prepared report on faults power supply Diagnosed and prepared report on power transmission faults Fault machine is diagnosed and prepared Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 251 Duty 2 BREAKDOWN MAINTENANCE Time 3 0 hrs 2 2 Replace Change Gear Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional manual Condition Read the pages of gear train transmissions Introduction types Prepare a gear to be replace change Fully equipped Machining shop and application of Collect the set of repair tools
10. 242 Duty 2 PERFORM PLAIN SURFACE SHAPING Time 30 hrs 2 1 Produce Flat Even Surface Exercise 27 hrs Demo 3 hrs Steps Terminal Performance Related Objective Knowledge Ne SD Oe 10 Tighten the nut of tool post slide 12 13 14 Return the tool at the same starting point 16 17 18 Obtain work piece material Obtain set of parallel blocks as per working dimensions Set up work piece as per the shape and size Hold the HSS shaping rough tool bit Adjust stroke length Position stroke length in the center Bring the table so that the tool touches the top surface of the work piece Move table by hand out of the work piece longitudinally Loosen the nut of tool post slide Give depth of cut as for rough cut Start the machine Give feeding by hand observing surface made until complete the total surface Stop the machine Give further depth of cut referring the steps no 10 11 and 12 Take further machining until complete surface machined File out the burrs on all corners of the surface Condition Fully equipped workshop with work piece material shaping tool and Shaping machine Tasks Produce flat even surface Standards Machined surface is Flat and even e Process of shaping a flat even surface e Auto feed mechanism of shaper machine Safety Precaution Always deburr the work piece before clamping Always wear safety goggles when
11. Interpret Insert Function Box Differentiate Relative and Absolute Cell Reference Explain the procedure to insert formula function 0 50 1 00 13 Create Chart Graph Explain differentiate types of charts Graph State the procedure to create chart graph 025 1 00 14 Filter Data Differentiate between filtering and sorting Explain the purpose of filtering Interpret filtered data 0 25 1 00 15 Sort Data Explain the purpose of sorting Interpret sorted data 0 25 1 00 16 Setup Page in Spreadsheet Explain different features and attributes of Page Setup Box Explain how to setup margins orientation size and columns Explain the procedure to setup page 0 25 1 00 Sub total 2 00 7 00 Module 4 Create Presentation using Presentation Package S N Task Statements Related Technical Knowledge Time hrs T P 17 Prepare Master Slide Interpret Presentation package interface including tools menu Differentiate among slides master slide outline notes page handout master notes master and slide sorter Explain the purpose of preparing master slide Enlist the procedure to prepare 1 00 1 00 55 S N Task Statements Related Technical Knowledge Time hrs T P master slide including formatting and editing 18 Prepare Slides E
12. Reset machine control Choose datum point as per drawing Perform Drilling and Boring in 0 Raise the table towards the datum point so milling machine Types of boring tool that half of the anvil part of Centro fixes used in boring head touches the workpiece side 11 Start the m c using the hand cross feed move the table very slowly until the Centro fix just touches to shows the center 12 Stop and set the cross feed scale to zero 13 Lower the table until the Centro fix clears 14 Move table using hand cross feed at the center axis for drilling a hole 15 Lock the table as far as possible 16 Move the table longitudinally 17 Repeat the steps from 15 to 21 18 Change center drill reset r p m 19 Start spindle raise the table very slowly until the depth of center drill is sufficient 20 Change guide drills and perform holes from small to large 21 Change boring head with tool 22 Raise the table set the boring diameter 23 Give depth of cut 24 Give feed by raising the table 25 Go further machining until required bore is finished 27 Remove the workpiece and check the final measurement Eliminate backlashes of work table Drilling and boring in milling machine Standards Dimension should be according ro drawing Drilled and bored surface should be smooth and even Safety Precautions Be careful when setting the boring tool on boring head Be ensuring the cutting edge of boring tool is not blunt Se
13. Time 7 0 hrs 6 1 Repair of cast iron parts Exercise 6 0 hrs Demo 1 0 hrs Task and Steps Terminal Performance Related Technical Objective Knowledge Obtain workpiece of cast iron to be Condition repaired Obtain an Instruction Collect the accessories amp tools required Preheating cast iron parts Fully equipped workshop f Idi or welding with Arc welding Set up LPG Oxy acetylene with blow transformier wema Waye ol Welang an cast accessories and different iron joint torei electrodes Clean the worn parts Welding procedure Ground the work piece Pre heat as necessary Task Weld on worn parts and other areas Cool weld bead slowly by covering dry sands immediately after welding 10 Finish the weld at remaining welding mark smoothly referring steps above Repair welding of cast iron and forging metal parts Repair of cast iron parts Standards Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 150 Duty REPAIR WELDING PARTS Time 9 0 hrs 6 2 Fill a Large hole Exercise 8 0 hrs
14. of are within Tools and Equipments countersink 60 and 90 Drill m c with drill chuck key and drill bits centre punch steel hammer Drill vice Oil can Number punch Bench cleaning brush File brush Dust pan files Materials MS Flat Oil Safety 1 Check the cutting edge of the countersink 2 Use drift to remove taper shank from drill spindle 3 Use cleaning brush to clear out the chips 4 Refer to the safety precaution of taste drill a hole 33 Duty 4 PERFORM DRILLING Task 3 Counter Bore on Hole Time 4 hrs Theory 1 hrs Practical 3 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain workshop drawing Condition Given e Introduction to 2 Read drawing thoroughly e Well equipped workshop countebore 3 Obtain countersink as per the with set of hand toolsin e Types of countebore required size tool box e Importance of 4 Mount the same size of twist drillon e Drawing instruction and counterbore drill spindle on drill chuck work piece e Safety 5 Clamp the w p in drill vice or hold by hand placing at the m c table 6 Align the centre of m c spindle with the drilled hole to cut uniform angle 7 Change countersink on drill machine chuck 8 Set the RPM 9 Start machine 10 Check the alignment giving feed by hand 11 Re align if necessary 12 Give feed as per depth required Tasks What 13 Stop the machine Counterbore on hole 14 Remove th
15. 10 11 12 13 14 15 16 17 Obtain workshop drawing Obtain workpiece material Obtain necessary tool and equipments Measure rough dimension and file one side marrow plane for reference plane Based on marrow file out all six surface maintaining dimensions and right angle Mark layout line on workpiece for necessary drilling Punch dots on marking lines Checked the drill machine and clamping vice Make a drill hole according to the given drawing on punched dots Counter bore on required holes Counter sunk on all holes as its requirement Reamed the drilled hole as its requirements Check the final measurement Clean any oil and chips from the work piece Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Manufacture a Drill plate includes Counter bore amp Reamed hole Standard How well e Tolerances of dimensions are within the 0 1 mm Tools and Equipments Vernier caliper Counter bore Reamer Drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch Materials MS Flat Oil Safety Tighten the table lock nut to prevent the setting from being disturbed Use parallel block to prevent being drill on
16. 135 Duty PERFORM FLAT POSITION WELDING Time 5 5 hrs 1 5 Weld corner joint Exercise 5 0 hrs Demo 0 5 hrs Task and Steps Terminal Performance Related Objective Knowledge Obtain instructional drawing Condition Collect work piece Refer and follow the steps of surface weld from 3 to 9 Perform tack weld on both ends Check and re set the angle Strike the arc on a rough piece for trail Strike the arc on the work piece at one edge Task Move the electrode in a straight following the edges of both workpiece and complete Weld corner joint the bead at the other edge of the plate Remove the slag from the weld bead Standards Repeat the exercise till you achieve good result Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Maintain welding distortion Maintain joining of two metals Maintain uniform beads Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 136 Duty PERFORM FLAT POSITION WELDING 1 6 weld edge joints Time 7 hrs Exercis
17. 4 5 6 7 8 Schedule Maintenance Plan Standards Maintenance plan should be labeled as per provided plan Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 247 Duty 1 PREVENTIVE MAINTENANCE Time 3 0 hrs 1 2 Manage Stock Spare Components Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Obtain instructional manual Condition Read the pages of maintenance instructions Introduction of List down the machine components to spare Fully equipped Machining shop Stock materials Purchase the components as its frequency of with maintenance tools and Plan standard replace materials spares and Make a separate store with different racks materials for Control the store environment from being Task stocks ageing Prepare a record book to maintain the stock Manage Stock Spare balance Components Standards Record book should be match with provided original book Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 248 Duty 1 PREVENTIVE MAINTENANCE Time 3 0 hrs 1 3 Apply Lubricants and lubrication Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Obtain user s manual Condition Read the pages and charts of lubrication point Introduction of List down with lubrication intervals Fully equipped Machining shop lubricants and Dra
18. All the columns and row 13 Decide the information column and rows for drawing information s 14 Decide the dimensions of column and rows should be allocatd 15 Draw respectively from the bottom Title box should be within 16 Write titles of the column given area 17 Give darkness of all drawn lines with HB Title block should be made pencil in standard format 18 Clean up the drawing sheet Safety Precautions e Avoid using damaged drawing board e Avoid using damaged instruments 60 Duty 1 HANDLE INSTRUMENTS Time 3 0 hrs 1 3 Draw Engineering Lines Exercise 2 hrs Demo 1 hrs Objective Knowledge Set paper in drawing board Condition Introduction of drawing 2 Prepare a drawing sheet Engineering lines Scaled and mark the drawing sheet into spacing 10 mm leaving the margin in side boarder Attach the ebony working edge of T set Bring the working edge on the marked Introduction of Pencil point Task and its uses and types in Draw a continuous thick line o engineering drawing Move T set to next marked point and draw Draw representative lines the line Repeat the step 7 and draw the lines in full of the drawing sheet Write continuous thick line and dates in Standards information column e Line thickness should be 10 Change drawing paper according to international 11 Repeat same steps till step 5 standard 12 Draw invisible line Neatness and cleanliness is 13 Repeat the step 7 and draw the lines in fu
19. Duty 4 DRAW PICTORIAL PROJECTION 4 1 Draw Isometric Projection Steps Terminal Performance Related Technical Objective Knowledge Condition Obtain sample or drawing of object to draw isometric view Determine the position in which draw isometric view to be able to show all the Pictorial views details Trimetric and oblique Draw a horizontal base line projections and their Mark a point on the base line Task applications Draw projection lines in both direction of 30 angle from marked point Draw isometric projection Draw a vertical line from the base point Mark the divisional points towards width upto end point Standards Mark the divisional points towards length Line thickness should be upto end point unif Draw parallel vertical lines on all division points 10 Mark the divisional points on vertical line upto total height Angle of the view should 11 Draw the parallel lines with 30 angle on all be in standard divisional points 12 Draw other lines to figure out on the layout 13 Erase projection lines 14 Give darkness for necessary lines A type of drawing Fully equipped Classroom represents with Drawing board T set and drawing instrument Maintained symmetry and line joints Safety Precautions 73 Duty 4 DRAW PICTORIAL PROJECTION ome AS Exercise 6 0 hrs Demo 2 0 hrs 4 2 Draw Oblique Projection Steps Terminal Performance Related Technical Objective Knowledge Condition
20. FINISH THE FABRICATE MEMBERS Time 1 5 hrs 5 2 Perform clipping Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Related Knowledge Objective Condition i Condition e Introduction and Obtain details of instructional drawing f clibpi purpose of clipping Prepare work piece materials Fully equipped workshop with Confirm the process of fitting hand tools and punches and Obtain the machine or tools equipments to punching facilities fabricate the materials Perform benchworks cutting drilling Tasks and punching Perform assembly works clipping as required as design Check the dimensions Store it in safe and special place Clipping on the panel is rigid Perform clipping Standards Clipping is checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 302 Duty 5 FINISH THE FABRICATE MEMBERS Time 1 5 hrs 5 3 Perform gasket pressing Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Related Knowledge Objective Condition e Introduction of gasket e Material used for gasket Obtain details of instructional drawing Prepare work piece materials Fully equipped workshop with Confirm the process of fitting hand tools and punches and Obtain the machine or tools equipments to punching facilities fabricate the materials Perform benchwor
21. Obtain the work piece drawing Read drawing thoroughly Obtain the metal sheet of required size and required sheet metal tools Straighten and de burr the sheet metal Layout the pattern Layout the folding lines by marking with marking scriber Check the layout for accuracy Notch and cut the unnecessary part Place the sheet on hollowing tool or round peaked stake Strike by hammer slightly on the sheet Continue the striking operation till the required obtained Check dimensions of the completed job Punch the roll no on work piece Store the work piece and tools Condition Given Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Roll metal sheet by hand tools Standard How well Rolling work piece should be match with given drawing Tolerances dimensions the 0 5 mm of are within e Introduction of rolling e Hand tools stakes used in rolling metal sheets e Mallet and types Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file stakes Materials GI Sheet Safety Take care of marked lines folds must not be collecting together Use only mallet hammer to bend sheet 108 Duty PERFORM CUTTING FOLDING AND ROLLING Time 3 hrs Task 6 Fold the metal sheet by foldin
22. Set up shell end mill cutter on Vertical Universal and Vertical Milling plain surface on milling Stub arbor machine Vertical milling Set up machine controls Bring the cutter just above the workpiece Tasks Wet the piece of paper and stick on the surface Mill Plain Surface on Vertical Start the machine Milling Touch the cutter gradually on work surface so that the paper moves slidely Standards 10 Take off the cutter moving table longitudinally Identified the cutter and set on 11 Give depth of cut as required universal vertical milling 12 Give feed till finishing at the end 13 Repeat until the required surface obtained Milling surface is plain and even 14 File out the burrs at all corners of the surface Safety Precautions e Follow the same Safety precaution of task milling Plain surface on Vertical milling 224 Duty 3 MILL SHOULDER Time 14 hrs 3 1 Mill Stepped Surface in Vertical milling with Shell end mill cutter Exercise 12 hrs Demo 2 hrs Steps Terminal Performance Related Objective Knowledge Obtain workpiece material Condition Obtain sets of parallel blocks Obtain Shell end mill cutter as per required Fully equipped workshop with size Universal and Vertical Milling Set up workpiece material as per the size machine Width of cut Set up milling cutter on short arbor in vertical spindle Set the machine controls Tasks Process of step Prepare a square block following the
23. e Clean the over floated paints on surface or painting zone e Use flat screw driver or iron rod to stir the paint e Check the gun nozzle before filling the enamel on spray gun e Use hanger to paint for small parts e Make protector guard in sides and rear of the sprayer platform e Avoid over spray on same surface e Use light emery after 1 coat then spray 2 coat 283 Duty 8 FABRICATE PROJECT STRUCTURES Time 7 0 hrs 8 1 Fabricate windows grills Exercise 6 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional Grill Condition drawing Prepare work piece materials Fully equipped workshop with Prepare re formed designed materials Bench work Drilling machine Obtain the machine or tools equipments to Grinding machine and welding fabricate the materials facilities Perform drilling on required size Perform assembly works tacking welding e Calulation for cutting length of metal for grill e Design of grill Tasks joints as design Check the dimensions Fabricate grills Weld full tacks welding Make 1 set as fixture for next set of Standards assembly 10 Store it in safe and special place The outer dimension of grill should be match with given drawing Design should be match as per drawing Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Weldi
24. 11 12 13 14 15 16 Obtain the work piece drawing Read drawing thoroughly Obtain the metal sheet of required size and required sheet metal tools Straighten and de burr the sheet metal Layout the pattern Layout the folding lines by marking with marking scriber Check the layout for accuracy Notch and cut the unnecessary part Fold the edges as per drawing and form the job to shape Strike the folding part by light hammer as per hemming shape provided in drawing Place the work piece on a suitable stake Groove the other end in the same manner Groove the entire seam by striking with the hammer Check dimensions of the completed job Punch the roll no on work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Groove edge seam hem Standard How well e Edge seam should be match with given drawing e Tolerances of dimensions are within the 0 5 mm Introduction of joint Seam joint and its type Tools used for making seam joint Hemming and its purpose Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Seam punch Hand groover Materials GI Sheet Safety Take care of marked lines folds must no
25. 11 4 Aluminum structural fabrication 11 4 1 Introduction 11 4 2 Machine and equipment 11 4 3 Safety 11 5 Aluminum profile 11 6 Introduction and types of ACP Aluminum composite panel Total 117 BOOK AND REFERENCES S K Hajra Chaudhary Workshop Technology Vol 1 11 and 111 Media promoters Henp Fort Shop Theory Vol 1 H and III Trade School W A J Chapman Workshop Technology Vol 1 1 and III Elsevier Science Heinrich Gerling Elementary Metal Course Training Section I ETHIO Arbeitsstelle fur Unterricht und Technik GERMAN Technical Institute Holetta Heinrich Gerling All about Machine Tools New Wiley Eastern Ltd India 1965 Dhanpat Rai amp Co A Course in Workshop Technology Vol I amp II Educational and Technical Publishers 340 Annex I Tools amp Equipments Required for First year Mechanical Fitting orig Ben rw O Cs foss SSCS OCS Ce rare small SSC Sr Co Pameto Sid o e Triangular file median ooo C o Triangular file small C Half round file small 15 Rondo small 14 Square file media O CS 15 Square ie small Cd CS Cie Needle file SSCS Cr S Cor Bok square SSC S 20 Tool maker square SSCS S ooo 21 Angular gauge SSS CS C Cemer square SSS S o oO 24 bague SSCS CS e O Sm iS 26 Straightedge SSCS CSC S Cor TSteel hammer O S C mm O CS 29 Centerpunch O PS 32 Marking seriber
26. 20 PA be 22 23 24 25 26 ZT 28 29 30 31 Re clamp the w p on bench vice in horizontal Fix the first tap in the tap handle wrench 12 Obtain w s drawing Read drawing thoroughly Obtain pre machined work material Obtain drill size and required tools for internal threads Obtain sets of taps and tap handle wrench Mark and punch on centre to drill hole Drill hole of required tap drill size Countersink the hole De burr the hole position slightly above the vice jaws Position the tap 90 with horizontal surface in the countersinked hole Hold the tap handle closer to the centre Exert steady downward pressure and turn the tap handle in clockwise direction to start the thread Ensure the thread as well as check the tap alignment removing the tap handle Check the tap alignment with Back Square to ensure the tap being 90 with the w p surface Make corrections if necessary by exerting slightly more pressure downward in the side having angle greater than 90 Fit the tap handle without disturbing the tap alignment Make 1 2 clockwise turn and re check the alignment Turn the tap handle lightly without exerting any downward pressure Turn anticlockwise quarterly after every clockwise full turn Apply cutting oil frequently Cut thread until the tap is fully inside the hole being threaded Remove the first tap Repeat the steps 18 to 23 for intermediate Tap no 2 and b
27. 4 50 54 Task 3 File external radius 2 20 22 Task 4 File internal profiles 2 16 18 Duty 2 Perform Marking Punching 4 21 25 Task 1 Measure and Mark on the work piece 2 4 6 Task 2 Stamp Letters and Numbers on metal plate 1 12 13 Task 3 Punch Dot and Center 1 5 6 Duty 3 Perform Cutting 7 51 58 Task 1 Saw metal by hand hack saw 2 18 20 Task 2 Chisel flat surface 2 12 14 Task 3 Chisel grooved surface 1 11 12 Task 4 Cut internal thread using hand taps Tapping 1 5 6 Task 5 Cut external thread using threading dies Dieing 1 5 6 Duty 4 Perform Drilling 5 17 22 Task 1 Drill a hole 2 6 8 Task 2 Countersunk on hole 1 3 4 Task 3 Counter bore on hole 1 3 4 Task 4 Ream drilled hole using hand reamers 1 5 6 Duty 5 Perform Off Hand Grinding 4 10 14 Task 1 Grind center punch 1 3 4 Task 2 Grind flat chisel 1 3 4 Task 3 Grind marking scriber 1 2 3 Task 4 Grind twist drills 1 2 3 Duty 6 Handle Measuring Instrument 5 25 30 Task 1 Check square ness using back square 1 5 6 Task 2 Check radius with radius gauge 1 5 6 Task 3 Take angular measurements using bevel protector 1 5 6 Task 4 Measure the dimensions using Vernier caliper 2 10 12 Duty 7 Perform Project Works 180 180 Task 1 Manufacture a drill plate includes counterbore 15 15 and reamed holes Task 2 Manufacture steel hammer of 500gm 30 30 Task 3 Manufacture C clamp 20 20 Task 4 Manufacture back square of 120mm 15 15 Task 5 Manufacture Ce
28. BIBLIOGRAPHY SN Name Author Publication 1 All about MACHINE TOOLS Heinrich Gerling 2 Elementary Metal Course Training _ BBF Section I 3 Fitter trade Practical CIMI Madras 4 Mechanical engineering ILO learning element 5 Hand Book of Fabrication process Orville D Lascoe ASM International 6 Hand Book of Aluminium work SORBET ASM International 304 Welding Technology II Gas TIG MIG Total 234 hrs Class week 6 hrs S No Duties and Tasks Time hrs A Oxy Acetylene Gas Welding OAW Demo Practical 1 Set up Gas Welding Equipment 1 1 Prepare acetylene gas 2 4 1 3 Set up welding equipments and nozzles 4 1 3 Adjust neutral flame 1 3 2 Run Beads in a Line 2 1 Run fusion without filler rod 2 13 2 2 Run fusion with filler rod 4 14 3 Perform Flat Position Welding 3 1 Weld edge joint 3 6 3 2 Weld square butt joint 4 3 3 Weld lap joint in the flat position 1 4 3 4 Weld T joint in the flat position 2 4 3 5 Weld pipe pipe 1 8 4 Perform Oxy Acetylene Flame Cutting 4 1 Cut MS plate by gas welding equipment 1 8 manual 5 Perform Hard Soldering Brazing 5 1 Braze brass in mild steel plate 3 6 5 2 Braze MS plate with MS pipe 5 5 3 Weld Butt joint in Copper plate 6 5 4 Weld Butt joint in Brass plate 6 Sub Total 23 94 Total 11
29. Dimension of workpiece should be as per drawing Safety Precautions Do not use broken handled hammer e Use safety gloves helmet and goggles e Deburr every corner and edges before holding by hand e Use gauges instead of measuring instruments to check the forge dimensions e Use some pre formed blocks for ease shaping the parts 276 Duty 4 PREPARE JIGS AND FIXTURE Time 24 hrs 4 1 Prepare Drill Jigs Exercise 22 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional Drill Jigs Condition drawing Prepare work piece materials Fully equipped workshop with Confirm the process of fabrications Bench work Drilling machine Advantage of using Drill Obtain the machine or tools equipments to and welding facilities Jigs fabricate the materials Perform welding joints drilling taping T l ee asks and other fitting works a Designing concept of Perform assembly works required as Prepare Drill Jigs drill jigs design Check the dimensions Take trail performance Check the center distance of drilling Drill jigs should be as per dimensions drawing 10 Make corrections if necessary Center distance of drilling 11 Complete the jigs fabrication dimension should be match 12 Store it in safe and special place with given drawing Introduction of Drill Jigs Types of Drill Jigs Standards Safety Precautions e Use safety gloves helm
30. Duty PERFORM TURNING OPERATIONS Time 16 0 hrs 2 8 Perform External Taper Turning Exercise 14 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Obtain workshop drawing Obtain work piece material Identify the operations to be perform Perform facing Perform center drilling 1f necessary Taper calculation for Perform plain turning setting on the machine Perform step turning if necessary Task Identify the angle to be cut and set Ss Process of taper turning Loosen the nuts of the swivel device on the Perform taper turning by cross slide method cross slide Set the required angle reading swivel scale and tighten the nuts Standards Bring and touch gently the cutting tip onthe Maintained surface edge of the work piece quality Reset the sliding length of top slide as per e Measurement of taper taper length angle made is checked Run the machine and give feed from cross slide Give feed manually from top slide slowly Repeat turning taper until the required dimension obtain giving feed from cross slide respectively Make sure all the dimensions is as given in workshop drawing Types of taper turning on lathe machine Fully equipped workshop with Center lathe machine and cutting tools AO AE A a Safety Precautions e Refer to the task Facing Plain turning Step turning and center drilling 95 Duty PERFORM TURNING OPERATIONS Tim
31. Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workpiece material Fully equipped workshop Process cutting threads Obtain required tools and equipment with Center lathe machine on lathe machine Set up workpiece on three jaw chuck Turning tool Center drill i Poni orn aeng bik an Grooving tool and threading Perform center drilling if necessary die taps and handles Reset the workpiece elongating enough length to machine Perform plain turning Task Perform step turning into thread diameter if necessary Cut threads on machine Perform grooving at the shoulder end using threading die taps Perform chamfering at the end for thread cutting 45 x 2 mm Set the threading die on its holder Standards Hold the die on threading start supporting with tailstock spindle Set the RPM lever in neutral position Insert the chuck key on key point Length and surface is as Turn Chuck anti clockwise by hand pressing per drawing continuos support from tailstock Turn 4 backward to break the chips at every Y round cutting thread Stop at the end Turn back the die Remove from the workpiece Check the thread with Check nut Make sure the dimensions are as given in workshop drawing e Thread size and shape should be as per drawing Safety Precautions e Support should be applied continuously from tails tock spindle Never tries to run machine for cutting thread e Avoid falling
32. eliminating Change drill bits along with collect chuck ES backlashes Position the coolant pipe Mill Blind Groove Start spindle raise the table very slowly Process of milling a until the hole is drilled Key ways 9 Change Key way cutter 10 Reset r p m 11 Start the spindle raise the table inserting the cutter through a hole 12 Move the table longitudinally very slowly until the cutter diameter reaches the length of the groove 13 File out burrs from edges of slot 14 Remove the workpiece and check the final measurement Standards Produced blind groove is checked as given measurement of groove Safety Precautions e Follow the safety precautions of task Perform drilling and boring in milling machine and task end milling a slot 232 Duty 7 MILL KEY WAYS Time 6 hrs 7 1 Mill Key Way through the length in a Round Workpiece Exercise 5hrs Demo 1 hrs Steps Terminal Performance Related Knowledge Objective Obtain pre machined round w p 2 Obtain a pair of vee blocks of suitable size for mounting the workpiece Obtain parallel clamps with T Bolts and nuts Obtain parallel block as per the slot of m c table Key way cutter Mount the vee blocks keeping the parallel block in using as a stopper Set the workpiece in the vee blocks Tasks Set up Key way cutter in collect chuck Mill Key Way through the length Condition Fully equipped workshop with Vee Block setting on Uni
33. l 2 3 4 5 7 10 A ed E CAS O ees pT Oil Spenser E G Cleaning brush E G y Oil paper E G Oil sprayer ooo G T A a 10 Setofrepairtools CC d Breakdown Maintenance 348 ATI EST 2 Fies setof8 pes o oo G 3 Screw driver Phillips NST 4 Screw driver la NST 5 _ AllenKey metric Set3 20mm 6 Allen Key imperial assorted in size Setuptol IA ETT EE 8 Telescopic gauge oo o 9 Tachometer o o 10 Steel mirror o o 11 Safety glove o o MET o 13 Safety harness o o TE o 15 First Air box with medicines o 16 Combination pliers gt gt gt 17 Cuttingpliers o o y E o 19 Wire Stripper o 20 Side cutter o o 21 Measuringtape o o 22 Stnosepliers o o 23 Bendnose pliers 0m 24 Monkey pliers o o o 25 Pin punch setin assorted size 26 Slidewrench O e 27 Double side open spanner o o o y 28 Double sidering spanner _ o oo 29 Hook spanner o o 30 Box socketwrench o o Tireleverbend Tire lever bend i s1 i Screw extractor Y Clamp SSCS SSS and vice Pipe wrench Y CA A Bearing puller Y Bearing puller SSCS SSCS Circlip pliers SSCS Oo o Cirelip pliers SSCS SSS Flat tongues Y 46 Chain socketpuller O O SSS ar Conveyer clipper SSCS o 48 Spider coupling O 49 Hydraulic press machine O 30 Precision sorewdriver_ SCS SSS 31
34. with maintenance tools and gear Dismantle the gear to be replace materials Gear transmission Clean the parts by kerosene bath calculation Greased the parts to be assembly Task Gear alignment Assemble the parts process Align the gear mesh 10 Check the gear mesh 11 Cover up the safety cover or housing 12 Restore all remaining materials Standards 1 2 3 4 5 6 7 8 9 Replace Change Gear Gear is fixed and true aligned Re lubricated on gear and housing Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 252 Duty 2 PREVENTIVE MAINTENANCE Time 3 0 hrs 2 3 Adjust replace V and Flat belts Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Obtain instructional manual Condition Read the pages of Belt transmission Introduction types Prepare the belt to be replaced Fully equipped Machining shop and application of Collect the repair tools with maintenance tools and V belts Flat belts Check and note the specification of the belt materials and pulleys Switch off the machine and de fuse if possible Chart of belts Loosen enough the belt adjustment knob nut y ask specification or bolt Calculation of belt Remove the belt from pulley Adjust replace V and Flat transmission ratio 9 Change the belt in pulley belts 10 Tighten enough the belt adj
35. 7 Make the centre line to locate the position of the middle letter 8 Place the work piece on Tasks What anvil block facing up the Stamp letters and numbers surface to be stamped on metal plate 9 Check and Select the number or letter to be stamped 10 Stamp the middle letter on the centre column line by holding the punch with three fingers of one hand and striking the hammer on head of punch by other hand 11 Check the impressions 12 Stamp the remaining letters Standard How well to the right of centre and e Stamping work piece then to the left of centre should be match with 13 Punch the roll no on work given drawing piece e Tolerances of marking 14 Oil the surface of the work line is within the 0 5 piece mm 15 Store the work piece and tools 16 Clean the vice and work place Tools and Equipments Steel rule Steel hammer Marking scriber Letter amp number punch Flat anvil Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Sheet Oil Safety 1 Assure the head of the punch in flat 23 2 Avoid mushroom head punch 3 Wipe off oily substance if any from the face of the hammer 4 Make sure that the face of the hammer strikes on punch head use on fingers 5 While punching remove bangles and wrist watches 24 Duty 2 PERFORM MARKING PUNCHING Task 3 Punch dot center on the object Time 6 hrs Theory 1 hrs Practical 5 hrs Ste
36. CIE Honzontel positon accessories and different TEN welding sides of pipes Penetration of welding in electrodes Set the work piece on the V block on pipes welding table with supports needed in a Flat position Task Perform tack weld 3 or 4 according to the diameter of pipe Weld pipe to pipe joint in Check and re set the position rotated position Strike the arc on a rough piece for trail Strike the arc and start welding from tack Standards Welding procedure weld Maintain joining of two Rotate the pipe continuously developing metals welding arc and wave of both pipe and complete the bead at other end Remove the slag from the weld bead Repeat the exercise till you achieve good result Maintain welding distortion Maintain welding penetration Follow welding pipe to pipe joint procedure Flat position Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 148 Duty PERFORM PIPE WELDING IN FLAT POSITION Time 9 0 hrs 5 2 Weld Pipe and Flat metal joint Exercise 8 0 hrs Demo 1 0 hrs Steps T
37. Condition Given e Introduction 5 Obtain n instruction e Well equipped workshop development patter 3 Select the stock sheet metal as with set of hand tools in n specified tool box e Type development 4 Cut the sheet metal according to the Drawing instruction and drawing work piece 5 Straighten and de burr the sheet metal 6 Determine the diameter and height of the cylinder to be develop 4 Calculate the circumference of diameter Tasks What 5 Draw a horizontal line as Develop pattern of circumference and vertical as height cylindrical container of the cylinder 6 Make a square drawing parallel line 7 Determine the folding joint 8 Mark and draw the folding margin as per joint on both side 9 Notch the corner or if any 7 Check dimensions of the completed job 8 Punch the roll no on work piece 9 Oil the surface of the work piece Standard How well 10 Store the work piece and tools Pattern should be match with given drawing Tolerances dimensions the 0 5 mm of are within Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scriber in pockets Open the blades as far as possible
38. Define Definition of entrepreneur e Definition of entrepreneurship 0 5 0 5 1 0 entrepreneur entrepreneurship e Entrepreneurship development process Entrepreneur s characteristics 3 Describe entrepreneur s e Characteristics of 0 67 083 15 characteristics entrepreneurs e Nature of entrepreneurs Assessment of entrepreneur s A j s characteristics 4 o id e List of human characteristics 0 5 1 0 1 5 characteristics e Assessment of entrepreneurial characteristics Entrepreneur and other occupations Compare entrepreneur with e Comparison of entrepreneur 5 a E 1 0 1 0 other occupations with other occupations e Types and styles of entrepreneurs Entrepreneur and employee Differentiate between e Difference between 6 0 5 0 5 1 0 entrepreneur and employee entrepreneur and employee e Benefit of doing own business Self assessment e Understanding self 7 A Self i 0 6 0 4 1 0 ARER e Self disclosure and feedback taking Entrepreneurial personality test Entrepreneurial personality E fest e Concept of entrepreneurial 8 i kenra a N personality test 0 67 0 83 1 5 e Assess Self inclination e Assessing self entrepreneurial to business a Jin inclination Unit 2 Creativity and Assessment 6 5 4 0 10 5 Creativity 9 Create viable business idea e Concept of creativity 1 67 0 33 2 0 e Barriers to creative thinking 185 Innovation e Concept of innovation 1
39. Gear Exercise 16 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Obtain gear blank with corresponding mandrel pre machined workpiece material Obtain pre machined ready made mandrel Calculate the module depth of cut and indexing moments Set up indexing head and tailstock on the machine table the length of workpiece will come at the middle of the table as well as in between indexing head and tailstock Mount the cutter horizontally on long arbor Set up workpiece in indexing head checking Standards concentricity supporting with tailstock ae Set the center axis of cutter and gear blank in Cross axis Set the machine control Condition Introduction to gear Gear terminology Fully equipped workshop with Types of geas Universal Milling machine Indexing head and supporting plates Tasks Manufacture a spur gear Produced spur gear is checked as given dimension in workshop drawing Place a piece of thin wet paper over the gear blank Run the machine raise the table using vertical hand feed until the cutter just remove the paper Set the vertical scale to zero Move along the cutter from cross feed Set up the indexing crank lever Set the depth of cut Start the machine and face cut Check the depth Index the workpiece by moving the crank Repeat taking cut indexing the workpiece for every groove by moving the crank until the peripher
40. Joining sentences with why what which whom and How Articles Types Rules of using it Practice exercises Preposition place and time Definition Places and time preposition Situational understanding Definition Types Comprehension Practice Total 10 78 JAMAS ATA WaT Va HUT PA 2 HVET E UT By qu ulate Reame 33 at g a WAR ar area fan Rendes att qie arate ARA AMAYA wt alte Soar MEAR att ger ARAN Maem AA AAT AT Tae Me MAA AER AUT STH Y AAT AT AM AAA areal facta MAR wa AER gra arated faae ARAN RUFT BA ELE ASA HUT q ATER e RAR ARAN aa ATA Gaara Peat AN AAA Y e ga HATO AAA GUA YAA Y ATA 3 e qR fA At ATA R e ARE ERA AAA AA Y AA 3 e qR Rada da AT ATMA qua IINA qeria 3 e qa Rada aae Sat Y AT x Halted ARAN ARA a ar 7 AAA want e Aimi maa daa fers a TA AT Y e AA AAA alada dealer fava aT arated Ma Y ESE LE 5 2 AT ZA e AZ REA WHATS AAT Y ANT 4 e Maa daa Harel AA Y GANT 4 UF aaa RAA WA Hara Va caries Y aaa YA ASAT Memo Gael at FANT 4 e Olam Hated aad waa erat aa ata ARMS Rea AM aaa Sta HASH AA 9 ASA AE ARRE CAA AHA HATA Aled ATA ae Ag fed l AAA AAS RIGA Y e Halter HAT SRT St Aaa RO E AT RUE St Geel ZAAPA PA Tel eared feat ot fara aca RTT q 11 e AA TARA AGA AIA E ANT 3 e YAA AAA Gat Aaa A AWA Y ARTA R 3 Wdded Aaa e AMIA aA Ta aA ATA ANT 3 e p yda aA A Y AT 3 DAA AAMT qual am Aaa PUMA AA AT AMAIA NAAT Tae WA Ue ARAN ARA EAN HA A AU A o RUA
41. Marketing and selling e Market forces e 4Ps of marketing 186 e Marketing strategies Business exercise e Business exercise rules e Concept of small business Busi ee management usiness exercise e Elements of business i Explore small business Pa EEE KORSEG ae management concept Planning Organizing Executing Controlling Business plan Market plan e Concept of business plan e Prepare market plan e Concept of market plan an AR se e Steps of market plan Business plan Production plan 19 Prepare production plan e Concept of production plan 1 25 1 5 2 75 e Steps of production plan Business plan Business operation plan e Concept of business operation 20 Prepare business operation plan plan 2 5 2 67 5 17 e Steps of business operation plan e Cost price determination Business plan Financial plan e Concept of financial plan e Steps of financial plan e Working capital estimation 21 Prepare financial plan e Pricing strategy 4 5 75 12 0 e Profit loss calculation e BEP and ROI analysis e Cash flow calculation Information collection and preparing business plan e Introduction e Market survey Precaution to be taken 22 Collect market information ee 201 13 0 150 prepare business plan Sample questions for market survey Questions to be asked to the customers Questions to be asked to the retailer Questions to be asked to 187 the stockiest suppl
42. Measure and mark the notches and line for cutting Check the layout for accuracy Put the work piece on the table Place the snip on the edge of marking line Cut the metal slowly at beginning and proceeding it for required cutting Straighten and de burr the sheet metal Check dimension of the complete job Punch the roll no on work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Cut metal sheet in straight with snip Standard How well e Cutting work given drawing e Tolerances of are within dimensions the 0 5 mm piece should be match with e Sheet and its types e Size and gauges of sheet metal available in marked e Importance and use of sheet e Introduction of snips and their types i e straight and curve e Marking and layout e Hand tools equipment and machine used in sheet metal works e Notching e Sheet metal operation Tools and Equipments Steel rule Snips Back square marking scriber steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Safety Place snips and material on bench De burr the metal sheet edges Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips 104 Duty PERFORM
43. Measure the dimension and take further cuts Standards as required 10 Remove the workpiece Deburr the edges Produced ruler is checked as Fully equipped workshop with Universal and Vertical Milling machine and chucks the final measurement given dimension in workshop Position 2 Slide Bar drawing 12 Refer and follow the steps of prepare Square Produced slide bar is checked as block in Vertical milling given dimension in workshop 13 Reclamp the workpiece drawing 14 Refer and follow the steps of Mill end slot 15 Reclamp the workpiece 16 Change dovetail cutter of required size 17 Bring cutter middle of the slot 18 Touch one side running the spindle maintaining up milling 19 Clear off the workpiece 20 Give depth as required 21 Machine the dovetail slot 22 Check the measurement using standard cylindrical pin 23 Mill opposite side following the steps no 7 to 9 24 Remove the workpiece and check the final measurement Safety Precautions Deburr sharp edges when handling workpiece Clean up the vice jaws and parallel blocks every time when resetting the workpiece Check that the cutter is sharp edge and undamaged before setting Select the RPM slightly lower than the higher Be ensure the parallel blocks are tighten sufficiently when use Check that the main switch is put off and clean off whenever you leave the machine 237 Duty 9 PERFORM PROJECT WORK Time 16 hrs 9 3 Manufacture a Spur
44. RPM to be set machine Calculate the feed to be set Task Recognize the levers to set the RPM as per Tan calculated Set up machine control Recognize the levers to set the feed as per calculated Standards Calculate and set the levers of RPM and feed every time before starting to machining any operation Set gear lever as calculated RPM according to workpiece and cutting tool material Control machine parts as per its functions Set Norton gear box as per workpiece cutting tool material and depth of cut Safety Precautions e Always set the RPM as per the workpiece material cutting tool material and operation to be performed e Always shift the gear lever stopping the machine completely e Set the lever in neutral position when not in use 87 Duty PERFORM TURNING OPERATIONS Time 5 0 hrs 2 1 Perform Facing from the center of workpiece Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Set up workpiece on chuck following the same steps of set up workpiece on three or Full sacd ksh Importance of facing four jaw chuck ee ae ith ter lath hi Set up facing tool on tool post yale A acne Process of facing an and Facing tool Swivel tool post in facing position operation Set up machine control Run the machine Task Bring the tool at the center of the rotating PA workpiece by top slide Perform facing from the
45. S Gill S K Kataria amp Sons 2 Engineering Drawing for Instructional Material for Mechanical Trade Vocational Training India 3 Elements of Mechanical Samual Yaslov Delmar Publishers Drafting 4 Engineering Drawing N D BHATT Charotar Publishing House Pvt Ltd 5 Machine Drawing 1 Er R K DHAWAN S CHAND Angle Projection 183 Entrepreneurship Development Total 78 hrs Class week 2 Course description This course is designed to impart the knowledge and skills on formulating business plan and managing small business in general This course intends to deal with exploring acquiring and developing enterprising competencies identification of suitable business idea and developing of business plan Course objectives After completion of this course students will be able to Understand the concept of business and entrepreneurship Explore entrepreneurial competencies Analyze business ideas and viability Formulate business plan nF WN Learn to manage small business 184 Ti h S No Task statements Related technical knowledge Wine chars T P Tot Unit 1 Introduction to 575 408 1983 Entrepreneurship Introduction of business e Definition of business enterprise e Types of business 1 Introduce business ie 1 5 1 5 e Classification of business e Overview of MSMEs Micro Small and Medium Enterprises in Nepal Definition of entrepreneur 2
46. Safety Precautions e Refer the safety precautions of the task Run fusion with filler rod 320 Duty 5 PERFORM HARD SOLDERING BRAZING Time 6 0 hrs 5 4 Weld Butt joint in Brass plate Exercise 6 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain a workpiece material Fully equipped workshop Refer the steps no 3 to 6 of the task weld with Gas welding butt joint in copper plate equipments with different Adjust flux to make it a little oxidizing sizes of nozzles Preheat the whole area of the joining part When base plate is melted insert the filler rod into the end of molten pool Advance the blowpipe and filler rod straight as they are Tasks Weld Butt joint in Brass plate Apply flux to filler rod from time to time Standards in order to supply it to molten joining part while advancing Wash away flux with warm water Prepare Workpiece Perform fusion the filler rod Produce brazing penetration Control undercut Follow procedure of butt joint welding in brass plate Safety Precautions e Refer the safety precautions of the task Run beads in vertical position 321 Duty 1 SET UP WELDING EQUIPMENT Time 5 0 hrs 1 1 Set Up Welding Equipment Exercise 3 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Objective Knowledge Obtain instruction Condition Obtain accesso
47. Safety Precautions e Avoid using torch with broken handle e Always check the connection of torch Shield and Grips e Keep away the inflammable material e Always place the torch on hanger after welding e Keep the workplace dry 326 Duty 1 SET UP WELDING EQUIPMENT MIG Time 4 0 hrs 1 Set Up Welding Equipment Exercise 2 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Objective Knowledge Obtain instruction Condition Obtain accessories and tools required i i i Fully equipped workshop Introduction to MIG welding Prepare MIG welding machine with MIG welding DC ados Connect the electrical power rectifier MIG filler metal RARO WE GINS es Switch onthe machine wire and accessories Load the wire reel Task Connect torch to the machine Set the speed of wire Set up welding equipment Connect the gas cylinder 1 2 3 4 5 6 7 8 9 Standards Adjust the pressure voltage and flow of gas Set filler wire roll onto 11 Make any arrangements as required machine Set up current extrude filler rod on welder holder Safety Precautions e Avoid using welding gun with broken handle e Always check the connection of gun Shield and wire end e Avoid using damp MIG wire e Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry 327 Duty 2 PERFO
48. Soldering 5 10 Flanging and crimping 5 10 1 Standard sizes and gauges of sheet metals Arc Welding 19 6 1 Introduce welding technology 6 2 Safety precaution 6 3 Welding and welding procedures 6 3 1 Welding machines 6 3 2 Definition of Current 6 3 3 Types and use of Electrodes 6 3 4 Welding tools 6 4 Welding joints Symbols and Positions 6 4 1 Edge and corner Square butt joint V joint Lap joint T joint and Flange 6 4 2 welding position Flat Horizontal Vertical and Overhead 6 5 Welding defects and their remedies prevention 6 5 1 Producing electric arc 6 5 2 Undercuts 6 5 3 Fusion and joint 6 5 4 Penetration 6 5 5 Porosity 6 5 6 Overlap 6 5 7 Seams and laps 6 6 Inspections and testing of the welding 6 6 1 Destructive test Crack test Impact test and Bending test 6 6 2 Non destructive test Magnetic particle X ray Ultrasonic test Radiographic test 155 7 Lathe Machine 15 7 1 Lathe machine working principles and main parts 7 2 Safety precaution 7 3 Work holding in 3 jaw chuck self centering independent chuck 7 4 Work holding in collets 7 5 Tool holding devices 7 6 Elements of Tool posts 7 7 Lathe operations 7 7 1 Facing 7 7 2 Plain turning Steppe
49. Strike on the tail of rivet to make mushroom head by ball pin hammer 20 Insert rivet head cap on the tail of rivet 21 Punch the rivet head until the required head forms and the pieces join together 22 Repeat the same steps for next riveting 23 Check dimensions of the completed job 24 Punch the roll no on work piece 25 Oil the surface of the work piece Store the work piece and tools Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil 118 Safety Take care of your hand while striking tail of riveting and riveting the head Take care while you bushing out the sheet metal The length of the rivet should be carefully calculated e Avoid mushroom head rivet head set 119 Duty DEVELOP PATTERN Time 6 hrs Task 16 Develop Pattern of rectangular box Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge Condition Given e Introduction e Well equipped workshop development pattern Ea 10 11 12 13 Obtain an instruction drawing Obtain an instruction Select the stock sheet metal as specified Cut the sheet metal according to the drawing Straighten and de burr the sheet metal Mark from outside for margin or if any M
50. Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge Dor 11 12 13 14 15 Obtain workshop drawing Select the stock sheet metal as specified Cut the sheet metal according to the drawing Straighten and de burr the sheet metal Lay out the elevation view a half plan view of Body Hopper of funnel Project the line of elevation up to apex Mark a large curve by taking longer slant radius Repeat the same process from same center point by taking smaller slant radius Mark for margin if any Similarly develop the pattern for tail Nozzle of funnel Cut and notch the metal as per development Straighten and De burr the edges Check dimensions of the completed job Punch letter as Pattern Hopper Funnel and Nozzle Funnel Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Develop a pattern of funnel Standard How well e Pattern should be match with given drawing e Tolerances dimensions the 0 5 mm of are within e Introduction to funnel e Concept of pattern of conical object Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing
51. Tighten the carriage lock center of workpiece Give little depth of cut from cross slide Turn back the tool slowly observing the cutting surface Standards 10 Go ahead on center give depth of cut turn back the tool slowly Determine the in center 11 Repeat the steps until required surface out center facing as per obtained workpiece nature 12 Cut from the outside edge to the center for Perform process of facing rough facing and reducing work length operation Check surface finished Safety Precautions e Refer to the Set up workpiece on three and four jaw chuck and set up turning tool e Always set higher RPM than normal for turning Always wear safety goggles e Apply fluent coolant e Swivel the tool post slightly in opposite direction to the facing surface 88 Duty PERFORM TURNING OPERATIONS Time 3 0 hrs 2 2 Perform Center Drilling Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Refer and follow all the tasks and steps to perform facing operation Obtain center drill drill chuck and key of the y workshop Center drill E with Center lathe machine Tailstock spindle Se Facing tool Drill chuck and Mount drill chuck on Tailstock spindle Center drill z Process of center HoldCenter drill on drill chuck and tighten drilling with the key T ask Bring tailstock that the center drill touches the workpiece center and tighten it o
52. a Multiple Thread Shaft Exercise 12 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workshop material Obtain required tools and equipment Perform facing Perform center drilling Reclamp the workpiece and drill center drilling Set up workpiece center to center with lathe dog and dog clamp Perform plain turning Manufacture a Multiple Perform step turning thread shaft Perform grooves Perform chamfers Standards Perform external vee thread Check the thread with thread gauge Reset the workpiece for further machining in Thread should be match off side According to provided Make sure the dimension drawing Thread should be match with given pitch gauge Fully equipped workshop with Center lathe machine Facing tool turning tool Center drill Drill bits for guide hole plain boring tool Task Safety Precautions e Refer the task Perform step turning and cut external vee thread on lathe machine BIBLIOGRAPHY SN Name Author Publication 1 Technology of the Metal GTZ Deutsche Gesellschaft Trade fur Technische Zusammenarbeit 2 Mechanical engineering ILO learning element 3 All about MACHINE TOOLS Heinrich Gerling 4 Elementary Metal Course BBF Training Section I 5 Instructional manual Lathe The institute of vocational Machine Techniques training The ministry of Labour Japan 6 Machini
53. a spur gear 16 Sub Total 24 210 Total 234 B Shaper Machine Operation 1 Set up Machine amp Holding Devices 1 1 Set up shaper vice on machine table 1 2 1 2 Hold HSS cutting tool bit 0 5 1 1 3 Adjust stroke length 0 5 1 1 4 Position the Ram in center of the work piece 1 2 2 Perform Plain Surface Shaping 214 2 1 Produce flat even surface 3 27 3 Perform 90 Step Surface 3 1 Produce 90 right angle corner step surface 3 21 4 Perform Project Work 4 1 Manufacture step block 15 Sub Total 9 69 Total 78 Total A B 234 78 312 215 Milling Machine Operation Duty 1 SET UP MACHINE Time 3 0hrs 1 1 Set up machine control Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Identify the switches for main spindle coolant Condition pump and Auto feed Introductions of Determine the levers for selecting speeds and Fully equipped workshop with milling machine feeds Vertical Horizontal and Determine the controls for reverse forward Universal Milling machine and emergency stops of spindle and feeds Identify the levers or nuts for adjusting slides Task Advantages of and over arm scale graduation Main parts and their functions Read and set up the graduated scale drum for Set up machine control setting depth of cut and specific dimensions Identify the levers or stoppers for table lock of Standards vertical longitu
54. arc cut respective projection line such as 0 1 24 Take radius 0 2 12 and set at apex O amp draw an arc 25 Give same name whether 0 2 12 arc cut to its respective projection line 26 Draw a line by French curve 27 Erase projection lines if draw it 28 Represent the dimensions with symbol 29 Give darkness for necessary lines 30 Clean up the drawing sheet Projected representative lines Design the view with axially at required angle Draw the views 170 DUTY 1 DEVELOPMENT OF SHEET METAL Time 2 0 hrs 1 4 Draw a Truncated Square Prism Development Exercise 2 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Prepare a drawing sheet Select the dimensions of object or drawing to be drawn Draw top and front view of right square prism Draw a cutting plane at desired length and angle Task Give name where the cutting plane cut the front view by same name Project the projection line horizontally from top and base line of front view Draw a vertical projection line for reference at any point on horizontal line Standards which cuts upper horizontal projection line Condition Fully equipped Classroom with Drawing board T set and drawing instrument Draw right square prism development Take one side length of prism from top Calculation of drawing view by setting compass area Mark four times from reference point at lower horizontal line by
55. by adjusting the outer screw and repeat above steps 16 19 20 Check the thread with check nut 21 Clear the die and the bench vice 22 Clean oil and chips 23 Punch the roll no on work piece 24 Oil the surface of the work piece 25 Store the work piece and tools Tools and Equipments Set of files Check nut caliper Set of threading dies Die handle oil can with cutting oil Bench vice Centre punch Steel hammer Number punch Bench cleaning brush file set file brush Dust pan Materials MS rod Oil Safety Check screws on the die handle before starting Check the depth of cut too much depth can damage die and threads Apply cutting fluid frequently to reduce heat and wash out the chips avoid clogging 1 Ze 3 4 Keep the die handle at right angle to the job 31 Duty 4 PERFORM DRILLING Task 1 Drill a hole Time 8 hrs Theory 2 hrs Practical 6 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w s drawing Condition Given e Introduction of drill m c 2 Read drawing thoroughly e Well equipped workshop e Types of drill m c 3 Obtain pre finished w p material with set of hand tools in e Parts of drill machine 4 Obtain drill bit as per the required tool box e Twist drills and its size e Drawing instruction and types 5 Mark layout line on the w p work piece e Parts of drill bit 6 Punch the centre 7 Clamp the w p on m c vice
56. diameter of cutter Fully equipped workshop with Different shank type shank End mill cutter Collect chucks cutters fitted on the Obtain collect chuck arbor and arbor amidst Vertical collect chuck and Repeat the steps 1 to 5 of short arbor setting Horizontal and Universal Milling adaptors on vertical milling machine Unscrew the ring nut of a chuck arbor Insert the collect chuck in and screw the nut till just grips the collect Tasks Insert the cutter shank into the collect chuck Tighten the nut as tightly as possible using Set up milling cutter in collect special wrench provided chuck Standards End mill cutter is identically tightened in collect chuck and arbor Arbor is Tightened securely on draw in bar Safety Precautions Ensure the taper size of arbor and spindle nose is same e Cutter shank should be inserted as much as possible e Use cotton rags when holding the cutter e Always keeps the collets in order when storing e Use same size of spanners to tighten or loosen the nuts e Avoid clamping the taper shank of cutter in the collects 221 Duty 1 SET UP MACHINE Time 6 hrs 1 7 Grind Single Tip tool for Fly cutter Exercise 4hrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Obtain HSS tool bits Condition Wear Safety goggles Bevel protractor or grinding gauge Fully equipped workshop with Cutting angles of Dress the wheel if necessary Bench or Pedes
57. down while finishing a cut 20 Check the part that has sawed Apply V notch Cut cutting straight down Safety Precautions e Hold the job so as to be cut on the flat side rather than the edge or the corner e The teeth of the hacksaw blade should point in the direction of the cut and away from the handle The cutting movement should be steady and the full length of the blade should be used e At least two to three teeth should be in contact with the work while cutting e Avoid moving the blade too fast while finishing a cut slow down e Avoid clamping the work piece over hang 271 Duty 1 PREPARE MATERIAL 1 2 Cut the material by Oxy acetylene gas equipment Time 4 hrs Exercise 3 hrs Demo 1 hrs Steps Terminal Performance Related Knowledge Objective Obtain a workpiece material MS Plate Condition Set up all gas welding equipment Place the plate on the cutting table in such a way that the place to be cut comes over acetylene the hole or slot in the cutting table Oxy acetylee equipments Mark a chalk line about 34 from one edge Process of Flame cutting by of the plate Tasks gas welding equipment Select and set up the correct nozzle for the Safety precautions thickness of the metal to be cut Cuts the material by Oxy Light the torch adjust preheated flame Acetylene gas equipment Observe the nature of the cutting flame by pressing down the oxygen control lever Standards The valve is operate
58. drawing 5 Mark the work piece according to drawing 6 Punch the roll no on work piece 7 Oil the surface of the work piece 8 Store the work piece and tools 9 Clean the vice and work shop Condition Given e Working bench and Bench vice with fully equipped workshop e Drawing Tasks What Measure and mark on the work piece Standard How well The measured and marked work piece should be within the given drawing Measuring and Marking e Definition e Importance e Tool and equipment e Method e Safety Tools and Equipments Steel scale Steel Protractor Marking scriber Center punch Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Sheet Oil Safety 22 Hold marking tools carefully because of sharpen tip of marking tools Duty 2 PERFORM MARKING PUNCHING Time 13 hrs Task 2 Stamp letters and numbers on metal plate Theory 1 hr Practical 12 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w p drawing Condition Given e Letter and number 2 Read drawing thoroughly e Well equipped workshop punches 3 Obtain w p material with set of hand tools in e Stamping process 4 Obtain letter and number tool box e Three step stroking punch of required size e Drawing instruction and procedure 5 Prepare the material flat work piece and in required dimensions 6 Layout the base lines as per drawing
59. filler rod 312 Duty 3 PERFORM FLAT POSITION WELDING Time 4 0 hrs 3 2 Weld Square Butt Joints Exercise 4 0 hrs Demo 0 0 hrs Steps Terminal Performance Related knowledge Objective Obtain instructional drawing Condition Refer steps no 1 to 5 of Run fusion without f fillertod Fully equipped workshop with Gas welding equipments with Place the two workpiece on fire bricks side f different sizes of nozzles by side in position taper gap should be maintain 0 8 in beginning and about 3 mm at the end for about 2 mm sheet Refer steps no 6 to 8 of the Run fusion without filler rod Tack weld on both ends Warm up the edges of each workpiece Standards slightly by running the flame along the edges quickly Prepare workpiece for butt Heat both the workpiece at the point where joint welding welding has to start giving the torch a weaving motion across the edges of both the plates so as to bring them to welding temperature simultaneously Bring the tip of the filler rod under the flame and into the puddle as the puddle forms 10 Allow a correct size about 3mm wide and 0 5mm high bead to form 11 Continue in this manner till the whole lengths of edges are welded together Tasks Weld Square Butt Joints Follow the procedure of welding square butt joint Safety Precautions e As the welding goes on the two MS sheet should come together ahead of the weld with a gap
60. finish the workpiece 14 Check final measurements 15 Chamfer and deburr all sharp edges 16 Check the final measurement 17 Clean any oil and chips from the work piece 18 Punch the roll no on work piece 19 Oil the surface of the work piece 20 Store the work piece and tools Tools and Equipments Vernier caliper drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch tap set tap handle drill machine Materials MS Flat Oil Safety e Refer the task Drilling Sawing Thread cutting by using taps and Plain filing 47 Duty 7 PERFORM PROJECT WORK Time 15 hrs Theory 0 hrs Practical 15 hrs Task 4 Manufacture a Back Square of 120mm Steps Terminal performance Related Technical P objectives Knowledge Position 1 Condition Given e Well equipped workshop 1 Obtain workshop drawing with set of hand tools in 2 Obtain workpiece material as per required number tool box 3 Obtain necessary tool and e Drawing instruction and equipment work piece 4 Measure rough dimension and file out side by side to prepare a square block with geometrically 90 Mark a layout line on workpiece Punch dots on marking line 7 Saw the metals to cut out Tasks What unnecessary parts Manufacture a Back Square of File out the flat even surface 120mm File out opposite flat even surface 0 Maintain the
61. grinding 2 2 Perform forming a steel 2 1 Perform Bending 1 3 2 2 Perform Twisting 1 2 2 3 Perform Forging 1 4 3 Prepare Jigs and Fixture 3 1 Prepare drill jigs 2 22 3 2 Prepare welding fixture 2 18 4 Finish the Assembly Structure 4 1 Clean with emery 1 2 4 2 Clean with surface grinding 1 4 4 3 Clean with wire emery wheel 1 2 5 Perform Painting 5 1 Perform enamel coating by brush painting 2 5 2 Perform spray painting 1 3 6 Project Work 36 6 1 Fabricate a windows grill 6 2 Fabricate a helical fixed stair 6 3 Fabricate a collapsible gate Sub Total 12 105 Total 117 B Aluminium Fabrication 1 Perform Bench work on Aluminum profile 24 1 1 Perform cutting 1 2 Perform drilling 1 3 Perform filling 1 4 Perform punching 1 5 Perform screwing 1 6 Perform riveting 2 Fabricate windows E 2 1 Fabricate casement windows panel 1 5 2 2 Fabricate multi panel sliding windows frame 1 5 3 Fabricate doors 3 1 Fabricate flush door panel 1 5 3 2 Fabricate swing door panel 1 5 3 3 Fabricate glass door panel 1 5 4 Fix partition 4 1 Fix half partition 1 5 4 2 Fix partition of casement section 1 5 269 4 3 Fix partition with sliding door 1 5 5 Finish the fabricate members 5 1 Perform glass board fitting 0 5 1 5 2 Perform clipping 0 5 1 5 3 Perform press gasket 0 5 1 5 4 Perform silicon filling 0 5 1 Sub T
62. hr Unit sub unit Areas and Topics Time hrs 1 Introduction to Material Science 1 1 Introduction amp history of material science 1 1 2 Matter 8 1 2 1 Atoms molecules and their structure 1 2 2 Element amp Periodic table 1 2 3 Electron Proton and Neutron 1 2 4 Bonding of solids 1 2 5 Forces between atoms 1 2 6 Types of bonds and their energies 1 2 7 Structures of solid materials 1 2 7 Face center cubic lattice 1 2 8 Body center cubic lattice 1 2 9 Body center hexagonal lattice 1 3 Classification of materials 2 1 3 1 According to state natural and artificial metal and non metal 1 3 2 Differentiate metal and non metal 1 3 3 Differentiate ferrous and non ferrous metals 2 General properties of material 4 2 1 Physical properties of material 2 2 Mechanical properties of materials 3 Ferrous metal 3 1 Iron and steel 6 3 1 1 Mining amp iron ore 3 1 2 Define amp differentiate iron and steel 3 1 3 Production of iron blast furnace 3 1 4 Production of steel open hearth convertor electricfrnace and duplex process 3 2 Carbon steel 4 3 2 1 Define carbon steel 3 2 2 Classification of carbon steel with their definition properties and application 3 2 3 Effect of carbon and other minor elements on steel 3 2 4 Read iron carbon diagra
63. instruction Apply auto feed if fine surface requires Safety Precautions e Refer all the safety precautions of the task perform center drilling and perform facing e Pay attention when manufacturing the shoulder 92 Duty PERFORM TURNING OPERATIONS Time 9 0 hrs 2 6 Perform Grooves Exercise 7 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Refer and follow all the steps of task perform Condition Plain turning Refer and follow all the steps of task perform Fully equipped workshop Step turning with Center lathe machine amp Make only the corner shoulder grooving tool Obtain grooving tool according to the size of the groove Reset the grooving tool on tool post so that Task the cutting blade is parallel to the workpiece Identify and mark for groove to be cut Perform Grooves Set low RPM than turning same diameter Run the machine Bring the tool near to the groove to be cut Standards Touch the tool gently with workpiece Measurements of grooves Set the dial scale 0 of both the top and cross checked slide Perform cutting feeding cross slide towards Measurement should be the machine center reading dial scale according to given Stop feeding turn back Set the same 0 dimension again Slide Top slide according to wide to be cut reading dial scale Repeat step no 12 until depth obtain Verify the width and depth of the groove with V caliper Move
64. machine _ 42 Slip roll folding machine __ as Drill machine O Bee and dt SSS A ET AU SCS as ATT ME SSCS 46 Soldering hammer O ar Soldering Merc 48 Safety gloves OA Welding Technology I S ES AE ISSN E Z gt 7 1 0 2 3 4 5 6 7 8 9 0 1 2 3 1 1 1 1 1 1 1 1 2 2 2 2 2 343 Lathe Operation I ea O a 13 Lathe centers Live Dead Revolving According to m e spindle __ a Drill chuck with ehuek keys O pame A 6 EVE TS AU A MARN STE o e S e ceban O Tooo o oa SSCS o CTS o e SSCS 0 Boring RC read 0 O HL Vemiercaipr A Beal Protractor A s Safe goggles A 14 Grinding machine Bench orPedesrian 1s Grinding wheel dresser O 16 Threading Die with handle ser aas 17 Knurling tool hand or machine Diamon 18 Dial test indicator with magnetic stand A 119 Cleaning brasa M n OOOO ME AE 344 Annex II Tools amp Equipments Required for Second Year Structural Fabrication Po STERER E S 1 Working Bench 80x89x280om EAT S S G MEA G y 6 Vemiercaliper SO mm k 8 Steelhammer TS TT O 10 Numberpunch mm Simm 8mm II Letterpunch gt gt gt 3mm5mmg8mm 12 HandhacksawFrame 14 Universal plair A G ME E G y MOTE E G 17 Countersink II G 18 Openspanner O y 19 Safety goggle Is 20 _ Bench Pedestal drillingmachine Sleeves oo G Drill
65. machining Parallel blocks should not be use while clamping rough work pieces Be ensure the parallel blocks are tighten sufficiently when use Avoid sharp edges when handling work piece Clean and store all used accessories in proper place after completing the tasks Check that the main switch is put off and clean off before leave the machine Refer the same safety precautions of task adjust stroke length 243 Duty 3 PERFORM 90 STEP SURFACE 3 1 Produce 90 Right angle corner step surface 24 hrs 21 hrs 3 hrs Time Exercise Demo Steps Terminal Performance Objective Related Knowledge AO OO eS O 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Obtain workshop drawing Obtain work piece material Obtain sets of parallel blocks Obtain shaping tool rough and corner Set up work piece material Clamp the rough tool on tool head Prepare a square block following the same steps of previous task Mark symmetrical line using height gauge Reclamp the work piece Refer the steps no 8 to 13 to produce flat even surface Give feeding observing surface made until the few mm remain to touches the marked line Stop the machine Return tool at same starting place Give further depth of cut as per required dimension Take machining to remove maximum rough material Change corner tool for shoulder Repeat same as for the step no 10 Repeat machining
66. of 0 8mm If the sheets come close too fast tack weld ahead of the weld If they are to a slow allow the weld to cool a little e Refer safety precautions of the Run fusion weld with filler rod 313 Duty 3 PERFORM FLAT POSITION WELDING 3 3 Weld Lap joint in the flat position Time 5 0 hrs Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain a instructional drawing Obtain a workpiece material Set up all gas welding equipment Lay one plate on top of the other plate on the welding table as per given drawing Refer steps no 6 to 8 of the Run fusion without filler rod Tack weld on both sides Start welding from right to left maintaining the move meet to bottom parts If additional build up is required filler rod may be added as the puddle is carried across the joint Weld one side of the plate and then practice on the reverse side Safety Precautions e Refer to the Task Weld edge joint Condition Inspection and testing of the gas welding joints Fully equipped workshop with Gas welding equipments with different sizes of nozzles Tasks Weld a Lap joint in the flat position Standards Prepare workpiece for lap joint welding Follow the procedure of welding Lap joint 314 Duty 3 PERFORM FLAT POSITION WELDING 3 4 Weld T Joint in the Flat Position Time 6 0 hrs Exercise 4 0 hrs Demo 2 0 hrs Steps Terminal Perform
67. of cut for rough cut Align the coolant pipe Run the machine and start cutting helical groove thread Turn back the tool in front position give depth of cut and cut ahead Cut the thread until obtain required depth of cut Check the thread with pitch gauge thread gauge Make sure the dimensions are as given in workshop drawing Thread dimension should be as per drawing Safety Precautions e Pay full concentration when cutting the thread engaging the auto lever of half nut e Refer to the task Set up turning tool Plain turning and Center drilling 200 Duty 3 PERFORM THREAD CUTTING Time 30 hrs 3 3 Cut Internal Vee Thread on Lathe Machine Exercise 26 hrs Demo 4 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain workshop drawing Obtain workpiece material Obtain required tools and equipment Set up workpiece on three jaw chuck Perform facing Perform center drilling Refer and follow the step no 8 to 20 of the task perform Plain boring Reset the V shaped internal thread cutting tool on tool post Calculate the pitch and gear to be set Set the gear lever refer chart on the m c Calculate amp set RPM for thread cutting Bring and touch gently the cutting tip on bore edge of the work piece Run the machine engage the half nut lever on Standards carriage Give light depth of cut and observe the Thread size and shape helical mark on periphery of work p
68. of m c RP Specs ence ane table 8 Clamp the drill bit on drill chuck by a ae gat CHU key A size and w p material 9 Set the RPM as per the drill bit size Handling of drill and the w p material m c Operation and 10 Start the machine changing of belt 11 Set the coolant housing pipe e Se 12 Give hand feed Tasks What y 13 Apply the coolant on the rotating Drill a hole drill bit 14 Reduce the feeding pressure at the bottom to the end 15 Make sure the drill passes through Standard How well 16 Stop the machine e Drilling work piece 17 Remove the w p from m c vice should be match with 18 De burr the drilled hole given drawing 19 Clean oil and chips e Tolerances of 20 Punch the roll no on work piece dimensions are within 21 Oil the surface of the work piece the 0 1 mm except drill 22 Store the work piece and tools hole 23 Clean the vice and work shop Tools and Equipments Drill m c with drill chuck key and drill bits centre punch steel hammer Drill vice Oil can Number punch Bench cleaning brush File brush Dust pan files Materials MS Flat Oil Coolant Safety 1 Tighten the table lock to avoid dislocation of the w p Apply coolant fluently Oy ao tS Use parallel block to prevent drilling on m c vice or table Check the cutting edge of drill before drilling Mount the drill shank to its maximum length inside the drill chuck Check the drill centre alignment
69. of the workpiece Task Process of using Steady Introduction of Steady Fully equipped workshop a with Center lathe machine and Steady rest Importance of using rests Set up the turning tool on the tool post rests Open the rest from its clamp Set up workpiece on positioning the rest surface exactly on the rest Close the rest and tighten the nuts Standards Align concentricity with the help of height AAA gauge e Process of clamping 10 Tighten fully chuck and nuts of Steady rest workpiece 11 Start the operation as needed Take care of safety Set up workpiece along a steady rest precaution Safety Precautions e Use sufficient oil on the rest surface while rotating the work e Keep the carriers away from the Headstock while setting the Steady rest e Switch off the main electrical line while setting up the workpiece e Pre set enough lighting in machine area e Always keep the machine and its surroundings neat and clean 192 Duty 4 SET UP MACHINE Time 3 0 hrs 1 4 Set up Work piece Along a Follower Rest Exercise 0 0 hrs Demo 3 0 hrs Steps Terminal Performance Related Knowledge Objective Refer the step no 1 to 6 of set up workpiece Condition Introduction of center to center with lathe dog and dog follower rest clamp Center lathe machine and Importance of using Set up the Follower rest on the carrier Follow r t st rests Reclamp workpiece projecting all machine Task Process of using len
70. pRa AN ae WH Mula ara Y YA y e mR au a wala aaga ara AZ ANT R Y zae saka ari AAN art e amare Sled ade Aa ate AER ea aA Fart fata feet aaa WTAE TH ATAU AT Use Catalogue AAT E FART We AZ AAS I e UE AM AAA Aral ATT 2 12 10 11 Applied Mathematics I Total 78 hrs Class week 2 hrs Areas and Topics Calculate SI units conversion factors 1 1 Basic Units 1 2 Derived Sl units and relationship 1 3 Decimal multiples and parts of units 1 4 Example and Exercises Calculate other system of units FPS system CGS system Metric system 2 1 Conversion and Comparative table of previous technical units and SI units 2 2 Example and Exercises Calculate fractions 3 1 Concept and Value of a fraction 3 2 Multiplication 3 3 Division 3 4 Addition 3 5 Subtraction 3 6 Example and Exercises Calculate square root 4 1 Square number 4 2 Splitting up 4 3 Procedure 4 4 Example and Exercises Calculate percentage 5 1 Conversion of the percentage into actual number 5 2 Conversion of the real number into percentage 5 3 Example and Exercises Calculate conversion of length measurement 6 1 Metric System 6 2 SI System 6 3 Examples and Exercises Calculate circumferences 7 1 Definition of circumference 7 2 Circumference 7 3 Sector 7 4 Polygons 7 5 Examples and Exercises Calculate Pythagoras Theorem 8 1 Terms used in Pythagoras Theorem 8 2 Pythagoras formula 8 3 Summary 8 4 Examples and Exercises Calcu
71. part with bucket cone seaming bottom flash 19 aco all the seams of assemble is straight Standard How well 20 Check dimensions of the completed job BUKET should he mate 21 Punch the roll no on work piece with given drawing e 22 Oil the surface of the work piece e Tolerances of dimensions 23 Store the work piece and tools are within the 0 5 mm Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 128 Duty PERFORM PROJECT WORK Time 12 hrs Task 24 Fabricate a cylindrical 90 elbow Theory 2 hr Practical 10 hrs Steps Terminal performance Related Technical P objectives Knowledge 1 Obtain workshop drawing Condition Given e Concept of 2 Select the stock sheet metal as e Well equipp ed pattern of specified workshop with set of truncated 3 Cut the sheet metal according to the hand tools in tool cylinder drawing box 4 St
72. required Fully equipped workshop Set the workpiece with Arc welding Wear safety equipments transformer and Hand vice Connect electrical line to machine and Hand surface grinder Start grinding from end of the beads Make clear surface grinding all welding spots 9 Hold workpiece material into vice 10 Grind 45 degree on all surface corners 11 Check the angle and even surface 12 Grind to confirm even surface Introduction Types of offhand grinding machine Types of grinding wheel 1 2 3 4 5 6 7 8 Task Perform Off hand grinding Standards Prepared the edges for groove weld Chamfered the burrs Grinded the welding beads to prepare re weld Safety Precautions e Avoid using Welding holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 273 Duty 2 PERFORM COLD FORMING THE MATERIALS Time 4 0 hrs 2 1 Perform Bending manually Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain prepared work piece material Mark layout line on the work piece Fully equipped wor
73. sharpening Bevel protractor or Angle the thread cutting tool gauge Tasks Grind thread cutting tool Standards Thread cutting tool should be match with given drawing e Too much depth may coloured the tip and may cause short hardness Any damage to the grinding wheel if noticed should be reported to the instructor When switching on the grinding machine stand aside until the wheel reaches full speed e Refer the same safety precautions of the task grind Twist drill 206 Duty 4 PERFORM OFF HAND GRINDING Time 6 0 hrs 4 6 Prepare Boring Tool Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Prepare a cylindrical rod as per required Condition length Drill a hole at the end of the rod from side Fully equipped workshop Types of boring tool according to HSS bit to be insert with Bench or Pedestrian Process of preparing File a hole into square hole grinding machines Safety boring tool of HSS bit Check the hole inserting the HSS bit goggles and HSS Tool bits Drill a through hole at the face toward square Bevel protractor or Angle hole as per thread to be tap gauge Tap the hole clamping the rod on the Bench vice Obtain a headless screw as per thread Tasks Insert the bit and tighten the screw Dress the wheel if necessary Prepare boring tool Set up tool rest if necessary Identify the shape of tool to be grind Identify the angles of tool to be
74. sides must be 10 Check other adjacent angles 90 to each other i e no as same as the first one light should pass 11 Wipe the back square between the blade and 12 Clean any oil and chips from the surface the work piece 13 Punch the roll no on work oe OEP pan should be pee match with given 14 Oil the surface of the work drawing piece 15 Store the work piece and tools Tools and Equipments Back square Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch Materials MS Flat Oil Safety e Ensure that blade and the stock of back square are not damaged and are 90 to each other e Clean the w p and de burr before checking with back square e Hold the stock firmly against the w p while sliding it down e Avoid placing back square where there is chance of falling and damaging 41 Duty 6 HANDLE MEASURING INSTRUMENTS Task 2 Check radius with radius gauge Time 6 hrs Theory 1 hrs Practical 5 hrs Steps Terminal performance objectives Related Technical Knowledge ER 10 11 12 13 14 Obtain drawing Read drawing thoroughly Obtain pre filed work piece Obtain radius gauge as required size Hold the radius gauge in one hand amp work piece in other hand Held radius gauge perpendicular to the radius to be checked Observe the contact surfaces of any light passing t
75. size Grind the surfaces repeatedly until the Tasks surface free from oxides Clean the rub surfaces by brush Ene suas Standards Surface should be smooth Safety Precautions e Wear safety gloves safety goggles and safety helmet e Use chipping hammer to clean the welding spatters and welding beads e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 280 Duty 5 FINISH THE STRUCTURE Time 3 0 hrs 5 3 Clean the surface by wire emery wheel Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Introduction Obtain pre fabricated structures Condition Ss Types of emery wheel Obtain instructions Chips off the surfaces by chisels or chipping hammer Fully equipped workshop with Bench work Drilling machine welding machine and Denting Set the Hand grinding machine with Cup Painting facilities disc wire wheel as required size Perform as grinding task to clean surfaces Tacks Repeat until the surface free from oxides ra by ware Clean the rub surfaces by brush wheel Standards Rusted surfaces of the structural fabrication work should be cleaned Oiled surfaces should be cleaned Protected the steel fabrication from corrosion Safety Precautions e Wear safety gloves safety goggles and safety helmet e Use chipping hammer to clean the welding spatters a
76. steps surface milling of previous task Mill Step Surface in Vertical Raise the table so that the face of the cutter Milling with Shell end mill cutter is top of the workpiece using vertical hand feed Place a thin piece of paper over the surface 10 Start the spindle using vertical hand feed move up the table very slowly until the Machining rules in milling Use of depth caliper Standards Milling surface is step and right angled Step height should be match as per given drawing cutter just remove the paper Set vertical hand feed scale to zero Move along the table Give depth of cut as per required dimension Bring the periphery of cutter on the side of the workpiece Place a thin piece of paper at the side Start spindle using the cross hand feed move the table very slowly until the cutter just remove the paper Set the cross feed scale to zero Move along the table Give width of cut Start the machine and feed the work Repeat machining till the dimension obtained De burrs the edges Remove the workpiece and check for the final measurement Safety Precautions e Follow the same safety precautions for task preparing a square block milling 225 Duty 4 MILL ANGULAR SURFACE Time 15 hrs 4 1 Produce angular Surface tilting Vertical head Exercise 12hrs Demo 3 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Con
77. systematically 17 Duty 1 PERFORM FILLING Time 50 hrs Task 2 File flat surface Plain Theory 4 hr Practical 46 hrs Steps Terminal performance Related Technical objectives Knowledge A Se E x 10 11 12 13 14 15 Obtain required drawing Read drawing thoroughly Obtain rough flat file Obtain material as per drawing Clean up the vice and working area Obtain steel rule marking scriber and back square Mark on the work piece as per drawing Clamp the work piece centrally so that the big flat surface can be file down on Bench vice Hold the file by one hand with griping the file handle so that the end of the handle presses against the ball of the thumb Press the file blade with the ball of the thumb by the other hand Position the feet to safe distance during filling Position the body to speedy and regular movements of the body Put the file on top of the work piece pressing and pushing from one hand and pressing only from other hand Return the file without pressure Apply the same motion to produces even removal of filling surface Apply full length of file Check the flatness in cross and diagonally with back square Check measurement by steel rule Repeat the same motion of filling across and diagonally until produce even surface De burr the work piece Punch the roll no on work piece Oil the surface of the work piece Store the work piece
78. the angles of tool to be grind Wear safety goggles Tasks Refer and follow the steps of the task grind Facing corner tool in HSS bit Grind roughing tool in HSS 10 Check the angles with the gauge or bevel bit protractor 11 Deburr the edges using oilstone Standards All the angle should be as per drawing Cutting tip should be sharp Safety Precautions Too much depth may coloured the tip and may cause short hardness e Any damage to the grinding wheel if noticed should be reported to the instructor When switching on the grinding machine stand aside until the wheel reaches full speed e Refer the same safety precautions of the task grind twist drill 204 Duty 4 PERFORM OFF HAND GRINDING Time 4 0hrs 4 4 Grind Grooving Tool Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective 1 Obtain Bench or Pedestrian grinding Condition machine 2 Obtain HSS tool bits Fully equipped workshop Angle of grooving tool 3 Obtain Safety goggles Bevel protractor or with Bench or Pedestrian Process of re sharpening grinding gauge grinding machine Safety the grooving tool 4 Dress the wheel if necessary goggles HSS Tool bits 5 Set up tool rest if necessary Bevel protractor or Angle 6 Identify the shape of tool to be grind gauge 7 Identify the angles of tool to be grind 8 Wear safety goggles Tasks 9 Run the machine 10 Refer and follow the steps of the tas
79. the auto lever and start feeding Standards Check the mark on the surface Stop auto feeding and return to starting position Clean with the brush Knurling should not be Repeat the process from step no 10 until fine overlapped knurling surface obtain Introduction of Fully equipped workshop aa and iSi with Center lathe machine and Knurling tools Types of knurling tools Use of knurling parts Knurling length and depth should be as per drawing Safety Precautions e Avoid giving more depth as required e Avoid knurling overlapped e Apply light oil with brush when knurling and take care that the brush can rolled Take care the knurl could be overlapped 194 Duty 2 PERFORM MACHINING OPERATION Time 6 0 hrs 2 2 Perform Parting Off Machined Part Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance RelatedKnowledge Objective Finished all the operations that has to be Condition perform as directed Obtain parting off tool Set up tool on tool post perpendicular to the machine center Identify the length to be part off Bring the tool and touch gently the cutting tip Task on w p that has to be part off UE Set half a RPM than normal range Perform parting off Start the machine machined part Give feed from cross slide handle till min two circle Turn back move top slide left right half of Standards the tool width Give feed as step no 8 double the depth than Dimension should be
80. the coolant to cool the sharp tool after every second interval Repeat the processes until the required depth obtain Change holding position for side clearance angle Repeat the same step no 12 to 16 for side clearance Change holding rest only the left arm on the tool rest Reposition for the top rake angle Repeat the same step as for the clearance angle Check the angles with the gauge or bevel protractor Deburr the edges using oilstone per drawing Safety Precautions Too much depth may coloured the tip and may cause short hardness e Any damage to the grinding wheel if noticed should be reported to the instructor When switching on the grinding machine stand aside until the wheel reaches full speed e Refer the same safety precautions of the task grind twist drill 203 Duty 4 PERFORM OFF HAND GRINDING Time 4 0 hrs 4 3 Grind Roughing Tool in HSS Bit Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain Bench or Pedestrian grinding Condition machine Obtain HSS tool bits Fully equipped workshop Angle of roughing tool Obtain Safety goggles Bevel protractor or with Bench or Pedestrian Process of re grinding gauge grinding machine Safety sharpening the Dress the wheel if necessary goggles HSS Tool bits roughing tool Set up tool rest if necessary Bevel protractor or Angle Identify the shape of tool to be grind gauge Identify
81. the taps and dies on the floors e Apply oil fluently when cutting thread manually 199 Duty 3 PERFORM THREAD CUTTING Time 30 hrs 3 2 Cut External Vee Thread on Lathe Machine Exercise 26 hrs Demo 4 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workpiece material Obtain required tools and equipment Set up workpiece on three jaw chuck Refer and follow the step no 5 to 11 of task Cut threads on machine using threading Manufacture a thread Fully equipped workshop cacha with Center lathe machine turning tool Center drill Taking a measuring of Grooving tool Thread thread element cutting tool Pitch gauge and die taps Check nut Reset the V shaped threading tool on tool teen post Calculate the pitch and gear to be set Task Set the gear lever refer chart on the machine Calculate and set the RPM for thread cutting Cut external vee thread on Bring and touch gently the cutting tip on edge lathe machine of the work piece Run the machine engage the half nut lever on carriage Standards Give light depth of cut and observe the helical mark on periphery of work piece Return the tool back disengaging the half nut lever then stop the machine Thread surface should be Check the helical mark with pitch gauge N6 or as specified Set the dial scale 0 on both top and cross slide Calculate the depth of cut Give depth
82. thickness required and flat even surface 11 File out the width of blade with geometrically 90 12 Drill the holes on side as per given Standard How well HD O drawing e Tol f di i 13 Chamfer and deburr all sharp 2 Sinners OS ed are within the 0 1 mm ges 14 Perform internal thread using hand taps 15 Check the final measurements Position 2 1 Refer and follow the step of Pos 1 from 4 to 11 2 Mark the layout line for drilling the holes 3 Punch center on drilling marks 4 Drill the holes as per required size 5 Counter sunk the holes with 60 6 Chamfer and deburr all sharp edges 7 Check the final measurements Tools and Equipments Vernier caliper drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set back square drill machine drill vice Materials MS Flat Oil Safety e Refer the task File flat surface Saw the metal by hand Drill a hole internal thread using hand taps and Countersink the hole 48 Duty 7 PERFORM PROJECT WORK Time 20 hrs Theory 0 hrs Practical 20 hrs Task 5 Manufacture a Center Square Steps Terminal performance Related Technical P objectives Knowledge Position 1 Condition Given e Well equipped workshop 1 Obtain workshop drawing gt with set of hand tools in 2 Obtain workpiece material as per required number tool box 3 Obtain necessa
83. till total depth of the dimension obtained Stop machine Raise the tool from sliding tool head slide Set the clapper box opposite to the shoulder side Give depth of cut as remain to reach total width by longitudinal movement Start machine amp give feeding from tool head slide Repeat machining until the dimension obtained File out the burrs at the edges Remove the work piece and check the final measurement Condition Fully equipped workshop with work piece material and Shaping machine Tasks Produce 90 Right angle corner step surface Standards Machined step surface is 90 right angle corners e Types of shoulder e Shaper tool for shaping a shoulder e Process of producing a shoulder Safety Precaution Follow the same safety precautions of task Produce a plain surface 244 Duty 4 PERFORM PROJECT WORK Time 15 hrs 4 1 Manufacture a Step Block Exercise 15 hrs Demo 0 hrs Steps Terminal Performance Related Objective Knowledge Bue SON ues 8 9 10 Obtain workshop drawing Obtain workpiece material Prepare a rectangular block referring to prepare square block Mark the layout on vernier height gauge Punch dots on layout mark Reclamp the workpiece Produce step surface referring following to produce 90 right angle corner step surface Remove workpiece File out burrs from edges Check the final measurement Condition Fully eq
84. to the tool post Hold tool on Tool post projecting 15mm out Tighten slightly all the bolts respecting with the tool Compare the center of cutting edge with center tip of Dead center Aligned cutting edge with Tighten all bolts the center of the dead Open the bolts and place the packages until center the center of cutting edge shows parallel to i the Dead center tip Tool length is project as Adjust the screw to set the center for cutting determined length edge if the tool post is single as Multi fix tool Cutting tool is according Task Set up turning tool on tool post 2 3 4 5 6 T 8 9 1 Standards post to the lathe operation Safety Precautions e Always use same size of wrench or keys when tightening the tool e Avoid projecting over length of the tool e Always set up the cutting edge with the spindle center e Use Quick fixed Tool post as far as possible e Always keep the machine and its surroundings neat and clean e Pay attention when aligning anything in front of the tighten tool 86 Duty SET UP MACHINE Time 2 0 hrs 1 5 Set Up Machine Control Exercise 0 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Identify the material to be machine o the diameter to be turn Fully equipped workshop Main parts and their entify the operation to be perform with Center lathe machine functions of the lathe Calculate the
85. twisting turning clock wise or Process of twisting counter clockwise Perform Twisting manually Turn the handle to the number of your requirement Standards Align the level of the curve and rest of the part Level shoud be alligned manually Safety Precautions e Never use broken or loose handle fitted tap handle e Use safety gloves e Perform hot work far as possible Never beaten on top of the vice or any clamping devices 275 Duty 2 PERFORM COLD FORMING THE MATERIALS Time 5 0 hrs 2 3 Perform Forging manually Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain layout or marked work piece material Fully equipped workshop with Types of forging Confirm the process of Forging Hot and cold forging tools and operations Obtain the machine or tools equipments to Blacksmiths fire facilities forge the material Hold with tongs keeping the material on T y asks top of the anvil as per layout Process of forging Hammer on the work piece so that the Perform Forging manually manually material change into the shape as required Use performed blocks if necessary Check the angle and shape Repeat the same process for another side Forged shuface should be of folding smooth Align the level of the curve and rest of the part Introduction of Forging Equipments and tools for forging Standards
86. work piece should be match given drawing e Tolerances of filing work piece is within the 0 1 mm e Introduction of making and layout using steel rule compass e Radius gauge e Method of filing radius surface e State the feature of compass e Radius filing procedure Tools and Equipments Flat files Rough medium fine radius gauge Marking scriber Center punch Number punch Steel rule Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Square Oil Safety 20 Refer the same safety precautions of the task File flat surface Duty 1 PERFORM FILLING Time 19 hrs Task 4 File internal profile Theory 1 hrs Practical 18 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain required drawing Condition Given 2 Read drawing thoroughly e Well equipped workshop Internal Radius filing 3 Obtain rough medium and fine with set of hand tools in procedure flat files tool box 4 Obtain needle file if necessar y e Drawing instruction and 5 Obtain work piece material work piece 6 Obtain a internal radius gauge of the required size 7 Obtain a centre punch and hammer 8 Obtain a steel rule 9 Obtain a divider compass 10 Clean up the bench vice and surrounding 11 Mark the centre point of the Tasks What radius by divider File internal Profile 12 Make the radius by compass 13 Drill 5 mm small holes t
87. works riveting on joints as design Check the dimensions Store it in safe and special place Safety Precautions Use safety gloves helmet and goggles Follow the safety of Prepare materials Follow the safety of Welding Follow the safety of Bench work Duty 8 FABRICATE PROJECT STRUCTURES Condition Fully equipped workshop with Bench work Drilling machine Grinding machine and welding facilities Tasks Fabricate Collapsible gate Standards Dimension of gate should be match with given drawing 286 Time 18 hrs Exercise 18 hrs Demo 0 0 hrs Designing of Collapsible gate Fabrication of Collapsible gate Task Analysis Aluminum Fabrication Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE Time 2 hrs 1 1 Perform cutting by Hacksaw Exercise 2 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain work piece material Obtain Steel scale Obtain Marking scriber Condition Line up the mark on as dimension given Obtain center punch Hammer Fully equipped fitting Obtain Hand hacksaw frame with blade workshop Tool room with Mark the symmetrically lines Hand hacksaw frame Blade Punch dotted on marked line and bench vice Clamp the work piece so that the marked line must be outside from the vice Check the blade Tasks Set up the blade on the hacksaw frame 11 Take a small triangular file Perform cutting by Hacksaw Mark a small vee not
88. workshop drawing Condition Obtain a work piece material Fully equipped workshop with Prepare Vee shape on work piece material Gas welding equipments filler Process of welding on Pipes for welding metal with different sizes of Set up all gas welding equipment nozzles Place the tube in a Vee Block leaving a gap of about 2mm to 3mm between the two edges to be welded Refer steps no 6 to 8 of the Run fusion hon Al ei Weld Pipe Pipe black Weld tacks the joint in min three places Realign the pipe if necessary Start welding from one of the tack weld joint keeping at top side Advance the torch to the bottom in Follow the procedure of Tasks Standards Prepare Pipes for welding operator side with criss cross motion of welding Pipe to pipe joint the torch and rod not semi circular Keep the first 10mm of the weld deposit narrow and flat but proper fusion and penetration into the joint Keep the welding tip straight with the line of travel as the welding advances the pipe Turn the pipe when the welding nears the 14 of the pipe Start from the other side of the joint amp continue as before reaching the next 4 of the pipe Fuse well in to the end of the previously deposited weld Finish the weld at remaining part of pipe smoothly referring above steps If additional build up is required filler rod may be added as the puddle is carried across the joint Safety Precauti
89. 0 Application 4 Non Metals 8 4 1 Introduction to non metals 4 2 Polymers properties classification and uses 4 3 Plastics properties classification and uses 4 4 Rubber properties classification and uses 4 5 Ceramics properties classification and uses 4 6 Composite materials properties classification and uses 4 7 Glass properties classification and uses 5 Abrasives amp Bonds 8 5 1 Define amp application of abrasive 5 2 Types of abrasive Natural amp artificial abrasive 5 3 Aluminium oxide 5 4 Silicon carbide 5 5 Diamond 5 6 Define bonds 5 7 Rubber and Shellac bond 5 8 Vitrified and silicate bond 5 9 Resionoid bond 5 10 Mounting Loading amp Glazing of grinding wheels 5 11 Trueing and Dressing of Grinding wheel 5 12 Hard stock material removing 5 13 Finishing 5 14 Total 39 BIBLIOGRAPHY SN Name Author Publication 1 Technology of the metal Appold Feiler Reinhard Deutsche Gesellschaft fur trade Schmidt Technische Zusammenenarbeit GTZ GMbh 2 Callister s Material Adapted by R New Age International Publishers Science and Engineering Balsubramaiyam Rajendra Sing 3 Manufacturing process Vikas Upadhyay amp Vikas S K Kataria amp Sons Agrawal 4 3 213 Milling amp Shaping Operation Total 312 hrs Class week 8 hrs
90. 0 Innovate business idea e SCAMPER Method of 0 83 0 67 1 5 innovation Transformation of idea into 11 Transfer ideas into action concep Cia tering ied 1 0 0 5 1 5 into action e Self assessment of creative style Personal entrepreneurial competencies Assess personal entrepreneurial Concept of entrepreneurial 12 0 5 1 0 1 5 competencies competencies e Assessing personal entrepreneurial competencies Risk taking attitude y e Concept of risk 13 feeds emonak tiking e Personal risk taking attitude 1 5 1 0 2 5 e Do and don t do while taking risk Decision making e Concept of decision making 14 Mak e Personal decision making e decision 1 0 0 5 1 5 attitude e Do and don t do while making decision Unit 3 Identification and Selection of Viable Business Ideas Ue ees eee Identification and selection of potential business e Sources of business ideas Identify select potential e Points to be considered while business idea selecting business idea e Business selection process e Analyze strength e Potential business selection 2 Weakness Opportunity among different businesses DiS h aee and Threat SWOT of e Strength Weakness business idea Opportunity and Threats SWOT analysis of business idea e Selection of viable business idea matching to self Unit 4 Business Plan 16 67 36 58 53 25 Market and marketing e Concept of market and 16 Assess market and marketing man stine 1 33 0 75 2 08 e
91. 19 20 Obtain workshop drawing Read drawing thoroughly Obtain Bench or Pedestrian grinding machine Obtain blunt Flat chisel Obtain Safety goggles Bevel protractor or grinding gauge Check the grinding wheel abrasive type trueness of wheel and cracks Dress the wheel if necessary Set up tool rest if necessary Hold Flat chisel by both hand pointing the tip towards wheel Wear safety goggles Run the machine Position the angular part of tip up ward on face of wheel fronting left hand side so that it can be move freely by right hand side Give feeding slightly moving across the full face Check the angle with gauge or Bevel protractor Repeat the grinding until desired angle and sharpened tip obtained Check the final measurement Clean oil and chips Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Grind Flat Chisel Standard How well e Chisel should be match with given check list e Tolerances of dimensions are within the limit provided Introduction of Chisels e Distinguish the features of chisels e Procedure of re sharpen the flat chisel Tools and Equipments Bench or Pedestrian grinding machine Safety goggles Bevel protractor or grinding gauge Blunt flat chisel steel hamme
92. 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Electrical Maintenance 349 Screw driver set of 8 pcs No 1 Combination plair Knife Knife S y 16 Saddle o y 17 Wooden Serews o l 2 3 4 5 7 10 11 12 13 14 15 16 17 350 Expert Involved in Curriculum Revision 2014 Binay Manandhar IOE Thapathali Campus Deepak Khanal Korea Nepal Institute of Technology Butwal Keshav Pokherel Panauti Technical Schoo Panauti Kavre Lal Bahadur Basnet Korea Nepal Institute of Technology Butwal Prem Kumar Nakarmi IOE Thaathali Campus Pushpa Raj Poudel Technical Institute for Technical Instruction TITD Sanothimi Rajendra Prasad Manandhar Balaju School of Engineering amp Technology Balaju Raju Bajracharya Technical Institute for Technical Instruction TITD Sanothimi Suman Shrestha Balaju School of Engineering amp Technology Balaju Tej Prakash Sapkota Balaju School of Engineering amp Technology Balaju Thakur Bhattarai Nepal Banepa Polytechnic Institute Banepa Kavre 351
93. 4 Draw Square Rectangle Exercise 1 5 hrs Demo 0 5 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board Condition 2 Prepare a drawing sheet Decide the dimension of square or rectangle to be draw Scaled and mark on the drawing sheet Fully equipped Classroom Measuring with Drawing board T set Drawing shapes and drawing instrument Instruments that uses to Refer and follow the steps of drawing sheet draw square rectangles in preparation for construction lines Task drawing Erase the projection lines if drawn Ensure the rectangle or square drawn is dark enough Clean up the drawing sheet Draw square rectangle Standards Corner should meet equally All lines should be uniform Opposite line should be parrallel Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 66 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 2 0 hrs 2 5 Draw Triangle Using T set Set Square and Protractor Exercise 1 5 hrs Demo 0 5 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board Condition 2 Prepare a drawing sheet Decide the dimension of equilateral triangle to be draw Scaled and mark on the drawing sheet Fully equipped Classroom with Drawing board T set and drawing instrument Drawing geometrical shapes Taking a measurement of Draw a botto
94. 5 gq un Spark lighter 0 2 3 6 7 8 9 0 1 2 3 4 5 6 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 21 Wermiercaliper 222 23 Marking height gauge S o Vernier height gauge with marking block O Bevel Protractor o o NS Ooo Oooo Oooo Bevel Protractor A 26 Toolgrindinggauge Angle 27 Safety goggles II 28 Grinding machine BenchorPedestrian 29 Grindingwheeldresser III 30 Bench vice with workingbench 31 Setoffile Medium 32 Thread plug gauge set Metric S 33 Thread Pitch gauge and SS 34 Checknutset TO and SSP 35 Threading Die with handle set OD and SSP 36 Knurlingtoolhandormachine Diamond 37 Dial test indicator with magnetic stand Clamping set with T bolts and nuts Po PO PRA Milling Operation 1 Angular milling cutter Wado 2 Anguarplate o o y 3 Boring Head dT accordimgtospindle 5 Collectchuck arbor with ring wrench according to spinde 6 _ Dial test indicator with magnetic stand Levertype 7 Direct indexing head with tail stock o y 8 Fimefile Medium i AAA SM Ri N O Marking Scriber o G Open Spanners set 19 20 Safety goggles o G Safety shoe 13 14 15 16 7 1 oo ie ye 5 n ye ES o Nn Safety shoe Set of Adaptor arbor according to spindle Set of end mill cutter according to collect chuck and a
95. 7 B Tungsten Inert Gas Welding TIG Demo Practical 1 Set up Welding Equipment 2 3 2 Perform Surface Welding 2 1 Perform Surface welding without filler rod 1 6 2 2 Perform Surface welding with filler rod 1 8 3 Weld in Flat Position Welding 3 1 Weld square butt joint without temporary 1 8 backing bar with filler rod in flat position 3 2 Weld square butt joint with temporary 1 8 backing bar with filler rod in flat position Total 6 33 Total 39 C Metal Inert Gas Welding MIG Demo Practical 1 Set up Welding Equipment 2 2 2 Perform Flat Position Welding 2 1 Perform surface weld in flat position 1 12 2 2 Weld butt joint in Flat position 1 12 2 3 Weld lap joint in flat position 10 2 4 Weld T joint in flat position 1 10 305 3 Perform Vertical Position Welding 3 1 Perform surface weld in Vertical position 1 8 3 2 Weld butt joint in Vertical position 1 8 3 3 Weld T joint in Vertical position 1 8 Total 8 70 Total 78 Total A B C 117 39 78 234 306 Duty 1 SET UP GAS WELDING EQUIPMENT Time 8 0 hrs 1 1 Prepare Acetylene gas Exercise 6 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective 1 Obtain Instruction Condition Close down the valves checking gas indicator shows zero Fully equipped workshop with e Introduction of Acetylene 3 Carry out the gas cylinder to the open Gas welding equipme
96. 82 Duty 7 PERFORM THE PAINTING Time 4 0 hrs 7 1 Spray enamel coating Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain pre primer coated fabricated Condition structures e Introduction of spray Fully equipped workshop with moe painting Obtain desired color enamel paint flat Bench work Denting Painting and Air compressor with set of screw driver kerosene oil cotton Spray painting facilities Handling of nachitie waste gloves painting mask and equipments for spray turpentine oil painting Obtain the Air compressor with set of Tasks spray painting gun Spray enamel coating e Methods of spray Clean the spray paining gun with painting kerosene oil Standards Check the condition of air compressor _ Sprayed enamel coating should and pressure of air filled be smooth Obtain instructions Open the lid of enamel paint Cleaned the painting area or Stir the paint thoroughly to mix zone uniformly Add turpentine oil to thinner the paint as required Dip the brush and side splash to control over flow Brush the surface up and down ward from the left upward corner Continue the brushing from the end of the painting enamel until finish the complete structure Clean up the brush with kerosene oil Cover the lid tightly and store in safe place Safety Precautions e Wear safety gloves safety goggles painting mask and safety helmet
97. CURRICULUM TSLC Mechanical Engineering Pre SLC Intake Council for Technical Education and Vocational Training Curriculum Development Division Sanothimi Bhaktapur Developed in 1991 First Revision 1999 Second Revision 2007 Third Revision 2014 Table of Contents Introduction Aims Objectives Course Description Group size Entry Requirements Duration Patterns of Attendance Certificate Requirements Evaluation Details Basic Requirements Curriculum structure Applied English TARE TAT Applied Mathematics Bench Work Computer Application Engineering Drawing Lathe Operation Material Science I Sheet Metal Fabrication Welding Technology I Workshop Technology I Applied Mathematics II Computer Aided Drafting Engineering Drawing II Entrepreneurship Development Lathe Operation Il Material Science II Milling amp Shaping Operation Repair amp Maintenance Structural Fabrication Welding Technology II Gas TIG MIG Workshop Technology II O N QQ uuu wu bh A A A A A m e K SU oa ua 101 103 131 153 158 160 167 184 189 212 214 246 269 305 336 Annex 1 Tools amp Equipments Required for First year 341 Annex Il Tools amp Equipments Required for Second Year 345 Expert Involved in Curriculum Revision 2014 351 Introduction The TSLC curriculum of Mechanical Engineering is designed to produce competent workforce equipped with knowledge skills and a
98. CUTTING FOLDING AND ROLLING Task 2 Cut metal sheet in round shape with snip o e Practical 2 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece drawing Condition Given e As same as related 2 Obtain instruction e Well equipped workshop knowledge of Task 1 3 Study the drawing thoroughly with set of hand tools in 4 Obtain the piece of sheet metal as tool box per drawing size e Drawing instruction and 5 Obtain required tools work piece 6 Straighten and de burr the sheet metal 7 Layout Measure and mark the notches and line for cutting 8 Punch the center of radius circle by center punch 9 Check the layout for accuracy Tasks What 10 Put the work piece on the table Cut metal sheet in round 11 Place the snip on the edge of shape with snip marking line 12 Cut the sheet metal according to the drawing 13 De burr and straighten Standard How well 14 Make a starting slit near the center of Cutting work piece the flange with a cold chisel should be match with 15 Cut out the hole of the flange with given drawing SU ees e Tolerances of 16 Cut around the outside edge of the TR flange with snips dimensions are within 17 Cut the metal slowly at beginning the 0 5 mm and proceeding it for required cutting 18 Straighten and de burr the sheet metal 19 Check dimension of the complete job 20 Punch the roll no on work piece 21 Sto
99. Calculate Lever Forces 3 1 Moment of force 3 2 One side lever 3 3 Two side lever 3 4 Elbow lever 3 5 Several forces 3 6 Examples and Exercises Calculate Reaction of supports 4 1 Equilibrium 4 2 Support reaction 4 3 Check 4 4 Examples and Exercises Calculate uniform speeds 5 1 Laws of motion 5 2 V is in a straight line 5 3 V is circular 5 4 Acceleration 5 5 Examples and Exercises Calculate average speed 6 1 Stroke speed 6 2 Piston speed 6 3 Summary 6 4 Examples and Exercises Calculate pressure and force 7 1 Concept of pressure 7 2 Contact pressure 7 3 Projected area 7 4 Force 7 5 Examples and Exercises Calculate shearing and punching 8 1 Cutting off 8 2 Cutting out and punching 8 3 Shear strength 8 4 Shear force 158 Total 78 hrs Class week 2 hrs Time hrs 4 8 5 Examples and Exercises 9 Calculate work power and efficiency 4 9 1 Work 9 2 Power 9 3 Efficiency 9 4 Examples and Exercises 10 Calculate Simple belt drive 4 10 1 Peripheral speed 10 2 Transmission ratio 10 3 Examples and Exercises 11 Calculate Multiple belt drive 4 11 1 Components transmissions 11 2 Total transmission 11 3 Examples and Exercises 12 Calculate gear wheel dimensions 4 13 1 Pitch 13 2 Module 13 3 Examples and Exercises 13 Calculate Simple gear drive 4 13 1 Dependency of pitch diameter and revolution 13 2 Dependency of number of teeth and revolution 13 3 Transmission ratio 13 4 Distance betwe
100. Demo 1 0 hrs Task and Steps Terminal Performance Related Technical Objective Knowledge Collect repairable work piece with hole to Condition be filled e Welding procedure Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Obtain instructions Collect and set up welding accessories and tools Grind off and clean the slags if needed Grind off more groove much as possible Set the work piece on the welding table with supports needed Task Fill up the welding beads surroundings of the hole Fill a Large hole Check and clean the slags Fill up the welding beads as multi run to Standards the surroundings to make small hole area _ Fill the holes and over 10 Repeat it until the hole covered fusion surfaces of the work 11 Remove the slag from the weld bead pieces 12 Repeat the exercise till you achieve good Follow filling the holes of result w p by welding procedure Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 151 BIBLIOGRAPHY
101. Eres hand 11 Tighten the spindle turning anti clockwise spindle by hand Safety Precaution e While adjusting the stroke length keep the tool just above from the work piece e Avoid hammering on the handle e The length of the stroke should be about 2cm more than the length of the job Not confusing to turn the spindle clockwise and anti clockwise direction 241 Duty 1 SET UP MACHINES HOLDING DEVICES Time 3 hrs 1 4 Position The Ram in Center as per Work piece Length Exercise 2 hrs Demo 1 hrs Steps Terminal Performance Related Objective Knowledge 1 Clamp the work piece material Condition 2 Hold shaper cutting tool in tool post Fully equipped workshop with Process of 3 Check the position of stroke length by Shaping machine and shaper positioning stroke moving tool head manually handle length in center as 4 Move ram extreme behind by hand per workpiece size 5 Insert the handle in handling position toward Tasks Or load oO ranm Position stroke length in center as 6 Loosen the ram lock us 7 Adjust the position of tool by moving the PEP ere Acree handle 8 Repeat moving the handle if necessary until Standards the tool is in position e Stroke length is centered to 9 Recheck the position of stroke length length of work piece 10 Repeat moving the handling until the position is correct Safety Precaution Refer the same safety precautions of task Adjust stroke length
102. FORM PROJECT Time 14 hrs 3 4 Manufacture a spindle with bearing journal Exercise 14hrs Demo 0 hrs Steps Terminal Performance RelatedKnowledge Objective Condition Follow and repeat the steps 1 to 6 of bush manufacture Reclamp the workpiece in lathe dog and center to center supporting revolving center Fully equipped workshop with Center lathe machine Facing tool turning tool TOME Center drill Drill bits for Turn out big diameter engaging auto feed dide hole plain borne tool Mark small grove for shoulder at journal end E E E Take rough cut to stepped length remains Task 1mm in required diameter To Change the tool according to the shoulder shape if necessary Take final and finishing cut Perform chamfers on all required corners Standards Measure dimensions to ensure all the dimensions are as required Reclamp the workpiece turning inside out e Measurement should be as Face the surface reduce the length as per given dimension required size Turn out big diameter if required Turn out shoulder if required Perform chamfers on all required corners Measure final dimensions to ensure all the dimensions are as required Safety Precautions e Refer the task Perform taper turning Manufacture a spindle with bearing journal References B S Raghuwanshi A Course in Workshop Technology Vol 1 and 2 Dhanpat Rai and Co 100 Material Science I Total 39 hrs Class week 1
103. IEWS Time 10 0 hrs 3 2 Draw Detail from Assembly View Exercise 10 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition Prepare a drawing sheet Obtain the drawing sheet of assembly view Identify nos of part Determine the part Measure and scale the dimension of individual part on drawing sheet Task 7 Give the numbers in individual part Draw free hand sketch in necessary views on rough paper amp dimensioned it Scaled and mark on the drawing sheet Construct the view as drawn in rough paper 9 Section the views if require Standards 10 Hatch the lines if sectioned eae 11 Draw projection lines and represent the Draw the supporting lines dimensions 12 Give tolerances as required 10 Erase the projection lines drawn 11 Give darkness for necessary lines 12 Clean up the drawing sheet Maintain the uniformity of line thickness Fully equipped Classroom with Drawing board T set and drawing instrument Draw detail from assembly view Projected representative lines Draw the views Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions e Refer the safety precautions of draw three view drawing 178 DUTY 3 DRAW ASSEMBLY VIEWS Time 8 0 hrs 3 3 Draw Assembly View from Detail Drawing Exercise hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set pape
104. Insert collect chuck on spindle nose holding draw bar wheel from left hand Set up machined workpiece Turn draw bar wheel few round to hold the on collet chuck collet chuck Insert the workpiece on collet chuck until desired machined surface Turn draw bar wheel in same direction as it Standards hold until completely clamped the workpiece Set the rpm lever in neutral position 10 Turn the draw bar wheel freely by hand to check the concentricity 11 Re clamp if necessary Tightened the collect chuck on machine spindle e Workpiece is clamped determining same diameter of collect chuck Safety Precautions e Follow the same safety precautions of the task setting up round workpiece on three jaw chuck e Use a wooden block on lathe bed when installing removing the chuck 85 Duty SET UP MACHINE Time 2 0 hrs 1 4 Set up Turning Tool on Tool Post Exercise 0 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Identify the shape and size of the tool to be clamp Filly eaiibned worksho Types of available Tool Obtain tool post key y equ pp p posts ith ter lath hi Check the cutting edge of the tool Wh Cent ane eae oe ae Tool holder Tool tightening f Stone it if necessary k Lathe tool settings ey and cutting tools Collect and set the packages if necessary Open up all bolts as required size of tool MountDead center on Tailstock spindle Bring Dead center near
105. MIG from 1 to 3 Condition Tack weld the materials at both ends as Fully equipped workshop Introduction of welding per drawing with MIG welding DC wave of MIG Welding Refer and follow the steps of surface rectifier MIG filler metal weld in flat position from 2 to 8 wire and accessories Procedure of deposition of Restore the tools and equipments MIG welding beads Task without filler rod Clean the working area Weld butt joint in flat position Standards Transverse welding wave in MIG welding Procedure of deposition of MIG welding straight beads in Flat position Safety Precautions e Avoid using welding gun with broken handle e Always check the connection of Holder Shield and wire end e Avoid using damp MIG wire e Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry 330 Duty 2 PERFORM FLAT POSITION WELDING 2 3 Weld T joint in Flat position Time 13 hrs Exercise 12 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of the steps of set up welding equipment MIG from 1 to 3 Condition Tack weld the materials at both ends as Fully equipped workshop Introduction of welding per the drawing with MIG welding DC wave of MIG Welding Refer and follow the steps of surface rectifier MIG filler metal weld in fl
106. NG Task 3 File external radius Time 25 hrs Theory 2 hrs Practical 23 hrs Steps Terminal performance objectives Related Technical Knowledge Obtain required drawing Read drawing thoroughly 3 Obtain rough medium and fine flat files Obtain work piece material Obtain a radius gauge of the required size 6 Obtain a centre punch and hammer 7 Obtain a steel rule ae ae 8 Obtain a divider compass 9 Clean up the bench vice and work area 10 Mark the centre point of the radius by divider 11 Make the radius by compass 12 Clamp the w p projecting the corner part which has to be made radius 13 File down to make flat surface close to the marked radius line using rough file 14 Change medium flat file and start filling in SEE SAW motion along the curved line until all marked line touches 15 Check periodically with radius gauge 16 Remove the w p and check the measurement 17 File down further in see saw motion with fine flat file until required radius is obtained 18 Remove the w p and check the final measurement 19 Punch the roll no on work piece 20 Oil the surface of the work piece 21 Store the work piece and tools 22 Clean the vice and work shop Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What File external radius Standard How well e Filing
107. OOOO SY 55 36 37 38 39 40 ar Ca Chisel faa OOOO PS Cas Chistes OOOO S CaA Engineering blue O Cas Surtfaoe plate O a 46 Bonge SSCS A 47 Counter boringtool Ao Cas Comer sink SSCS o o w Comer sink SSCS o 30 Boing OOOO S CS 1 Wees OOOO SSS S 52 ES TI SSCS CS MEN ETE Cr CS 341 Open spanner Safety goggle o G Depth gauge o G Bench Pedestal drilling machine o e Oooo Em m 1 Hand taps metrice MB to M24 Taphande O o Hand dies metrice MB to M24 Die hande o G o y gt gt EA AAA AAA AA LEA E ASA HA E Hand drilling machine O e Cleaning brush mm Sheet metal Fabrication ol Workingbench O o y 2 BenchVice O 3 ToolBox E G KeyandPadlock G Flat file medium Pt Triangular file oo o Y o Roundfile pO pO E er a nn Im Apo mo 7 10 3 Mallet o G Straight snips Oooo y 12 1 14 15 16 17 18 e Poman E E C clamps Medium pO pO O ee A 5mm A pO _ y pO pO Rivet head punch Rivet align punch Marking bar 342 E E a 9 20 22 23 HZ 25 26 2 28 20 21 22 23 24 25 26 27 28 29 30 MO AA SSS 132 Fat steel square ar 33 Swagmege O OoOo SOS 34 Setting hammer 35 Straight Mardi O 36 Sta hatchet O 7 Hamid grover SSCS SSCS SSCS E TI Sim dT CSCS 39 __ Folding machine Si SSCS SSS 40o Beading machine _ 4i Sharing
108. RM FLAT POSITION WELDING Time 21 hrs 2 1 Perform surface weld in Flat position Exercise 20 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow the steps of set up welding machine MIG from 1 to 3 Clamp the work return lead to a clean Fully equipped workshop Condition Introduction of welding of the table with MIG welding DC wave of MIG Welding Clean the materials thoroughly rectifier MIG filler metal wire and accessories Procedure of deposition of MIG welding beads Task without filler rod Put the materials on working position Hold the torch approximately 10 mm from the work piece and approximately 70 to the work piece Perform surface weld inflat Press switch trigger from the point position where you want to start and allow the arc to be struck Standards Weld continuous till the end point Transverse welding wave in Protect contact tip and gas nozzle MIG welding against spatter by a thin layer using silicon free spray Procedure of deposition of 9 Restore the tools and equipments MIG welding straight beads in Flat position 10 Clean the working area 1n Flat position Safety Precautions e Avoid using welding gun with broken handle e Always check the connection of gun Shield and wire end e Avoid using damp MIG wire e Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the g
109. Related Objective Knowledge Refer the steps no 1 2 3 from task produce angular surface tilting vertical head Obtain Angular milling cutter as per required size 45 60 Set up workpiece material Mount the cutter according to cutter type Set the machine controls Bring the edge of cutter over the corner Set the longitudinal cross hand feed scale to zero Position the cutting edge where an angle is to be machined Give depth of cut as per machine rule by longitudinal hand feed Position the coolant pipe Start the machine and give feeding Repeat machining till the dimension obtained Clean and stored all used accessories in proper place Check that the main switch is put off and clean off Condition Fully equipped workshop with Process of feeding Universal and Vertical Milling and depth of cut machine Process of milling angular surface Tasks Process of measuring Produce angular surface with Bevelled surface Angular cutter Standards Angle should be according to drawing Surface should be plain and even Safety Precautions e Follow the same safet precaution of task preparing a Square block 227 Duty 4 MILL ANGULAR SURFACE Time 10 hrs 4 3 Perform angular surface setting the workpiece on machine table or vice Exercise hrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Condition Refer steps 1 to 6 from task Produce angular surface tilt
110. Relieving 4 5 4 Copying 4 6 Types of Tool 4 6 1 Left hand and right hand 4 6 2 Solid and Tipped 4 6 3 Form tool 4 6 4 Thread cutting 4 6 5 Parting off Grooving 4 6 6 Knurling tool 4 7 Lathe Operations 4 7 1 Truing plain turning 4 7 2 Step turning 4 7 3 Grooving 4 7 4 Taper Turning 4 7 5 Thread cutting 4 7 6 Knurling 4 7 7 Center to Center turning 4 7 8 Parting Off 4 7 9 Eccentric Turning Milling Machine 18 5 1 Introduction 5 1 1 Introduction milling machine Conventional 5 1 2 Introduction to NC CNC milling machine 5 2 Machine safety 5 3 Types of machine 5 3 1 Column and Knee type 5 3 2 Horizontal vertical and universal 5 4 Main parts and their function of the machine 5 4 1 Over Arm 5 4 2 Column 5 4 3 Spindle 5 4 4 Table 5 4 5 Knee 5 4 6 Saddle 5 4 7 Base 5 4 8 Elevating Shaft 5 5 Milling Accessories 5 5 1 Work holding devices 5 5 1 1 Machine Vice 5 5 1 2 T bolts and Clamps 5 5 1 3 V blocks 5 5 1 4 Angle plate 5 5 2 Cutter mounting devices 5 5 2 1 Short arbor Stub arbor 5 5 2 2 Long arbor 5 5 2 3 Adopter sleeve 5 5 2 4 Collects 5 6 Milli
111. TION WELDING 1 4 Perform multi run straight beads Time 7 0 hrs Exercise 6 0 hrs Demo 1 0 hrs Task and Steps Terminal Performance Related Objective Knowledge Obtain workshop drawing Condition Obtain instruction Collect work piece Clean the metal surface with a wire brush and wipe off the oil and grease Set the arc welding machine Refer and follow the steps of surface weld from 3 to 12 Weld other beads as per the drawing Task Remove slags and spatters Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Arc wave and Travel speed Deposition of beads and overlaps Perform multi run straight beads Start welding on bead corner to the end of the previous welded bead Repeat the same welding until the workpiece width permits 11 Clean welding beads Standards Maintain a correct angle of the electrode Maintain beads start and beads finish Maintain undercuts Maintain deposition of beads overlap Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry
112. Task Statements Related Technical Knowledge Time hrs T P Configure Plotters Printers Define Plotter Manager Explain Plot Style Manager State the Printer Plotter Installation process 0 5 1 0 Plot drawing Explain paper size and paper units drawing orientation plot area and plot scale plot offset Describe the procedure for printing a drawing 0 5 1 0 Sub total 1 00 2 00 Project works 1 Following drawings are to be prepared and submitted e copy and hard copy both using CAD software e Draw an Isometric drawing e Draw an Oblique drawing e Draw Orthographic drawing 42 0 165 e Draw Workshop drawing e Give dimension Orthographic Isometric Sub total 0 42 0 Total 12 68 Grand total 78 Suggested texts and references e Kognet learning solution Simple steps in AutoCAD Dream tech press India e George Omura Mastering AutoCAD 2013 and AutoCAD LT 2013 India 166 Engineering Drawing II Total 78 hrs Class week 2 hrs Duties and Tasks Time hrs Demo Practical Development of Sheet Metal 1 1 Draw square box development 2 2 1 2 Draw truncated cylindrical development 2 1 3 Draw truncated cone development 2 1 4 Draw truncated square prism development 2 1 5 Draw Pyramid Development 2 1 6 Draw c
113. Weld Lap joint Move the electrode in a straight following the edges of both workpiece Standards and complete the bead at the other edge Maintain joining of two of the plate metals Remove the slag and spatters from the o weld bead Maintain spatters Repeat the exercise till you achieve good Maintain porosity result Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 138 Duty PERFORM FLAT POSITION WELDING Time 9 0 hrs 1 8 Weld Square butt joint from both sides Exercise 8 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional drawing Condition 2 Obtain workpiece meterial Refer and follow the steps of surface weld from 4 to 9 Place the work piece on the welding table with supporting in a flat position Perform tack weld on both ends Check and re set the position Strike the arc on a rough piece for trail Task Strike the arc on the work piece at one ra edge Weld Square butt joint from both sides Fully equipped workshop with Arc welding transformer welding accessories and di
114. a paper to electronic drawing world by means of using CAD as a drafting tool Students develop competencies focusing mainly on different features such as Geometric shapes Layers and Linetypes Annotating a drawing with Text Hatching and Dimensioning and creating output Prerequisite Engineering Drawing Basic Computer Application Total 78 hrs Class week 2 hrs Module 1 Computer Fundamentals Review S N Task Statements Related Technical Knowledge Time hrs T P 1 Apply Basic Computer Skills Overview of a computer operating system and peripherals printers and plotters system settings and the windows environment Application Packages Microsoft MS Office package or equivalent e Word Processing package MS Word or equivalent e Spreadsheet Package MS Excel or equivalent e Presentation Package MS Power Point or equivalent Basic concept of E mail Internet Computer handling Open save save as cut copy paste etc Sub total 2 00 1 00 160 Module 2 Familiarize Computer Aided Drafting CAD Software Time hrs S N Task Statements Related Technical Knowledge P Introduction Enlist different types of CAD software System requirement for CAD Startup CAD by start menu Interpret CAD graphics window 1 Startup Computer Aided including screen layout pull 1 1 Drafting CAD sof
115. able to machine other side of slot 19 Mill other side of slot as for the first side 20 File out burrs from edges of slot 21 Remove the workpiece and check the final measurement Tasks Standards Safety Precautions e Follow the same safety precautions of the task prepare a Square block milling 230 Duty 6 MILL GROOVES Time 10 hrs 6 2 Mill V Groove Exercise 8 hrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain pre machined workpiece Obtain sets of parallel blocks Fully equipped workshop with Set hole type double Obtain hole type angular milling cutter as Universal and Vertical Milling side milling cutter in per vee to be cut machine long arbor Set up horizontal arbor in the m c spindle Mount the cutter on the arbor Work table Set up workpiece material Tasks backlashes Set the machine controls Bring the table so that the cutter is close to Mill V Groove Process of milling a the top of the workpiece V Groove 10 Bring the cutter from the edge of the workpiece to the side of the slot 11 Use depth caliper to set the distance 12 Start the spindle and check the direction of the rotation of the cutter 13 Raise the table until the cutter just touches the workpiece 14 Set the vertical hand feed scale zero 15 Move along the cutter by longitudinal feed 16 Set depth of cut for trail cut 17 Position the cool
116. according to the drawing Straighten and de burr the sheet metal Mark the layout as per development drawing or pattern made for both Hopper and Nozzle Cut shear the metal as per development Straighten and de burr the seam Fold seam margin of both sides in opposite direction Fold to cone shape to the development and soldered seam Hook the seam folded margins Mallet the seam placing on a form anvil Solder the seams of both Hopper and Nozzle part following the steps of soldering joints Assemble both Hopper and Nozzle of the Funnel following the same steps of soldering joints Make sure the soldered assemble is straight in axis Check dimensions of the completed job Punch the roll no on work piece 18 Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Fabricate a Funnel Standard How well e Funnel should be match with given drawing e Tolerances of dimensions are within the 0 5 mm e Concept of pattern of funnel Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scr
117. ad size and required sheet metal tools tool box e Introduction of 4 Straighten and de burr the sheet e Drawing instruction and beading machine metal work piece e Operation of 5 Layout the pattern machine 6 Check the layout for accuracy e Selection of dies 7 Notch and cut the unnecessary part 8 Lay out the marks where beads are to 10 11 12 13 14 15 16 17 be made Make a round shaped object by rolling machine or by hand tools and round peaked stake Place the single bead rolls on the beading machine and bead the work piece Place the sheet between the beading dies of the machine Clam the sheet in the die of machine Roll the dies of machine with the help of handle Straightening the work piece Check dimensions of the completed job Punch the roll no on work piece Store the work piece and tools Tasks What Perform round beading Standard How well Bead should be match with given drawing Tolerances dimensions the 0 5 mm of are within Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Beading machine and dies Materials GI Sheet Safety Take care of marked lines folds must not be collecting together Aware from clamping the finger by machine jaw To avoid damage on surface of sheet insert a protecting jaw of al
118. adius filing 49 Duty 7 PERFORM PROJECT WORK oe Time 30 hrs Task 6 Manufacture a Divider Theory 0 hrs Practical 30 hrs Steps Terminal performance Related Technical P objectives Knowledge Position 1 Condition Given e Well equipped workshop 1 Obtain workshop drawing with set of hand tools in 2 Obtain workpiece material 3 Obtain necessary tool and tool box equipments e Drawing instruction and 4 Measure rough dimension and file work piece one side marrow plane for reference plane 5 Based on marrow file out all six surface maintaining dimensions Tasks What and right angle Manufacture a Divider 6 Mark layout line on workpiece for necessary sawing and filing 7 Saw the side portion for steep length 8 Make rectangular block of required size according tothe given Standard How well 9 Chamfer and deburr all sharp e Tolerances of dimensions edges are within the 0 1 mm 10 Check the final measurement Position 2 1 Refer and follow the step of Pos 1 from to 10 2 Mark the layout line for drilling the holes 3 Punch center on drilling marks Assemble the both parts with countersunk head screws Tools and Equipments Vernier caliper drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch drill machine drill vice Materials MS rod Oil Safety e Refer the task File
119. against the base plate and preheat Standards around the piece with the white core a a Process of brazing or hard little separated until it becomes reddish soldering Heat the end of the brazing rod and attach flux there Perform fusion the filler Hold the brazing rod at an angle to rod 45 against the base plate and move the rod so to pulling it back Continue to heat the place between the base plate and piece feeding molten Control undercut brazing material with blowpipe Move the blow pipe in an oval form and the filler rod slightly up and down melting it above the welding line Attach flux to the brazing rod from time to time and continue brazing cool the work as it being held by grip and clamp Remove the jelly oxide on the brazed surface with a wire brush Clean the blowpipe removing attached material in the nozzle with a cleaning needle soldering brazing Characteristics of brazing Substitute of flux Prepare Workpiece Produce brazing penetration Follow procedure of butt joint welding in brass in mild steel plate Safety Precautions e Refer the safety precautions of the task Run fusion with filler rod 318 Duty 5 PERFORM HARD SOLDERING BRAZING Time 5 hrs 5 2 Braze MS plate with MS pipe Exercise 5 hrs Demo hrs Task and Steps Terminal Performance Related Knowledge Objective Obtain a instructional drawing Condition Obtain a work piece material Fully
120. al position accessories and different stand with clamps and supports in a decoded Penetration of welding in Vertical position Vertical position Check and re set the position Strike arc on a rough piece for trail Task Welding procedure Strike arc and weld from the bottom end to upwards maintaining short arc length Perform surface weld in Move the electrode developing welding Vertical position arc following the edges of both w piece and complete the bead at other end of the Standards plate Maintain joining of two Remove the slag from the weld bead metals Repeat the exercise till you achieve good Maintain welding distortion result Maintain welding penetration Follow welding procedure of Vertical position welding Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 144 Duty PERFORM VERTICAL POSITION WELDING Time 9 0 hrs 3 2 Perform Square butt in Vertical position Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition
121. amps T bolts Stepped blocks and parallel Tasks blocks 8 Put the parallel blocks under the workpiece close to the tee bolts Set up milling workpiece on machine table 9 Set the parallel clamps and step block on the tee bolts 10 Tighten slightly the nuts Standards 11 Make alignments if necessary Positioned the clamps and 12 Tighten all nuts gradually parallels to edge 13 Ensure the parallel blocks are fixed machining Work piece should be tighten Safety Precautions e Tee bolts must always be close to the workpiece e Parallel blocks should place right under the clamping position e Avoid using extra lever to tighten the nuts e Refer safety for vice setting 218 Duty 1 SET UP MACHINE Time 3 hrs 1 4 Mount milling cutter on long arbor and in Horizontal spindle Exercise 2 hrs Demo 1 hrs Steps Terminal Performance Objective Related Knowledge Set rpm lever for lowest spindle speed Condition Clean up taper shank of long arbor and the spindle nose Fully equipped workshop with Insert the taper shank into the spindle nose plain milling cutter long arbor positioning arbor notches fits onto the amidst Horizontal and Universal spindle key Milling machine Screw the arbor by draw in bar from the rear of the spindle Tasks Tighten draw in bar lock nut Unscrew and remove the arbor nut Set up milling cutter on long Pull out the Over arm to accommodate the arbor and in Horizontal milling arbo
122. ance Related knowledge Objective 3 4 Weld T Joint in the Flat Position ae Condition Obtain a instructional drawing Obtain a workpiece material Fully equipped workshop with Prepare the dimension as per drawing on Gas welding equipments with the workpiece material different sizes of nozzles Set up all gas welding equipment Stand one plate on top of the other plate on the welding table forming T Joint as per given drawing Tasks Refer steps no 6 to 8 of the Run fusion without filler rod Weld T Joint in the Flat Realign the position if needed Position Tilt the tacked pieces 45 to the work surface placing the fire brick under one side to support the pieces Hold the torch so the tip forms and angle of about 45 to the bottom plate Maintain the heat on both plates while manipulating the torch If additional build up is required filler rod may be added as the puddle is carried across the joint Weld one side of the plate and then practice on the reverse side Procedure of welding Fillet T joint Standards Prepare workpiece for Fillet T joint welding Follow the procedure of welding Fillet T joint Safety Precautions e Refer to the Task Weld Square butt joints 315 Duty 3 PERFORM FLAT POSITION WELDING Time 9 0 hrs 3 5 Weld pipe to pipe M S Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain a
123. and diadvantages of sliding door Tasks Perform assembly works required as design Fix partition with sliding door Check the dimensions Store it in safe and special place Standards Joints are fixed Fixed partition with sliding door 1s checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 300 Duty 5 FINISH THE FABRICATE MEMBERS Time 1 5 hrs 5 1 Perform glass board fitting Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain details of instructional drawing e Finish the fabricate Prepare work piece materials Fully equipped workshop with members Confirm the process of fitting hand tools and punches and Obtain the machine or tools equipments to punching facilities fabricate the materials e Design of glass board fittings Perform benchworks cutting drilling Tasks and punching Perform assembly works fitting glass board as required as design Check the dimensions Store it in safe and special place Glass Board fitting is rigid Perform glass board fitting Standards Glass Board fitting is checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 301 Duty 5
124. and tools 24 Clean the vice and work shop Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What File flat surface Plain Standard How well e Filing work piece should be match given drawing e Tolerances of filing work piece is within the 0 5 mm e Material of w p e Material of files and introduction e w p clamping devices e care and safety features of files bench vices steel rule try square e Type of file e Proper way of holding file while filing e Position of feet and body while filing e Measuring and marking tools e State basis units of length measurements and its multiples e Techniques of flat filing i e straight cross and draw filing Safety General personal machine tool and equipment workshop Tools and Equipments Flat files steel scale Back square try square Marking scriber Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Flat Oil Safety 1 Follow safety rule 2 The height of bench vice should be set before filing 3 The handle of file should be fixed tightly 4 Avoid using broken files on files without handle 18 BOI Oy EA Do not leave files remained above work pieces on bench vice Don t touch the surface by naked fingers Full length of file should be used De burr the edge of the material 19 Duty 1 PERFORM FILLI
125. ant pipe 18 Start the machine and take a trail cut 19 Check position of vee on central of the slot 20 Set the worktable if necessary 21 Take further machining until depth dimension is reached 22 File out burrs from edges of slot 23 Remove the workpiece and check the final measurement Standards Size and shape should be match as per drawing Safety Precautions e Check that the cutter is sharp and undamaged e Make sure that the contact faces keys and slots are clean and free from burrs Beensure the cut should always be up milling e Always deburr the corners of machined surface before taking measurement e Set slightly lower speed and feed if the machine does not have exact values e Lock the table after setting as far possible before taking the cut e Always stop machine and clear away chips before taking measurement 231 Duty 6 MILL GROOVES Time 15 hrs 6 3 Mill Blind Groove and Through Grooves Exercise 12 hrs Demo 3 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain pre machined workpiece Obtain sets of parallel blocks Fully equipped workshop with Set up Key way Obtain two lips Key way cutter as per width Universal and Vertical Milling cutter in collect of groove to be cut Centro fix Centre drill machine chuck amp drill bit as per groove Refer the steps no 9 to 22 of performs Set up work table drilling and boring in milling Tasks
126. ark for height depth of object Mark for length and width of the object Notch the corner of material or if any where metal may overlap to each other Check dimensions of the completed job Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools with set of hand tools in tool box e Drawing instruction and work piece Tasks What Develop pattern of rectangular box Standard How well e Pattern should be match with given drawing e Tolerances dimensions the 0 5 mm of are within e Type development Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 120 Duty DEVELOP PATTERN Time 6 hrs Task 17 Develop Pattern of Cylindrical Container Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain an instruction drawing
127. arpen twist drill 1 7 4 2 Grind facing or corner tool in HSS bit 1 6 4 3 Grind roughing tool in HSS bit 1 5 4 4 Grind grooving tool 1 5 4 5 Grind thread cutting tool 1 5 4 6 Prepare boring tool it 8 Perform Project Work 0 5 1 Manufacture lathe center 24 5 2 Manufacture taper fitting component 16 5 3 Manufacture knurled head screw 55 12 5 4 Manufacture knurled head screw 60 10 5 5 Manufacture multiple thread shaft 12 Sub Total 43 191 Total 234 189 Duty 1 SET UP MACHINE Time 4 0 hrs 1 1 Set up Irregular Work piece on Face Plate Exercise 0 0 hrs Demo 4 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain a work piece Obtain Face plate Obtain clamps T bolts and nuts with washer Identify the position to clamp the work piece application Place the work piece as position and clamp Importance of using with the T bolts and nuts T 3 counter weight on face A ask Clamp the counter piece if necessary plate Set the speed change gear lever for low Set up irregular work piece Process of clamping speed on face plate irregular different Remove the chuck if necessary shaped work piece on Clean up threads on the spindle nose Standards Face plate Mount the face plate along with the work A piece e Process of clamping Reset the rpm lever in neutral position regular irregular 10 Check trueness of work piece clamping workpiece 11 Realign if necessary 14 Tighten all the nuts bolt
128. ary Hold twist drills lightly between the thumb and the first finger pointing the tip towards wheel Wear safety goggles Run the machine Hold the drill level and turn it to 59 to the face of the wheel so that the cutting edge is horizontal and parallel to the grinding wheel face Swing the shank of the drill slightly downward and towards the left Rotate the drill to the right by turning it between the thumb and the finger Apply a slight forward motion while swinging down this will help to form the clearance angle Repeat the process from step no 13 to 16 to re sharpen the second cutting edge Check both the cutting edges with a drill angle gauge or Bevel protractor for correctness of the lip angle and equality of the lip length Repeat the grinding until desired angle and sharpened tip obtained Check the final measurement Clean oil and chips Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Re sharpen Twist Drills Standard How well Twist drill bit should be match with given drawing Tolerances of dimensions are within the 0 5 mm e Introduction of drill bit and its types e Angle of drill bit e Procedure of re sharpen drill bit 39 Tools and Equipments Bench or Pedestrian grinding ma
129. as previous cut per drawing Turn back move the tool at first cut place Give feed as step no 8 double the depth than step no 10 Turn back move the tool at second cut place Give feed till the finished workpiece cut and fell Process of parting off the machined part Importance of parting off Fully equipped workshop with Center lathe machine and Parting off tool Safety Precautions e Refer to the task Perform grooves e Set up low RPM to avoid chattering 195 Duty 2 PERFORM MACHINING OPERATION Time 14 hrs 2 3 Perform Internal Grooves Exercise 12 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workpiece material Obtain required tools and equipment Set up workpiece on three jaw chuck Perform facing following the same steps Perform center drilling following the same steps Perform plain boring following the same steps of previous tasks Reset the internal grooving tool Task Bring and touch the side of tool tip gently on 77 the facing surface Perform internal grooves Set the dial scale 0 on top slide Insert the tool as mentioned on drawing for internal groove distance reading dial scale Standards Touch the tool tip gently on the bore surface Set the dial scale 0 on cross slide Dimension should be as Calculate and set the levers of RPM per drawing Disclose the tool and run the machine Turn the cross sli
130. as welding nozzles Process of Flame cutting by gas welding equipment Tasks Perform Oxy Acetylene Flame Cutting by gas welding equipment Standards Set up the gases and welding nozzle for flame cutting Cut the MS material in any profile e Wear safety apparels safety goggles safety gloves Safety helmet e Place apiece of steel close to the line of cut to slide the torch along e If the edges of the cut appear to melt and have a very ragged appearance the metal is not burning through and torch is being moved too slowly When an exceptionally straight cut is desired clamp a bar across the plate along side the cutting line to act as a guide for the torch to follow 317 Duty 5 PERFORM HARD SOLDERING BRAZING Time 9 0 hrs 5 1 Braze brass in Mild steel plate Exercise 6 0 hrs Demo 3 0 hrs Task and Steps Terminal Performance Related Knowledge Objective Obtain a instructional drawing Condition Obtain a workpiece material Fully equipped workshop with O Hata Set up all gas welding equipment Gas welding equipments with Remove grease paint and rust on the different sizes of nozzles joining part with a wire brush and sandpaper Tasks Classification of brazing Hold the material with a welding grip and filler rod Refer steps no 6 to 8 of the Run fusion Braze brass in Mild steel Characteristics of brass without filler rod plate brazing material Hold the blowpipe at an angle of 45
131. at position from 2 to 8 wire and accessories Procedures of deposition of Restore the tools and equipments MIG welding straight beads for Fillet weld Clean the working area Task Weld T joint in flat position Standards Transverse welding wave in MIG welding Procedures of deposition of MIG welding straight beads for Fillet weld in Flat position Safety Precautions e Avoid using welding gun with broken handle e Always use Wire brush to clean up the welding beads e Always check the connection of Holder Shield and wire end e Avoid using damp MIG wire Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry Duty 3 PERFORM VERTICAL POSITION WELDING Time 9 0 hrs 3 1 Perform surface weld in Vertical position Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of the steps of set up welding equipment MIG from 1 to 3 Condition Refer and follow the steps of surface Fully equipped workshop weld in flat position from 2 to 4 with MIG welding DC Introduction of welding wave in vertical position Hold the torch approximately 10 mm rectifier MIG filler metal welding from the work and the angle wire welding stand fitted at approximately 80 to the work piece table and accessories Procedures of deposition of Ref
132. awing area so Layout of three view that the drawing should come in the center drawing of the sheet Task Introduction of third angle Method of obtaining Poy capped con orthographic projections with Drawing board T set and drawing instrument Draw front view referring the steps of draw projection isometric view drawing Draw three views drawing in Introduction of types of Draw side view first angle projection projection in drawing Draw top view Erase projection lines if draw it Standards Give darkness for necessary lines DERE Maintained symmetry Projected line should be visible Line should be approprite Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 75 Duty 5 DRAW ORTHOGRAPHIC PROJECTION Time 8 0 hrs 5 2 Draw Three View Drawings in Third Angle Projection Exercise 7 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain sample or drawing of object to draw Condition three view Prepare a drawing sheet Determine the front side and top view Calculate the space from drawing area so Method of obtaining orthographic projections in third angle Layout of three view Fully equipped Classroom with Drawing board T set and drawing instrument that the drawing should come in the center drawing of the sheet Task Introduction of third angle Draw front view referring the steps of draw pro
133. awing sheet Select the diameter for truncated cone Fully equipped Classroom Draw a top view and front view of cone with Drawing board T set Divide the top view circle into 12 equal parts French curve and drawing Name on each point of the divided circle instrument Project the projection line from each point of parting circle vertically down wards which intersect the base line of front view Task 8 Give same name whether the projection line intersect Draw truncated cone 9 Project the line from the each point development 10 Draw a cutting plane line in desired angle and height from the base line of front view 11 Give name when cutting plane cut each Standards projecting line by its same name 12 Draw horizontal projection line from each Calculation of drawing point of cutting plane at 0 1 projection line area 13 Give same name as dash at 0 1 line by respecting point of projection line 14 Take radius 0 1 by compass 15 Draw an arc by taking radius 0 1 at any where place as far as possible 16 Join the arc for reference from approx 0 17 Take 1 part of distance by compass from top Maintain the uniformity view of line thickness 18 Mark at initially drawn arc 12 line by Maintain the line joints distance taking compass Maintain the neatness and 19 Give name respectively cleanliness 20 Draw projection from each point 21 Take radius 0 1 22 Set one tip of compass on apex 0 and draw an arc by taking radius 0 1 23 Give name where drawing
134. back and for to maintain surface at the depth Make sure all the dimensions are as given instruction Types of grooves and its use Process of turning grooves Safety Precautions e Refer to the task Plain turning e Avoid using narrow and blunt tool e Avoid clamping overhanging tool e Avoid applying the depth on sides 93 Duty PERFORM TURNING OPERATIONS Time 6 0 hrs 2 7 Perform Chamfers Exercise 4 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Refer and follow all the steps of task perform Plain turning Refer and follow all the steps of task perform Step turning Perform and finished the operation as required following the steps of previous tasks Reset the Roughing tool on tool post Task Importance of chamfers Process of turning chamfers Fully equipped workshop with Center lathe machine and cutting tools Identify the size of chamfering Bring and touch gently the mid of cutting tip Perform Chamfers on the edge of the workpiece Set the dial scale 0 of both the top and cross slide Standards Run the machine The angle of chamfering is Give feed as plain turning from longitude dial determined movement reading dial scale e All machined corners are Repeat and follow the chamfer at all corners chamfered and edges of the workpiece Safety Precaution Refer to the task Perform Plain turning and Step turning 94
135. both side on live and Process of clamping dead or revolving center workpiece with a lathe Tighten the work from tail stock dog Turn the workpiece by hand until 1t stops on Supports a workpiece with stopper in anticlock wise direction a Tailstock Introduction of Lathe dog and Dog clamp Center drilling for Dog clamp Process of clamping work pieces on center to center Importance of center to center works Fully equipped workshop with Center lathe machine Live and Revolving center Faceplate Lathe dog and clamps Task Set up workpiece center to center with lathe dog and dog clamp Standards Lathe dog is tightened Safety Precautions e Use small piece of Vee block when tightening the dog on machined surface e Clean the spindle noses of Head and Tail stock before setting the center e Keep the carriers away from the Head stock e Switch off the main electrical line while setting up the workpiece e Follow the same safety precautions of center drilling and facing operation e Always keep the machine and its surroundings neat and clean 191 Duty 1 SET UP MACHINE Time 3 0 hrs 1 3 Set up Workpiece Along a Steady Rest Exercise 0 0 hrs Demo 3 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain workpiece Obtain steady rest Set up wokpiece on the chuck to turn at the rest surface Mount the Steady rest on lathe bed in the position according to the length
136. brush File brush Dust pan Finishing file Folding machine Materials GI Sheet Safety e Take care of marked lines folds must not be collecting together e Aware from clamping the finger by machine jaw e To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover 109 Duty PERFORM CUTTING FOLDING AND ROLLING Time 3 hrs Task 7 Roll metal sheet by rolling machine Theory 1 hr Practical 2 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece Condition Given e Hand tools Hardies drawing e Well equipped workshop used in rolling metal 2 Read drawing thoroughly with set of hand tools in sheets 3 Obtain the metal sheet of tool box e Mallet and types required size and required e Drawing instruction and e Rolling m c and sheet metal tools work piece application 4 Straighten and de burr the sheet metal 5 Layout the pattern Tasks What 6 Check the layout for Roll metal sheet by rolling accuracy machine 7 Notch and cut the unnecessary part 8 Place the sheet metal in between the roller of the Standard How well machine l e Rolling work piece 9 Align the marked line parallel should be match with to the roller given drawing 10 C1 heet firml amp sheet firmly e Tolerances of 11 Roll the roller of machine by E Sa the liver dimensions are within 12 Repeat the rolling operation by the 0 5 mm lowering the upper ro
137. ce 19 Store the work piece and tools Tools and Equipments Vernier caliper Counter bore Reamer Drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch Materials MS rod Oil Safety e Refer the task File flat surface Punch dot and center Saw the metal by hand and Drill a hole and Radius filing 46 Duty 7 PERFORM PROJECT WORK Time 20 hrs Task 3 Manufacture a C Clamp Theory 0 hrs Practical 20 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain workshop drawing Condition Given 2 Obtain workpiece material e Well equipped workshop 3 Check rough dimension and file with set of hand tools in out one side marrow plane as a tool box reference plane e Drawing instruction and 4 Mark a layout for necessary work piece dimension to saw 5 Punch dots on marking lines 6 Drill holes to get internal radius R7mm 7 Drill chain holes to cut out unnecessary metal Tasks What 8 Remove stock material by Manufacture aC Clamp chiseling the webs 9 Maintain the thickness of 15mm with correct flatness and squareness in geometrical tolerances 10 Drill a hole 8 5mm for M10 Standard How well thread e Tolerances of dimensions 11 Make diamond surface on the are within the 0 1 mm drill surface 12 Make radius of R12 and R7 5 on two corners as per given drawing 13 Chamfer and
138. ces Time 4 0 hrs Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Introduce tolerences E A Introduction Fully equipped drawing class ES Define limit fits and tolerences ees oe E Limit fit amp allowance Differenciate hole basis and shaft Surface tolerance basis Geometrical tolerance Calculate tolerences Task Brief tolerences Be familier with limits fits Sample exercise referring the steps of and tolerances Dimension in detail Standards e Tolerence should be allocated according to the nature of workpiece Safety Precautions 71 DUTY 3 DRAW IN SCAL Time 4 0 hrs 3 4 Draw the Symbols Exercise 2 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board 2 Prepare a drawing sheet Decide the drawing that has to be draw which symbol Condition First angle and third angle projection symbol Scaled and mark on the drawing sheet Dimensioning symbols Erase the unnecessary lines in draw Welding symbols Give darkness for necessary lines Surface symbols Machine element symbols Fully equipped Classroom with Drawing board T set and drawing instrument 17 Clean up the drawing sheet Task Draw the symbols Standards e Symbol should be clear and appropriate for the representation Safety Precautions 72 Time 16 0 hrs Exercise 14 0 hrs Demo 2 0 hrs
139. ch at starting point Hold hacksaw frame as for the rough file Start cutting slowly moving the blade forward 15 Apply pressure only during the forward stroke Holds panels securely Return the blade faster without touching blade Repeat the same motion to complete the Cutting dimension is checked stroke as for filling as per given drawing Check the cutting ways that goes straight down Move slows down while finishing a cut 20 Check the part that has sawed Holding different sections of work piece for hack sawing Hack saw blade SOL GOIN EG O Standards Cutting line is straight Safety Precautions Hold the job so as to be cut on the flat side rather than the edge or the corner e The teeth of the hacksaw blade should point in the direction of the cut and away from the handle The cutting movement should be steady and the full length of the blade should be used e At least two to three teeth should be in contact with the work while cutting e Avoid moving the blade too fast while finishing a cut slow down e Avoid clamping the work piece over hang 287 Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE 1 2 Perform drilling Time 4 hrs Exercise 3 hrs Demo 1 hrs Steps Terminal Performance Related Knowledge Objective Obtain a workpiece material Condition Introduction Obtain center punch Hammer Drill bit Obtain drawing Types of drill bit Mark the symmetrically lines Type
140. chine Safety goggles Bevel protractor or grinding gauge Blunt twist drill bit Oil can Number punch Bench cleaning brush File brush Dust pan Materials Twist drills Oil Safety e Move the work across the full face of the wheel to prevent uneven wearing off of the grinding wheel e Refer the same safety precautions of the task grind center punch 40 Duty 6 HANDLE MEASURING INSTRUMENTS Task 1 Check square ness using back square Time 6 hrs Theory 1 hrs Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain work shop drawing Condition Given e Introduction of back 2 Read drawing thoroughly e Well equipped workshop square 3 Obtain pre machined w p with set of hand tools in e Features of back square material tool box e Checking back Square 4 Obtain a back square of o Drawing instruction and before use required size work piece e Care of back square 5 Hold the w p in one hand and place the stock of the square against the vertical surface 6 Slide the stock down the Tasks What vertical surface until the Check square ness using blade touches the flat back square surface of work piece 7 Position the work so that the light falls on it from behind 8 Check whether any light passes between the work piece and the blade if not the surfaces of w p are 90 to each other 9 If yes correct the surface by Standard How well re filing e Adjacent
141. chuck o Drill chuck 22 23 i 24 25 26 27 28 i i Hand drilling machine 7 Screwdriver Phillips flat o G y METE S G y E HE AH 10 Hand drill and drill bits 11 TA O y 12 Aluminum profile cutting machine J o o G 13 TI G o 14 Silicongun O y 15 Plumbo S G y 16 Router machine o o y pO pO Pp E n DO ooo O ALUMINIUM Ooo pO Pp Pp pO pO Pp 22 23 24 25 26 27 28 E 6 345 Welding Technology IIT 7 1 Welding Holder S No eres p AA Oo O O O ES A AA 4 Wi ns 5 p NES ee pS Oo Oo ra AA AAA Toas SSS Pie eater SSS SSS Gas welding ble Lathe Operation II 1 Center Lathe Machine IIS y 2 Three Jaw independent Chuck According to m c spinde 3 FourJawchuck According to m e spinde 4 Colect chuck with draw bar f Set 5 Faceplate According to m e spinde 6 Lathe dog clamps with face plate f o Se 7 Lathe centers Live Dead Revolving According to m c spindle 8 Drill chuck with chuck keys J 9 E T o e 10 Alenkeys Set e 11 Steady Rest E G 12 Follower Rest O o y va x 6 14 Center Drill PS 15 Drill bits Set 16 SteelHammer SH 17 Centerpunch OP 18 Boringtool RC Thread 60 55 19 Counter Sink TH and HS 20 Hand hacksaw Frame withblade J 346 o
142. complete the bead at other end of the plate Standards Remove the slag from the weld bead Maintain joining of two Repeat the exercise till you achieve good metals result Maintain welding distortion Maintain welding penetration Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 141 Duty PERFORM HORIZONTALPOSITION WELDING Time 13 0 hrs 2 1 Perform surface weld Exercise 12 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition 2 Obtain work piece Material iu to Work piece clamping Refer and follow the steps of surface IS I P AS weld from 3 to 9 except 4 WAL weing Wave of welding in Serio wodepiers onthe welding stid transformer welding Horizontal position accessories and different with clamps and supports in a horizontal codes Penetration of welding in position parallel to nose Horizontal position Strike the arc on a rough piece for trail Strike arc and weld from left to right Task Welding procedure maintaining short arc
143. cture Simple Present and Continuous When Simple Past Past Continuous When Simple Past Past perfect Present Perfect Present Continuous Causative Verb Punctuation Rules and Examples Affirmative Negative Sentences Concept Practical Exercises Yes No question Concept Practical Exercises WH question Concept Practical Exercises Tag question Concept Practical Exercises Letter writing Parts of a letter Types of letter Social letter Application Complaint letter Business letter Memorandum writing Definition important points Skill in writing a memo Report writing Definition and methods of writing a report Read understand and use the technical terms Practical job reports Filling work Drilling activities G I Pipe cutting Sawing Read short technical publications Read amp Follow English language instruction Techniques of writing instruction Going to Future Concept and Uses Prepare a Speech 5 minute speech on birth control Pollution HIV Aids Voice Active amp Passive Introduction Kinds Rules of changing active into passive voice Reported speech 9 Time hrs 4 4 W N W N Introduction Rules of changing direct into indirect speech Statement Imperative Interrogative Rearrangement of words Techniques Illustration and Practical exercises Conditional sentences Types Structure Examples Practice Exercises Relative clauses Defining relative clause sentences examples Joining sentences
144. d How well by divider or compass e Pattern should be match 14 Mark twelve times from the initially with given drawing draw reference line by taking length e Tolerances of dimensions from compass are within the 0 5 mm 15 Draw vertical projection line from each point respectively upper projection line 16 Project the projection line from cutting plane s point horizontally 17 Joint each point by french curve 18 Determine the folding joint 19 Mark and draw the folding margin as per joint on both side 20 Notch the corner or if any 21 Check dimensions of the completed job 22 Punch the roll no on work piece 23 Oil the surface of the work piece 24 Store the work piece and tools Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file 122 Materials GI Sheet Rivet Aluminum or MS Oil Safety e De burr the metal sheet edges e Place snips and material on bench e Avoid carrying scriber in pockets e Open the blades as far as possible for your hand and using the throat of the snips e Start the cut at the edge of the material e Avoid sharp corners e Avoid leaving jagged edges cut the material by closing the blades just short of their full length 123 Duty DEVELOP PATTERN Time 6hrs Task 19 Develop a pattern of funnel
145. d either with the thumb or forefinger Set up the gases and Adjust the flame if necessary to keep the welding nozzle for flame preheating cones burning with a neutral cutting flame Cut the MS material in Bring the preheated flame on the edge to any profile be cut amp heat edge to cherry red Press down the oxygen pressure lever Move the torch forward slowly along the chalk line A shower of sparks will be seen to fall from the underside indicating that the penetration is complete and the cut is proceeding correctly Reheat from the beginning if the cut does not seem to go through the metal Blow with hammer to separate the two sections Fully equipped workshop with Gas welding equipments with Flame cutting nozzle Introduction of oxy Safety Precautions e Wear safety apparels safety goggles safety gloves Safety helmet e Place apiece of steel close to the line of cut to slide the torch along e If the edges of the cut appear to melt and have a very ragged appearance the metal is not burning through and torch is being moved too slowly When an exceptionally straight cut is desired clamp a bar across the plate alongside the cutting line to act as a guide for the torch to follow 272 Duty 1 PREPARE MATERIAL Time 2 hrs 1 3 Perform Off hand grinding Exercise 2 hrs Demo 0 hrs Objective Knowledge Obtain instruction Condition Obtain pre welded workpiece material Obtain accessories and tools
146. d in windows panel Types of glass used in door panel Design of glass door panel and punching Tasks Perform assembly works required as EUA design Check the dimensions Fabricate glass door panel Store it in safe and special place Standards Joints are fixed Glass door is checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 297 Duty 4 FIX PARTITION Time 6 0 hrs 4 1 Fix half partition Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Perform benchworks cutting drilling e Introduction of partition e Concepts and punching Tasks Perform assembly works required as design Check the dimensions Fix half partition Store it in safe and special place Standards Joints are fixed Fixed half partition is checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 298 Duty 4 FIX PARTITION Time 6 0 hrs 4 2 Fix part
147. d turning 7 7 3 Center drilling 7 7 4 Drilling 7 7 5 Boring counter boring 7 7 6 Chamfering 7 7 7 Deburring Total 117 BOOK AND REFERENCES B S Raghuwanshi A Course in Workshop Technology Vol 1 and 2 Dhanpat Rai and Co S K Hajra Chaudhary Workshop Technology Vol 1 Media promoters Henp Fort Shop Theory Vol 1 Trade School W A J Chapman Workshop Technology Vol 1 Elsevier Science Heinrich Gerling Elementary Metal Course Training Section I ETHIO Arbeitsstelle fur Unterricht und Technik GERMAN Technical Institute Holetta Heinrich Gerling All about MACHINE TOOLS New Wiley Eastern Ltd India 1965 156 Second Year Subjects Applied Math II Computer Aided Drafting Engineering Drawing II Entrepreneurship Development Lathe Operation I Material Science II Milling amp Shaping Operation Repair amp Maintenance Structural Fabrication 0 Welding Technology II Gas TIG MIG 1 Workshop Technology I e WO ON WN nA BW NY 157 Applied Mathematics II Areas and Topics 1 Calculate Effects of force 1 1 Representation 1 2 Line of Application 1 3 Equi directional force 1 4 Opposite forces 1 5 Forces at an angle 1 6 Resolution of forces 1 7 Examples and Exercises Calculate pulleys without friction 2 1 Fixed pulley 2 2 Loose pulley 2 3 Block 2 4 Differential pulley 2 5 Examples and Exercises
148. daptor Set of Key way cutter E Set of Vee block and Clamps eS AZ 2 2 2 2 2 2 2 Sets of Drill bits 30 Sets of T bolts and nuts according to machine table Shell end mill cutter 4 5 6 7 9 3 3 2 3 8 Sets of Allen keys 1 set 0 1 2 3 347 Soft hammer mallet eee 34 Steelhammer O y Tool maker square Try square es Vernier bevel Protractor EA 37 Vemiercaliper SO mm Vertical draw in bar according to spindle ASA Vertical milling machine o CO o A E haping Operation S N Description Size Remarks 1 Shaper Machine 2 Shaper Vice 3 Vice handle 4 Tee Bolts and Nuts According to tee slot 5 Dial Test Indicator with Magnetic Stand 6 Parallel Blocks Set of paid 7 Fine File Medium 8 Open Spanner Metric 1 set 9 Soft Hammer Aluminum 10 Parallel Clamp with Step Block 1 set 11 HSS Tool Bit Rough tool 12 HSS Tool Bit Corner tool 13 HSS Tool Bit Grooving tool 14 HSS Tool Bit Dovetail tool 15 Grinding Gauge 16 Back Square Try square 90 17 Vernier Height Gauge 150mm 18 Steel Scale 300mm 19 Marking Scriber 20 Safety Goggles 21 Center Punch 22 Steel Hammer 23 Bevel Protactor 24 Vernier Caliper 150mm 25 Vernier Depth Caliper Repair and Maintenance Preventive Maintenance IA Oileam o y E 3 Greasegnm_________ 4 Funnel o y 5 oi ET 2 7 E
149. de anticlockwise reading Grooved surface should dial scale so that the tool cuts toward operator be as per drawing Stop the machine bring back the tool give side from top slide if necessary Repeat step no 11 to make a complete groove Stop the machine bring back the tool measure all the dimension open the workpiece and tool Collect all tools and store in its place Process of turning internal grooves Uses of internal grooves Fully equipped workshop with Center lathe machine and Facing tool turning tool Center drill Drill bits for guide hole plain boring tool internal grooving tool Safety Precautions Refer to the task Perform Boring and grooving external surface 196 Duty 2 PERFORM MACHINING OPERATION Time 22 hrs 2 4 Perform Internal Tapers Exercise 18 hrs Demo 4 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workpiece material Obtain required tools and equipment Set up workpiece on three jaw chuck Perform facing Perform center drilling Perform plain boring Setting angle for e worksiop internal taper operation with Center lathe machine and Facing tool turning Process of turning tool Center drill Drill bits internal taper operation for guide hole plain boring tool Applications of internal Identify the angle to be cut and set tappers Loosen the nuts of the swivel device on the cross slide l l l Task Set the
150. dge Objective Condition 4 1 Replace Electrical Accessories Obtain instruction layout diagram Prepare wiring diagram Obtain electrical accessories as per Introduction of one bulb diagram control by one way Mark the layout on the board as per switch with push button diagram Task switch control by buzzer Prepare the auxiliary accessories as per Fully equipped Electrical workshop with hand tools diagram measurement e Replace electrical Install the auxiliary accessories on the accessories board Lay wire according to the wiring diagram Standards Connect all electrical accessories according to the wiring diagram Clean and store the electrical instrument used in safe and sound place Bulb sockets fuses plugs holders switch with push button switch buzzer should be replaced Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 265 Duty 5 REPAIR MOTOR CONTROL AND INSTALLATION SYSTEM Time 6 0 hrs 5 1 Connect direct on line starter DOL Exercise 4 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective oa Condition Obtain instruction plan control and power diagram Introduction of direct on Fully equipped Electrical Ob
151. dinal and cross movement Cutting speed according to tool diameter Height should be maintained Safety Precautions e Do not operate any machines without knowing thoroughly e Check all guards are in positions e Wear personal safety apparels e Keep the machine and surroundings clean e Avoid leaving the machine when it is in operation e Check oil levels before start the machine 216 Duty 1 SET UP MACHINE Time 4 0 hrs 1 2 Set up milling vice on machine table Exercise 2 0 hrs Demo 2 0 hrs Objective Knowledge Place milling vice Condition 2 Place tee bolts and nuts Obtain lever type Dial test indicator with Fully equipped workshop with Use and care of Dial magnetic stand milling vice and T bolts amidst test indicator Clean the machine vice amp m c table Vertical Horizontal or Apply thin film of oil at the bottom of Universal Milling machine machine vice Clamp the vice on machine table with tee bolt and nuts Tighten slightly both the nuts Hold dial test indicator on magnetic stand and then magnetized on machine column Bring fixed jaw of the vice to contact with dial test lever Standards 10 Move the table along longitudinal axis to other end Machine vice is aligned 11 Observer the indicator parallel to longitudinal 12 Set the indicator lever zero movement to the m c table 13 Move the table longitudinal axis to other end of the vice Tighten milling vice very Proc
152. dition Obtain work piece Material TE ae er oe Workpiece clamping Refer and follow the steps of surface 1y equipper P ah weld from 3 to 9 except 4 with Arc welding Wave of welding in Refer and follow the steps of surface transformer weldmg overhead position Se i d different O weld of outer head position from 4 to o eG er Welding in overhead 9 position Welding procedure Task Weld square butt joint from both side Standards Maintain welding distortion Follow welding procedure of overhead position welding Safety Precautions e Avoid using electrode holder with broken handle e Always use chipping hammer and Wire brush to clean up the welding slags e Always check the connection of holder shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 147 Duty PERFORM PIPE WELDING IN FLAT POSITION Time 9 0 hrs 5 1 Weld Pipe to pipe joint in Rotated position Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition Obtain work piece Material Workpiece clamping Collect and set up welding accessories Fully equipped workshop ae and tools with Arc welding Wave of welding in Deburr and grind 45 groove edge on all ISO PES
153. dition Obtain workpiece material Obtain sets of parallel blocks Fully equipped workshop with Setting a vertical Obtain Shell end mill cutter as per required Universal and Vertical Milling head at angle to be size machine cut Mount shell end mill cutter on short arbor in Vertical milling Process of feeding Set the machine controls and depth of cut Set up workpiece material as per the size Prepare a square block Tasks Produce angular surface tilting Process of milling Loosen the nuts of vertical head Vertical head angular surface 10 Tilt the head as per given angle 11 Tighten the nuts gradually Use of Vernier Bevel 12 Bring the face of cutter over the corner Protractor where an angle to be machine Standards 13 Set the longitudinal hand feed scale to zero 14 Move along the cutter from work piece moving cross movement of table 15 Give depth of cut by longitudinal hand feed 16 Position the coolant pipe 17 Start the machine and give feeding 18 Repeat machining till the dimension obtained Angle should be accordinng to drawing Surface should be plane and even Safety Precautions e Beensure the graduation mark on the vertical head has been corrected e Follow other safety precautions of task preparing a square block milling 226 Duty 4 MILL ANGULAR SURFACE Time 8 hrs 4 2 Produce angular cutting with angular cutter Exercise 7hrs Demo 1 hrs Steps Terminal Performance
154. drill vice or machine table Check the cutting edge of drill bit before drilling a hole Mount the drill shank as much as possible Be ensuring the drill center is as you wish Apply fluent coolant Use cleaning brush to clean out the chips 45 Duty 7 PERFORM PROJECT WORK Task 2 Manufacture a Steel Hammer of 500mm Time 30 hrs Theory 0 hrs Practical 30 hrs Terminal performance Related Technical Steps erie objectives Knowledge 1 Obtain workshop drawing Condition Given 2 Obtain workpiece material e Well equipped workshop 3 Obtain necessary tool and with set of hand tools in equipments tool box 4 Measure rough dimension and file Drawing instruction and one side marrow plane for work piece reference plane 5 Mark layout line on workpiece for necessary sawing and filing 6 Punch dots on marking lines he o side portion for steep Tasks What 8 Make rectangular block of required Manufacture a Steel Hammer size according to the given drawing of 500mm 9 File radius on pin side 10 File next radius on bottom side 11 Drill a hole for wooden handle 12 File a hole of circular to oval 13 Enlarge side by side on both side in all periphery 14 Chamfer and deburr all sharp edges Standard How well 15 Check the final measurement e Tolerances of dimensions 16 Clean any oil and chips from the are within the 0 1 mm work piece 17 Punch the roll no on work piece 18 Oil the surface of the work pie
155. duction 3 2 2 Types of calipers Odd leg Inside amp Outside 3 3 Vernier Calipers 3 3 1 Introduction 3 3 2 safety precautions 3 3 3 Main parts 3 3 4 Least Count 3 4 gauges 3 4 1 Introduction 3 4 2 Types and Use of feeler gauge radius gauge Pitch gauge and Wire gauge limit and adjustable 3 5 Introduce angle measuring instruments 3 5 1 Introduction 3 5 2 Types and Use of Drill grinding gauge Back Square Center back square and Protractor Drills and Drilling 15 4 1 Safety precaution 4 2 Drills and drilling 4 3 Types of drills 4 5 Elements of twisted drill 154 4 6 Drill chucks keys and drift 4 7 Drill sleeves and sockets 4 8 Drilling machines 4 8 1 Types of drilling machines 4 8 2 Main Parts of drilling machine 4 8 3 Cutting speed feed and RPM 4 8 4 Drilling operations Sheet Metal 22 5 1 Safety precaution 5 2 Sheet metal and its application 5 3 Marking and laying out 5 4 Development of pattern 5 5 Hand tools used in sheet metal work 5 6 Explain machines for sheet metal forming machine 5 6 1 Shearing m c types and application 5 6 2 Folding machine 5 6 3 Beading machine 5 7 Punches and punch tools 5 8 Riveting 5 9
156. e 6 0 hrs Demo 1 hrs Objective Knowledge Obtain instructional drawing Condition Collect work piece Refer and follow the steps of surface weld from 3 to 9 Place the work piece on the welding table with supporting in a flat position Perform tack weld on both ends Check and re set the position Strike the arc on a rough piece for trail Task Strike the arc on the work piece at one edge Move the electrode in a straight following the edges of both workpiece Standards and complete the bead at the other edge Maintain joining of two of the plate metals Remove the slag and spatters from the o weld bead Maintain spatters Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Weld edge joint Repeat the exercise till you achieve good Maintain porosity result 137 Duty PERFORM FLAT POSITION WELDING Time 7 0hrs 1 7 Weld Lap joint Exercise 6 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional drawing Condition Collect work piece Refer and follow the steps of surface weld from 3 to 9 Place the work piece on the welding table with supporting in a flat position Perform tack weld on both ends Check and re set the position Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Strike the arc on a rough piece for trail Task Strike the arc on the work piece at one n edge
157. e 8 0 hrs 2 9 Perform Plain Boring Exercise 6 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Obtain workshop drawing Obtain work piece material Obtain required tools with Center lathe machine lathe machine Set up work piece on three jaw chuck Facing tool tool Center Process of boring Perform facing following the same steps drill Drill bits for guide hole operation Perform center drilling following the same steps Perform plain if necessary supporting with tailstock l l l Task Change center drill to guide drill Drill guide hole up to 2mm remaining to the Perform plain boring exact hole Reset the boring tool centering with the Fully equipped workshop Boring and drilling on plain boring tool center located on the tailstock Standards Bring and touch the tool tip gently on the boring surface Drilling guide hole is Set the dial scale 0 of cross slide performed Bring back to its first position and give depth of cut Boring tool is set Run the machine and give feed manual Performed process of plain Ensure the cut is without any disturbed boring Set the auto lever down and complete the cut Check the diameter Give remaining depth of cut leaving margin for finishing cut Repeat step 16 and 17 Chamfer the edge Measure all the dimensions to ensure the complete machining Measurement of boring diameter is checked Safety P
158. e corner angle 60 809 accessories and different Procedure of deposition of and height filler material TIG welding beads without Put the helmet down filler rod Now start welding from right to left till Task the end Perform another runs clam the previous Perform surface welding runs by steel works without filler rod Weld again if necessary Restore the tools and equipments Standards 10 Clean the working area l l Transverse welding wave in TIG welding Procedure of deposition of TIG welding beads without filler rod Safety Precautions e Avoid using torch with broken handle e Always check the connection of torch shield and grips e Keep always the inflammable material e Always place the torch on hanger after welding e Avoid using damp torch e Keep the workplace dry 323 Duty 2 PERFORM SURFACE WELDING Time 9 0 hrs 2 2 Perform surface welding with filler rod Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow set up welding equipment of TIG no 1 to 3 Condition Ferer and follow surface welding Fully equipped workshop Introduction of welding with filler rod 2 amp 3 with TIG welding AC DC wave of TIG Welding Hold the torch at an angle of 60 80 rectifier tungsten rod wire and the filler rod at an angle 20 30 TEO EOIS and aiMerent Procedure of deposition of filler material TIG welding beads with Refer and fo
159. e too fast slow down while finishing the cut 6 Neither the blades too much neither tighten nor loose 7 Avoid clamping the w p over hang 26 Duty 3 PERFORM CUTTING Task 2 Chisel flat surface Time 14 hrs Theory 2 hrs Practical 12 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w p and drawing Condition Given 7 i 2 Read drawing thoroughly e Well equipped workshop j e ost 3 Obtain work piece material with set of hand tools in e Fun draci of 4 Obtain flat chisel steel rule height tool box chipping gauge marking scriber center punch e Drawing instruction and Use ofchisels eune WORE pi ce e Procedure of e 5 Prepare rectangular block as per flat drawing referring following the same steps of previous task 6 Mark the chipping depth using height gauge as per drawing 7 Punch dotted on chipping depth line 8 Clamp the work piece securely in the vice 9 Install chip guard 10 Hold flat chisel in left hand Tasks What 11 Position the chisel at about 60 angle Chisel flat surface 12 Hold the hammer at the end of the handle for maximum leverage 13 Strike on chisel head starting from edge of the work piece 14 Stop chipping at the very close to end of the surface 15 Turn the work piece to chip at the end Standard How well from the opposite direction e Chiseled work piece 16 Repeat the chipping until required koud be mach Ah surface quali
160. e view from rectangle height 1 5xd Draw the views 14 Adjust the compass with marked point to Maintain the uniformity of rectangle height line thickness 15 Draw an arc upto full length of the nut 16 Draw horizontal line on arc ending point 17 Divide the center point vertically on both small rectangles 18 Draw the arcs from center point to small rectangle size 19 Make the 30 corner at both ends of the nut on arc drawn side 20 Draw the same arcs at the bottom of the nuts if necessary 21 Erase the projection lines drawn 22 Give darkness for necessary lines 23 Clean up the drawing sheet Nomenclature of threads Types of nuts How to construct hexagon Standards Draw the supporting lines Maintain the line joints Maintain the neatness and cleanliness Safety Precautions e Refer the safety precautions of draw three view drawing 174 DUTY 2 DRAW MACHINE ELEMENT Time 4 0 hrs 2 2 Draw Hexagon Bolts Exercise 2 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition Prepare a drawing sheet Determine the size of bolt in mm Identify the standards of bolt Scaled and mark on the drawing sheet Draw a center line Mark horizontally on center line for thread y aski length shank head and chamfers 8 Draw a vertical lines on every marked dots 9 Mark from center line with dividend for height and width on all vertical line 10 Draw horizon
161. e w p 15 Chamfer De burr if necessary 16 Check the final measurement 17 Clean oil and chips 18 Punch the roll no on work piece Standard How well 19 Oil the surface of the work piece e Counterbore work piece 20 Store the work piece and tools should be match with given check list Tolerances dimensions the 0 1 mm of are within Tools and Equipments Drill m c with drill chuck key drill bits centre punch steel hammer Drill vice Oil can Number punch Bench cleaning brush File brush Dust pan files counter bore tool set Materials MS Flat Oil Safety 1 Refer to the safety precaution of taste Counter sink on hole 34 Duty 4 PERFORM DRILLING Time S hrs Task 4 Ream drilled hole using hand reamers Theory 1 hrs Practical 6 hrs Terminal Related Technical Steps performance Knowledge objectives A A 10 11 12 13 14 15 16 17 18 19 20 21 22 Obtain workshop drawing Obtain pre machined work piece material Obtain guide drills drill size for reamer and Countersink 90 Clamp the work piece on machine vice Drill a hole referring the same steps of previous task from guide hole to drill size for reamer hole Change countersink and RPM Countersunk the hole just as chamfer Stop the machine Fix the work piece in the bench vice Hold tap handle on square end Place the reamer vertically on drilled hole Align the reamer
162. eb site domain name system DNS WWW search engine and internet 24 Browse Information through service provider 0 50 1 00 Internet State the precaution to be taken while browsing through internet List the steps for information browsing through internet Explain the concept of e mail 25 Differentiate Web based e mail Send mail through internet and POP e mail 0 50 1 00 Explain the procedure to send mail through internet Sub total 1 00 2 00 Project works 26 Following projects are to be prepared and submitted e copy using 34 00 different packages e Create a Bio Data in Word Processing giving Educational and Personal Details e Create a Spreadsheet Worksheet entering marks of five subjects of 20 students Perform sorting according to their rank and generate a suitable graph for the same data e Design a presentation with not less than 10 slides on trade specific topic e Create a Database in Database package with not less than 20 entries Query and then generate the report Sub total 0 34 00 Total 10 50 67 5 Grand total 78 57 Engineering Drawing I Total 117 hrs Class week 3 hrs Unit sub unit Duties and Tasks Time hrs Th Pr 1 Handle Instruments 1 1 Set up paper in drawing board 1 1 1 2 Draw title box using T set and Set square or Mini draft 1 2 1 3 Draw representative lines 1 2 1 4 W
163. ecautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 132 Duty PERFORM FLAT POSITION WELDING Time 7 0 hrs 1 2 Perform surface weld Exercise 6 0 hrs Demo 1 0 hrs Task and Steps Terminal Performance Related Objective Knowledge Obtain instruction Condition Obtain work piece material Clean the metal surface with a wire Fully equipped workshop brush and wipe off the oil and grease with Arc welding Mark the job by chalk as per instruction transformer welding Set the work piece on the welding table accessories and different in a flat position electrodes Set the arc welding machine and connect the welding cables Task Select and clam MS electrode in the a holder Perform surface weld Set a welding current on a machine amp Standards Wear the complete safety apparel and AO AR check the filter lens of the welding Maintain a correct angle of shield the electrode Strike the arc on a rough piece for trial os and observe the current setting Maintain arc length Strike the arc on the work piece at one Maintain arc wave and trave
164. ece of paper over the surface Mill Plain Surface on Horizontal of workpiece i Milling 9 Start the machine 10 Raise the table using vertical hand feed move the table slowly until the cutter just remove the paper 11 Move along the cutter from longitudinal S feed Identified the cutter and set on horizontal milling Tasks Standards 12 Make sure that the cut must be conventional 13 Give depth of cut as required 14 Give feed till finishing at the end 15 Take further machining until complete surface machined 16 File out the burrs on all corners of the surface Milling surface is plain and even Safety Precautions e Always place the matching size of keys on arbor e Apply sufficient coolant e Distance between workpiece and arbor support must be clear e Parallel blocks should not be use while clamping rough workpiece e Ensure the parallel blocks are tighten sufficiently when use e Avoid sharp edges when handling workpiece e Clean and store all used accessories in proper place after completing the tasks e Check that the main switch is put off and clean off before leave the machine 223 Duty 2 MILL PLAIN SURFACE Time 15 hrs 2 2 Mill Plain Surface on Vertical Milling Exercise 12 hrs Demo 3 hrs Objective Knowledge Obtain workpiece material Condition Obtain sets of parallel blocks Set up workpiece as per the obtained size Fully equipped workshop with Process of milling a
165. ed is same as components before 15 Distinguish the excellent one and parts needs to be replaced 16 Assemble the parts as its original position 17 Fill up new gear oil as required quantity 18 Cover up the gear box cover 19 Re connect the gear and shaft connection 20 Turn on the machine 21 Confirm oil leakage levers position and variable speed 22 Keep all tools and equipments on their specified place Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 254 Duty 2 BREAKDOWN MAINTENANCE Time 3 0 hrs 2 5 Align Lathe Tailstock Offset Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Perform plain turning on a shaft as long as Condition possible supporting tailstock Principal part of Check the diameter of both end and calculate Fully equipped Machining shop lathe Function of the taper ratio with maintenance tools and Tailstock Calculate the offset distance of tailstock materials Taper turning Loosen the screw of tailstock offsetting tailstock Hold the dial gauge on tool post Task Method of re Touch the lever on spindle of tailstock and set alignment offset ZOLO A Align lathe tailstock offset tailstock 7 Tighten other screw and align the dial gauge half distance that of calculation Check the taper ratio once again Standards Reset the tailstock and confirm the alignment 10 Tig
166. edure of setting milling vice with dial indicator Tasks Process of holding works on milling Set up milling vice on machine vices table 14 Align the vice hammering opposite to the securely indicating line 15 Repeat steps no 13 amp 14 until the indicating lever does not show zero at both ends of the vice 16 Tighten fully both the nuts Safety Precautions e Avoid clamping the nut without washer e Always use correct size of spanner e Always disconnect the dial test lever before hammering in the vice e Avoid using slide wrenches e Always clean the surfaces where magnetic stand is to be located e Switch off the main switch before setting the vice e Dial test indicator must not be dropped and should not be exposed to severe shocks 217 Duty 1 SET UP MACHINE Time 4 hrs 1 3 Set up workpiece on machine table Exercise 2 hrs Demo 2 0 hrs Steps Terminal Performance Objective Related Knowledge Obtain sets of Parallel blocks as required size Condition Obtain sets of tee bolts and nuts Introduction of T Obtain sets of parallel clamps with step Fully equipped workshop with Bolts and clamps blocks as required no set of T bolts and clamps Clean all parallel blocks amidst Vertical Horizontal or Clean machine table Universal Milling machine Place the workpiece on machine table Set the tee bolts as near to the machine surface Process of holding work on cl
167. eel of carriage Repeat cutting turning until the require Turned cylindrical parts is diameter obtained according to given Apply auto feed if fine surface requires dimeter and tolerence Perform plain turning Safety Precautions e Refer all the safety precautions of the task perform center drilling and perform facing 91 Duty PERFORM TURNING OPERATIONS Time 18 0 hrs 2 5 Perform Step Turning Exercise 16 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Refer and follow all the steps of task perform Plain turning Identify the shoulder to be machined Identify the length to be turn Identify the diameter to be machined Process of turning Mark on the step length by tool rotating the steps chuck manually Task Perform plain turning for rough cut A Types of shoulder and Fully equipped workshop it its use with Center lathe machine and cutting tools Repeat rough cutting until 2 mm left on both side and diameter Perform step turning Reset the tool if necessary Take a cut following as rough turning Standards Maintain the length turning as facing e Measurements of operation machined surface is Measure the length and diameter checked as per diameter Perform further turning till the diameter and length shoulder and step length obtained Stpe face is in according Make sure the step length and diameter is as to given angle or 90 given
168. en axis 13 5 Examples and Exercises 14 Calculate Multiple gear drive 4 14 1 Component transmission 14 2 Total transmission 14 3 Examples and Exercises 15 Calculate processing time for drilling 4 15 1 Calculation of feed speed 15 2 Calculation of processing time in min 15 3 Calculation of initial cut 15 4 Examples and Exercises 16 Calculate processing time for turning 4 16 1 Calculation of feed speed 16 2 Calculation of processing time in min 16 3 Examples and Exercises 17 Calculate processing time for planning slotting amp shaping 4 17 1 Processing time for planning 17 2 Processing time for slotting shaping 17 3 Examples and Exercises 18 Calculate processing time for milling 4 18 1 Calculation of run up 18 2 Calculation of feed speed 18 3 Calculation of processing time in min 18 4 Examples and Exercises 19 Calculate Indexing indirect indexing 4 19 1 By indexing numbers 19 2 By degrees of angles 19 3 Calculation of Hole circles 19 4 Examples and Exercises Total 78 BIBLIOGRAPHY e Technical Mathematics for the Metal Trade German Agency for Technical Cooperation GTZ 159 Computer Aided Drafting Course Description This course intends to impart the knowledge and skills required to create two dimensional 2D drawing and drafting using Computer Aided Drafting CAD software with a focus mainly on civil engineering drawings The course is designed to fulfill specific needs of student who wants the transition from
169. ents Related Technical Knowledge Time hrs T P Perform Typing Practice Explain the interface of Word Processing including different tools menu Describe how to open save document and exit Explain the procedure to type document in word processing software Demonstrate systematic way of typing 0 50 2 00 Setup Page in Word Processing Explain different features and attributes of Page Setup Box Explain how to setup margins orientation size and columns Define Breaks Line numbers and Hyphenation Explain the procedure to setup page 0 25 1 00 Insert Object Picture Photo 1 00 Insert Header Footer Differentiate Header and Footer Explain the procedure to insert different header and footer in different pages 0 25 1 00 10 Insert Table Explain row and column State the procedure to insert table Describe table formatting procedure Border and Color 0 50 1 00 Sub total 1 50 6 00 54 Module 3 Prepare Spreadsheets using Spreadsheet Package S N Task Statements Related Technical Knowledge Time hrs T P 11 Create workbook Explain the concept and uses of Spreadsheet Interpret Spreadsheet s Interface Differentiate among column row cell workbook worksheet labels values dates and formulas 0 50 2 00 12 Analyze data using basic formula function
170. equipped workshop with O Har Set up all gas welding equipment Gas welding equipments with Remove grease paint and rust on the different sizes of nozzles e joining part with a wire brush and Characteristics of brazing sandpaper Tasks Classification of brazing Place Ms pipe on Ms Plate and filler rod Hold the blowpipe at an angle of Braze brass in Mild steel Characteristics of brass 45 against the base plate and preheat plate brazing material around the piece with the white core a little separated until it becomes Substitute of flux Standards reddish 7 ae Process of brazing or hard Heat the end of the brazing rod and soldering attach flux there Hold the brazing rod at an angle to Perform fusion the filler 45 against the pipe and plate and rod move the rod so to pulling it back Continue to heat the place between the base plate and pipe feeding molten brazing material with blowpipe Control undercut Move the blow pipe in an oval form and the filler rod slightly up and down melting it above the welding line Attach flux to the brazing rod from time to time and continue brazing Cool the work as it being held by grip and clamp Remove the jelly oxide on the brazed surface with a wire brush or file Clean the blowpipe removing attached material in the nozzle with a cleaning needle soldering brazing Prepare Work piece Produce brazing penetration Follow procedure of butt joint weldin
171. er and follow the steps of weld in flat MIG welding straight beads position from 6 to 8 Task surface weld by upward rocess in vertical position Restore the tools and equipments P P a Perform surface weld in Clean the working area oe vertical position Standards Transverse welding wave in vertical position welding Procedures of deposition of MIG welding straight beads surface weld by upward process in vertical position Safety Precautions e Avoid using Welding gun with broken handle e Always use Wire brush to clean up the welding beads e Always check the connection of gun Shield and wire end e Avoid using damp MIG wire Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry Duty 3 PERFORM VERTICAL POSITION WELDING Time 13 hrs 3 2 Weld butt joint in Vertical position Exercise 12 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of the steps of set up welding equipment MIG from 1 to 3 Condition Refer and follow the steps of surface nt Fully equipped workshop Introduction of welding weld in flat position from 2 to 3 with MIG welding DC wave of MIG Welding Tack weld both ends as per the drawing rectifier MIG filler metal Refer and follow the steps of weld in wire welding stand fitted at Procedure of deposition
172. er line with dividend for height and width on all vertical line Draw gear drawings 9 Draw horizontally to join the lines 10 Follow the sinstruction Standards 11 Clean up the drawing sheet e score min 40 percent marks out of 100 in every internal assessment Safety Precautions 176 DUTY 3 DRAW ASSEMBLY VIEWS Time 12 0 hrs 3 1 Copy Simple Assembly Views Exercise 10 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Fully equipped Classroom Method of drawing Obtain the drawing sheet of assembly view with Drawing board T set and assembly views da draw drawing instrument Identify nos of part Determine the part Measure and scale the dimension of Task individual part on drawing sheet ae Scaled and mark on the drawing sheet Construct the view as the object nature if it have cylindrical part start from center line Hatch the lines if it have Standards 10 Erase the projection lines drawn en 11 Give darkness for necessary lines Draw the supporting lines 12 Clean up the drawing sheet Copy simple assembly view Projected representative lines Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions e Refer the safety precautions of draw three view drawing 177 DUTY 3 DRAW ASSEMBLY V
173. erminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition 2 Obtain work piece Material TE ae er oe Workpiece clamping Collect and set up welding accessories TRES p o and tools with Arc welding Wave of welding in Deburr and grind off 45 groove edge on o walung Flange joint i A accessories and different oe all welding sides of pipe itodes Penetration of welding in Set the work piece on the welding table pipes with supports needed in a Flat position Perform tack welds 2 or more according Task the diameter of pipe Check and re set the position Weld pipe and flat metal Strike the arc on a rough piece for trail Joint Strike the arc and start welding from left rotating pipe Standards Welding procedure Remove the slag from the weld bead Maintain joining of two Repeat the exercise till you achieve good metals result Maintain welding distortion Follow welding Flange joint procedure Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 149 Duty REPAIR WELDING PARTS
174. et and goggles e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 277 Duty 4 PREPARE JIGS AND FIXTURE Time 20 hrs 4 2 Prepare Welding Fixtures Exercise 18 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional welding Condition fixture s drawing Prepare work piece materials Fully equipped workshop with Confirm the process of fabrications Bench work Drilling machine e Advantage of using Obtain the machine or tools equipments to and welding facilities Fixtures fabricate the materials Perform welding joints drilling taping and other fitting works Perform assembly works required as Prepare Welding fixtures e Designing concept of design Welding fixtures 7 Check the dimensions Standards 8 Take trail performance e Introduction of welding fixtures e Types of Welding Tasks Fixtures 9 Make corrections if necessary Dimension should be as per 10 Complete the Welding fixture fabrication drawing 11 Store it in safe and special place Allembled as per drawings Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 278 Duty 5 FINISH THE STRUCTURE Time 3 0 hrs 5 1 Emery the surface Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performa
175. eting joint Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w p drawing Condition Given e Introduction of 2 Study the drawing thoroughly e Well equipped Rivet and types 3 Obtain the required number of sheet workshop with setof e Different metal of required size hand tools in tool box riveting joint 4 Obtain required hand tools e Drawing instruction e Calculation of 5 Straighten and de burr the sheet metal and work piece reverting length 6 Layout the sheet metal e Calculation of 7 Cut the sheet metal accordingly if Rivet hole necessary e Rivets available 8 Punch the centre by centre punch where in market holes are to be drilled e Rivetmate al 9 Bunch the sheet metal in layer so that Tasks What e Causes of the holes to be drilled are aligned on Perform riveting work riveting defects above another 10 Clamp the bunch of sheet metal with c clamp 11 Drill holes on every centre punched marks 12 Remove and de burr the pieces individually 13 Place the drilled sheet together for riveting as per drawing Standard How well 14 Calculate rivet length and select rivet e Riveting work piece 15 Insert the rivet should be match with 16 Insert rivet head set for aligning on the given drawing tail of rivet e Tolerances of 17 Punch slightly on the rivet head until dimensions are within align the given drawing 18 Remove the rivet head set 19
176. etting angles 18 5 Taper length 18 6 Examples and Exercises Calculate mass 19 1 Concept of mass and Density 19 2 Mass 19 3 Density 19 4 Examples and Exercises Calculate mass and weight force 20 1 Concept of weight and force 20 2 Weight 20 3 Force 20 4 Examples and Exercises Calculate stress 21 1 Concept of stress 21 2 Types of stress 21 3 Tensile strength 21 4 Factor of Safety 14 22 23 21 5 Load 21 6 Examples and Exercises Calculate thermal expansion 2 22 1 Introduction of thermal expansion 22 2 Coefficient of linear expansion 22 3 Change in length 22 4 Final length 22 5 Examples and Exercises Calculate heating and fuel consumption 2 23 1 Heat input or specific calorific capacity 23 2 Fuel consumption or amount of heat require for work done 23 3 Examples and Exercises Total 78 Book and References l 2 H P Dahal United s Math in action grade 10 United Nepal publication R Awasthi B H Subedi B B Subedi UNIQUE Mathenatics book 9 Unique Educational Publishers pvt Ltd Technical Mathematics book for metal Trade GTZ 15 Bench Work Total 429 hrs Class week 11 hrs P Time hrs Duty Task Duties and Tasks Demo Practical Total Duty 1 Perform Filling 10 90 100 Task 1 Familiarize with mechanical hand tools and 2 4 6 equipments Task 2 File flat surface Plain
177. even amp and straight 9 Deburr the edges 10 Remove the workpiece from clamping 11 Clean all area 12 Restore all tools equipments Task 1 2 3 4 5 6 Te 8 Perform filling Standards Clamped the section panel without damage Filing surface is even Filined wirk piece should be match with given drawing Safety Precautions e Avoid using file with broken handle e Always clamp the workpiece on vice securely Never beaten on top of the vice or any clamping devices 289 Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE Time 4 0 hrs 1 4 Perform Punching Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Introduction Types of punch Obtain instructional drawing Condition Obtain prepared work piece material Mark layout line on the work piece Fully equipped workshop with Confirm the process of punching punches and hammers facilities Hold the work piece manually Hold a steel hammer on other hand and strike on marked line Tasks Perform Punching Standards Punch is marked on as layout Safety Precautions Never use broken or loose handle fitted hammer e Use safety gloves 290 Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE Time 3 0 hrs 1 5 Perform Screwing Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition e Introduction of screws Obtain inst
178. exposure of the world of work The place for OJT assignment will be related to mechanical workshops and industries Target group Class 10 passed individual Group size Maximum 35 in a batch Entry Requirements a 10 class pass b Candidates will be selected on the basis of entrance examination as per CTEVT rule Medium of instruction Nepali and or English Duration 2 Years 3120 hrs 5 months 800 hrs 3920 hrs This course will be completed within 2 yrs 3120 hrs in formal setting The 5 months OJT will be compulsory after the final exam The total hours for the course will be 3120 800 OJT 3920 hrs Patterns of Attendance 40 hrs per week for 39 weeks per year and 90 attendance is required Certificate Requirements CTEVT will award the certificate in TSLC in Mechanical Engineering to the students who gain marks of 60 in practical test and 40 in knowledge test Evaluation Details a Regular internal evaluation of the trainees has to be conducted by the related instructors to ensure the proficiency over each task skill in each subject Related technical knowledge of the tasks learnt by the trainees is to be evaluated through the written test Internal assessment will be conducted 3 times by the institute every year during the institutional training period 80 marks is allotted to the practical work and 20 is allotted to the related technical knowledge trade technology in each sub
179. fferent electrodes Move the electrode developing welding arc following the edges of both w piece and complete the bead at other end of the Standards plate Maintain joining of two 10 Remove the slag from the weld bead metals 11 Weld other side by using same process 12 Remove slag and spatters Maintain welding penetration Maintain incomplete fusion and joints Maintain seams and laps Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 139 Duty PERFORM ELEMENTATY WELDING Time 7 0 hrs 1 9 Perform Tack Welding or v butt joint Exercise 6 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instruction Condition Obtain workpiecel material Obtain accessories and tools required Obtain electrode of required size Set the current Clamp the earth line to the table material Clamp the electrode on holder Task Hold hand shield by one hand and the on holder by another one Perform Tack Weld for v Fully equipped workshop Welding accessories with Arc welding transformer and different sizes of welding e
180. file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 124 Duty PERFORM PROJECT WORK Time 6 hrs Task 20 Fabricate a Rectangular Box Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain an instruction drawing roads Given e Introduction J Obtain aninstucion Well equipped workshop development pattern 3 Obtain workshop drawing with set of hand tools in e Type development with development tool box 4 Collect the required tools and Drawing instruction and materials work piece 5 Obtain pattern of rectangular box 6 Fold all the corners respectively on the seam in bar folder 7 Make sure that the folded Tasks What corners are 90 Fabricate a rectangular box 8 Check dimensions of the completed job 9 Punch the roll no on work piece 10 Oil the surface of the work piece 11 Store the work piece and tools Standard How well e Pattern should be match with given drawing e Tolerances dimensions the 0 5 mm of are within Tools and Equipments Rivet head set Ball pin ham
181. flat surface Punch dot and center Saw the metal by hand and Drill a hole and Radius filing 50 Duty 7 PERFORM PROJECT WORK Task 7 Manufacture a Hand Hacksaw Frame Time 50 hrs Theory 0 hrs Practical 50 hrs Steps Terminal performance objectives Related Technical Knowledge Position Frame 6 7 8 9 10 11 12 13 14 15 Obtain workshop drawing Obtain workpiece material Obtain necessary tool and equipments Measure rough dimension and file one side marrow plane for reference plane Mark layout line on workpiece for necessary sawing and filing Punch dots on marking lines Saw the side portion for steep length Make rectangular block of required size according to the given drawing File radius on pin side File next radius on bottom side Drill a hole for wooden handle File a hole of circular to oval Enlarge side by side on both side in all periphery Chamfer and deburr all sharp edges Check the final measurement Position 16 17 18 19 20 21 22 Obtain workshop drawing Obtain workpiece material Obtain necessary tool and equipments Measure rough dimension and file one side marrow plane for reference plane Mark layout line on workpiece for necessary sawing and filing Punch dots on marking lines Saw the side portion for steep length Assemble the welding parts Condition Given e Well equipped workshop with set of hand tools in t
182. for forward i 9 Check the tightness of the blade in frame ie sawing 10 Take a small triangular file the metal by hand 11 Mark a small Vee notch by triangular file on start point 12 Hold the hacksaw frame firmly as per file handling g 13 Ta a slowly moving the blade dl iy hand hack 14 Apply pressure only during the forward oe stroke 15 Release pressure during the return stroke 16 Repeat the strokes 17 Check the cutting line to be straight 18 Move slowly while finishing the cut 19 Apply cutting on the blade frequently while Standard How well ee e Sawing work piece 20 Check the part that has been sawed 21 Punch the roll no on work piece should be match with 22 Oil the surface of the work piece given drawing 23 Store the work piece and tools E Toler ances of 24 Clean the vice and work shop dimensions are within the 0 5 mm Tools and Equipments Hand Hacksaw frame Hacksaw blade steel rule marking scriber steel hammer flat anvil dot punch center punch Oil can Number punch Bench cleaning brush File brush Dust pan Triangular file Finishing file Materials MS Flat or MS Angle Oil Safety 1 Hold the job so as to cut on flat side rather than edge 2 The teeth of the hacksaw blade should point towards the forwards direction 3 The cutting movement should be steady and straight 4 The full length of the blade should be engaged per stroke 5 Avoid moving the blad
183. for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 121 Duty DEVELOP PATTERN Time 6 hrs Task 18 Develop Pattern of Truncated Cylindrical Container Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain an instruction drawing Condition Given e Introduction Obama instr cton e Well equipped workshop development patt 3 Select the stock sheet metal as with set of hand tools in ern specified tool box e Type 4 Cut the sheet metal according to the e Drawing instruction and development drawing work piece 5 Straighten and de burr the sheet metal 6 Select dimension such as diameter length and cutting angle 7 Draw atop view amp front view of cylinder 8 Divide the circle twelve parts by Tasks What compass and divider Develop pattern of truncated 9 Project the projection line from each of cylindrical container the point towards on front view respectively or vertically down ward 10 Cut the front view axially at any desired or required angle on the any desired height from the base 11 Project the projection line horizontally from the top and base line front view 12 Draw a vertical line of reference out any point on horizontal projection line 13 Take one part of length from top view Standar
184. g in brass in mild steel plate Safety Precautions e Refer the safety precautions of the task Run fusion with filler rod 319 Duty 5 PERFORM HARD SOLDERING BRAZING Time 6 0 hrs 5 3 Weld Butt joint in Copper plate Exercise 6 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain a work piece material Fully equipped workshop with Set up all gas welding equipment Gas welding equipments with Clean the surface of the joining part with different sizes of nozzles emery cloth Make flux pastry and coat the whole area of joining part with it Coat the end of filler rod the length of about 50mm with flux Refer steps no 6 of the run fusion without filler rod Hold the blowpipe at an angle to 60 80 and the filler rod at the angle of 25 30 Maintain the inner cone 6 9 mm away from the molten metal Perform fusion the filler Preheat the whole area of the joining part rod about 500 600 C Produce brazing 11 Immerse the filler rod at the end of molten penetration pool and advance the blowpipe and the rod straight as they are 12 Apply flux to the filler rod from time to Follow procedure of butt time in order to supply it to the joining joint welding in copper part plate 13 Wash away the flux with warm water Tasks Weld Butt joint in Copper plate Standards Prepare Workpiece Control undercut
185. g machine Theory 1 hr Practical 2 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece drawing 2 Read drawing thoroughly 3 Obtain the metal sheet of required size and required sheet metal tools 4 Straighten and de burr the sheet metal 5 Layout the pattern 6 Layout the folding lines by marking with marking Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Fold metal sheet by folding machine e Hand tools Hardies used in folding metal sheets e Mallet and types e Folding m c and application scriber 7 Check the layout for accuracy 8 Notch and cut the Standard How well unnecessary part e Folding work piece 9 Place the sheet metal in between the folding jaw of the machine 10 Align the marked line parallel with the upper jaw edge and bottom jaw edge 11 Clamp sheet firmly 12 Bend the sheet metal pulling the lever upward as much the machine allowed 13 Open the parallels jaw to remove job 14 Check dimensions of the completed job 15 Punch the roll no on work piece 16 Store the work piece and tools should be match with given drawing e Tolerances of dimensions are within the 0 5 mm Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning
186. ght beads Procedure of run fusion with filler rod Filled up holes and heavy weld Establish and maintain of molten puddle Produce uniform bead width and straightness Safety Precautions Refer to the Run fusion without filler rod 311 Duty 3 PERFORM FLAT POSITION WELDING Time 9 0 hrs 3 1 Weld Edge Joint Exercise 6 0 hrs Demo 3 0 hrs Steps Terminal Performance Related knowledge Objective Obtain instructional drawing Condition 2 Refer steps no 1 to 5 of Run fusion without Fully equipped workshop Purpose of root gap ae ibe ae n uui with Gas welding Clamp the workpiece together so that the equipments filler rod with edges to be weld parallel each other by C ditere taizes otnozates clamp or welding vice Position the workpiece on the welding table Task Refer steps no 6 to 8 of the Run fusion B Flux characteristic types without filler rod and application Tack weld at each ends and middle of the Pano total length with filler rod Advance the torch and rod along the Standards desired line on the edge of the workpiece Continue in this manner till the whole Prepare workpiece lengths of edges are welded together Distortion in welding causes and control Common welding defects in gas welding Produce gas welding penetration Control undercuts Perform gas welding burnt and melt through Safety Precautions e Refer to the Task Run fusion with
187. grind Standards Wear safety goggles Run the machine Amend the tip height Checked cutting edges Grind out the cutting edge length and angles ground Grind out the side cutting edge and the side relief angle Grind the top rake angle Relieve the end clearance angle Round off the nose if necessary Deburr the edges using oilstone Dress wheel performed Angle should be match as per drawing Safety Precautions e Make the wall distance of square sufficient to hold the tool when clamping e Use headless screw as far as possible and have less projection e Be careful when drilling a hole on periphery of the cylindrical rod e Refer the same safety precautions of the task grind grooving tool 207 Duty 5 PERFORM PROJECT WORK Time 16 0 hrs 5 1 Manufacture a Lathe Center Exercise 16 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Clamp a morse taper gauge in center to Condition center clamping Set the dial gauge in tool post Fully equipped workshop Loosen the top slide swiveling nut with Center lathe machine Bring and touch the dial gauge lever to the Facing tool turning tool smallest diameter of a sleeve Center drill Drill bits for Move ahead top slide manually setting the guide hole plain boring tool angle so that the indicator shows in entire length of the morse taper Tighten the nuts carefully Task Check once again the angle Exchange the dial gauge int
188. gth A Follower rests Support at the end from tail stock with Set up workpiece along with revolving center f llower rest Adjust the jaws of rest along with workpiece Standards diameter e se Set the tool according to the rest adjusted e Process of clamping Tighten all the jaws equally workpiece Try a cut to ensure the jaws of the rest follows to the cutting tool amp its surface Fully equipped workshop with Take care of safety precaution Distance of rest is set as per the length of workpiece Safety Precautions e Refer all the safety precautions of set up workpiece with steady rest e The spindle of tailstock shall not project out for Whenever the tailstock is not in use it is safer to apply a stopper at the end of the bed or to completely removed it 193 Duty 2 PERFORM MACHINING OPERATION Time 7 0 hrs 2 1 Perform Knurling on Machined Surface Exercise 6 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Refer and follow all the steps of task perform Conditions Plain turning Perform further operations if necessary Identify the distance and length to be knurled Obtain knurling tool machine knurling Calculate the feed and set on the m c Calculate the RPM and set on the m c Task Process of knurling Set the tool on tool post A Operation Bring and touch gently the tool roller on the Perform knurling on workpiece machined surface Run the machine Give depth of cut Set
189. han that require for profile size in chain drill if necessary 14 De burr the hole ends 15 Clamp the workpiece on bench vice so that the holes can be filed out 16 Take a small round file and file out the chain holes try to make Standard How well internal flat e Filing work piece should 17 Change the file as per required be match given check shape then file out list 18 Check out the sizes of the hole e Tolerances of filing with internal radius gauge or self work piece is within the made gauge 0 5 mm 19 Check periodically with radius gauge 20 Remove the w p and check the measurement 21 Punch the roll no on work piece 22 Oil the surface of the work piece 23 Store the work piece and tools 24 Clean the vice and work shop Tools and Equipments Flat files Rough medium fine radius gauge Marking scriber Center punch Number punch Steel scale Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Square Oil Safety Refer the same safety precautions of the task File flat surface and Drill a hole 21 Duty 2 PERFORM MARKING PUNCHING Task 1 Measure and Mark on the work piece Time 6 hrs Theory 2 hrs Practical 4 hrs Steps Terminal performance objectives Related Technical Knowledge Obtain required drawing Study the drawing thoroughly ur 3 Obtain required tools and materials 4 Measure the work piece according to given
190. he box area on all 4 side Mark and draw the line for edge folding margin on 4 edges 10 Mark and draw all corners to notch in 45 at all excess folding margin Draw the views 11 Erase projection lines if draw it Maintain the uniformity of 12 Represent the dimensions with symbol line thickness require Maintain the line joints 13 Give darkness for necessary lines Maintain the neatness and 14 Clean up the drawing sheet cleanliness Calculation of drawing area Projected representative lines Design the view with axially at required angle Safety Precautions 172 DUTY 1 DEVELOPMENT OF SHEET METAL Time 2 0 hrs 1 6 Draw Cylindrical T Joint Development Exercise 2 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Determine the length breadth and height of the box to be develop Draw a reference vertical line leaving the left border margin and horizontal line on bottom information column Task Calculate the total area of the box including 7 edge folding margin Draw the area Divide the area from center for length breadth and height Mark and draw the line in based folding Standards line for excess folding margin outside the 777 box area on all 4 side e Calculation of drawing Mark and draw the line for edge folding area margin on 4 edges 10 Mark and draw all corners to notch in 45 at all excess folding
191. he angle to be set Reset the angle in top slide swiveling Task Change the boring tool in tool post Manufacture a Taper fitting Take rough cut leaving 0 5mm manually by component cross slide Take final cut in fine surface Standards Check the measurements of all dimensions Remove and punch the numbers e According to provided drawing Safety Precautions e Refer the task Perform taper turning 209 Duty 5 PERFORM PROJECT WORK Time 8 hrs 5 3 Manufacture a Knurled head screw 55 Exercise 8 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Refer and follow the same steps of perform Condition knurling on machined surface Fully equipped workshop Re clamp the workpiece with Center lathe machine Face out and maintain the require length Facing tool turning tool Turn rough diameter according to thread size Center drill Turn groove on end of the shoulder Change threading tool of 55 Task Reset the lead screw according to lead Take rough cut leaving 0 5mm Manufacture a Knurled head 9 Change the r p m if necessary screw 55 10 Take final cut in fine surface 11 Check the measurements of all dimensions 12 Remove and punch the numbers Standards e According to provided drawing Safety Precautions e Refer the task Perform knurling on machined surface and cut external V machine thread 210 Duty 5 PERFORM PROJECT WORK Time 12 hrs 5 4 Manufacture
192. he regulators to pressures suited with Gas welding e Characteristic and uses of to the nozzles in use equipments with gas welding flame Adjust acetylene pressure different sizes of nozzles Adjust oxygen pressure Open the acetylene valve on the torch one half of a turning and ignite the gas with a spark lighter Adjust the acetylene valve till the flame burns clean with minimum smoke Open the oxygen valve on the torch Standards slowly As the amount of oxygen is ae increased the flame will become short and will become bluish Follow this process till the last trace of green un burnt acetylene disappears from the blue cone at the end of the e Process of setting gas nozzle tip welding flames To shut off the torch first close the oxygen valve on the torch and then acetylene valve Flame control Tasks Set up welding nozzles e Recognize a flame type as required for gas welding Safety Precautions e Avoid hanging a torch with its hose on regulator or cylinder valves e Avoid relighting a blown out torch without first closing both torch valves e Stop using acetylene at pressure over 15 P S I e Avoid opening the valve too much that the flame separates from the tip e Ifthe nozzle tip is dirty use a tip cleaner of the proper diameter The orifice or hole in the tip may be worn by constant cleaning and will not give a round nosed inner cone 309 Duty 1 RUN BEADS IN LINE Time 18 hrs 2 1 Run fusion wi
193. hrough Move along the filed length of the radius for checking File and adjust the radius gradually according to the radius gauge Wipe them clean with a clean cloth and apply a light film of oil before storing Clean any oil and chips from the work piece Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Check Radius with Radius Gauge Standard How well e No light should pass between the gauge and the surface e Introduction of the radius gauge e Features of radius gauge e Self made radius gauge e Procedure of checking radius surface Tools and Equipments Radius gauge Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch Materials MS Flat Oil Safety e Ensure that surface of radius gauge are not damaged e Hold the stock firmly against the w p while sliding it down e Before checking with a radius gauge ensure the radius gauge is perfectly clean e Remove burrs if any from the work piece 42 Duty 6 HANDLE MEASURING INSTRUMENTS Task 3 Take angular measurements using bevel protractor Time 6 hrs Theory 1 hrs Practical 5 hrs Steps Terminal performance objectives Related Technical Knowledge
194. hrs Steps Terminal Performance Related Technical Objective Knowledge Condition e Review the tolerence required for fitting Follow and repeat the steps 1 to 7 of bush Fully equipped workshop Ban manufacture with Center lathe machine Reclamp the workpiece clamping min Facing tool turning tool Portion inside the chuck supporting Center drill Drill bits for revolving center from tailstock guide hole plain boring tool True concentricity Turn out big diameter engaging auto feed Mark small groove for shoulder length Task Take rough cut to stepped length remains Imm in required diameter Manufacture a fitting a Change the tool according to the shoulder stepped part shape if necessary Take a cut and shaped the shoulder as per exchanged cutting tool Take final and finishing cut Perform chamfers on all required corners Dimensions of the product Measure dimensions to ensure all the is as per drawing dimensions are as required Reclamp the workpiece turning inside out True concentricity Face the surface reduce the length as required size Machined corners are Turn out big diameter if required chamfered Turn out shoulder if required Perform chamfers on all required corners Measure final dimensions to ensure all the dimensions are as required Standards Surface quality and tolerence is as per specified Safety Precautions e Refer the task Manufacture a Shaft with Stepped Surface 99 Duty 3 PER
195. hten all screws 11 Clean and replace all tools in their respective place Aligned tailstock should be parrallel with bed Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 255 Duty 2 BREAKDOWN MAINTENANCE Time 4 0 hrs 2 6 Repair Coolant pipe lines Exercise 2 0 hrs Demo 2 0 hrs Objective Knowledge Obtain instructions Condition Check the coolant flow system Introduction of Note the required size and length of pipe Fully equipped Machining shop pipes and their Note the required size of connectors with maintenance tools and connectors and Collect all the tools as required materials fixers Collect all the pipes and connectors Methods of fixing Install the pipes Task the pipe Turn on the pump connection Check the leaks and mend if needed Repair coolant pipe line Introduction of Restore all remaining materials sealing and their methods 1 2 3 4 5 6 7 8 9 8 Standards Coolant is taped from pipe Pipe should be leaked proof Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 256 Duty 3 PROJECT WORK ON MACHINE REPAIR Time 37 hrs 3 1 Repair machine Exercise 37 hrs Demo 0 0 hrs Objective Knowledge Obtain instructions Condition Obtain manual of the machine Diagnose Find the faults Fully equipped Machining shop Overhaul or replace the componen
196. iber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 127 Duty PERFORM PROJECT WORK Time 18 hrs Task 23 Fabricate a Bucket Theory 2 hr Practical 16 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain an instruction drawing Condition Given e Concept of 2 Obtain an instruction e Well equipp ed pattern of 3 Select the stock sheet metal as specified workshop with set of Bucket 4 Cut the sheet metal according to the drawing hand tools in tool 5 Straighten and de burr the sheet metal box or 6 Obtain development drawing e Drawing instruction 7 Collect the required tools and materials and work piece 8 Mark the layout as per development drawing or pattern made for both Hopper and base 9 Cut shear the metal as per development 10 Straighten and deburr the seam 11 Fold seam margin of both sides in opposite direction Tasks What 12 Fold to cone shape to the development e Fabricate a Bucket 13 Hook the seam folded margins 14 Mallet the seam placing on a form anvil 15 Apply bottom flashing at the end of the cone 16 Perform beading on double beads as marking 17 Assemble the Handle hooks at opposite sides of the bottom flashed side 18 Assemble the base
197. iece should be as per drawing Return the tool back disengaging the half nut Thread surface should be lever then stop the machine Check the helical mark with pitch gauge Set the dial scale 0 on both top and cross slide Calculate the depth of cut Give depth of cut for rough cut Align the coolant pipe Run the machine and start cutting helical groove thread Turn back the tool in front position give depth of cut and cut ahead Cut the thread until required depth Check the thread with pitch gauge thread gauge Make sure the dimensions are as given in workshop drawing Fully equipped workshop Setting of internal with Center lathe machine thread cutting tool on turning tool Center drill tool post Drill bits for guide hole Boring tool Internal thread cutting tool Thread plug gauge and Pitch gauge Process of cutting internal threads operation Task Cut Vee Internal thread on lathe machine N6 or as specified Safety Precautions e Refer to the task Cut Vee External thread on lathe machine Perform boring and internal grooving 201 Duty 4 PERFORM OFF HAND GRINDING Time 4 0 hrs 4 1 Re sharpen Twist Drills Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain Bench or Pedestrian grinding Condition machine Obtain blunt drill bits Fully equipped workshop Nomenclature of Drills Obtain Safety goggles Bevel protracto
198. iers e Preparing business plan Business plan appraisal e Return on investment 23 Appraise business plan e Breakeven analysis 0 5 5 5 6 0 e Cash flow e Risk factors Basic book keeping e Concept and need of book keeping 24 Maintain basic book keeping e Methods and types of book 1 0 2 0 3 0 keeping e Keeping and maintaining of day book and sales records Total 30 48 78 Text book NRP EA ARA aR an Rra raw aaa Ma qa arate area ARO RORS a Reniera aa falta Tere car Par ulate ren car ARA area ART APTA OSS Reference book Entrepreneur s Handbook Technonet Asia 1981 188 Lathe Operation II Total 234 hrs Class week 6 hrs Duties and Tasks Time hrs Set Up Machine Demo Practical 1 1 Set up irregular work piece on face plate 4 1 2 Set up work piece center to center with 3 1 3 Set up work piece with steady rest 3 1 4 Set up work piece with follower rest 3 Perform Machining Operation 0 2 1 Perform knurling on machined surface 1 7 2 2 Perform parting off machined part 1 8 2 3 Perform internal grooves 2 16 2 4 Perform internal tapers 4 22 2 5 Perform eccentric shaft 4 20 Perform Thread Cutting 0 3 1 Cut threads on machine using taps and die 4 18 3 2 Cut external V m c thread 4 32 3 3 Cut internal V m c thread 4 32 Perform Off Hand Grinding 0 4 1 Re sh
199. imeters on the caliper main scale which show in front of the zero i e Procedure of of the vernier scale 12 Then read the tenths of mm 0 1 or Using yernier twentieths 0 05 on the vernier scale Caliper 13 Measuring inside dimensions pianidand How well 14 Set the inside measuring jaws of the e Tolerances of dimensions 8 Ea caliper to a dimension smaller than the a em dimension to be measured 15 Place the fixed jaw against the w p 16 Move the sliding jaw so that the caliper grips the work piece 17 Read the measurement as for the outside dimension Tools and Equipments Vernier caliper Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set drill bit set Materials MS Flat Oil Safety Clean the work piece and remove any burrs before taking any measurement Vernier calipers are precision measuring instruments and must be cared for accordingly Avoid leaving the caliper in a place where it could fall contact with sharp cutting tools and thus get damaged Wipe the vernier caliper clean and place it in its correct storage place Vernier calipers should be used only for measuring 44 Duty 7 PERFORM PROJECT WORK Task 1 Manufacture a Drill plate includes Counter bore amp Reamed hole Time 15 hrs Theory 0 hrs Practical 15 hrs Steps Terminal performance objectives Related Technical Knowledge
200. ing Vertical head Fully equipped workshop with Setting a machine Mark the symmetrical line on w p with the Universal and Vertical Milling table or machine vice help of Bevel protector machine in angle to be cut Hold the workpiece on machine vice with the help of Bevel protector or by swiveling Tasks Process of feeding the vice and depth of cut Mount the milling cutter Perform angular surface setting Set the machine controls the workpiece on machine table Process of milling Refer the steps from no 9 to 17 of producing or vice angular surface angular surface tilting vertical head Standards Use of Vernier Bevel Protractor Machine table or vice angle should be accurate and tightened Safety Precautions e Follow the same safety precautions of task preparing a Square block milling 228 Duty 5 DRILL AND BORE Time 18 hrs 5 1 Perform drilling and boring in milling machine Exercise 16 hrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workshop material Setting up shank Obtain sets of parallel blocks Fully equipped workshop with cutter in collect Obtain required tools equipments Universal and Vertical milling chuck Prepare a rectangular block referring the machine steps of Prepare a square block Reclamp the workpiece protruding more than 15mm from the vice jaw Uses of Centro fix Hold Centro fix on collect chuck Tasks
201. ing slit near the center of the flange with a cold chisel 15 Cut out the hole of the flange with curved Standard How well ane e Cutting work piece 16 Cut out and notch the pattern with curved should be match with snips 17 Cut the metal slowly at beginning and giyen drawing SER E e Tolerances of preceding it for required cutting Le 18 Straighten and de burr the sheet metal mension Ary bl 19 Check dimension of the complete job aaa 20 Punch the roll no on work piece 21 Store the work piece and tools Tools and Equipments Steel rule Snips Back square marking scriber steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Safety Place snips and material on bench De burr the metal sheet edges Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 106 Duty PERFORM CUTTING FOLDING AND ROLLING Time 4 hrs Task 4 Fold metal sheet by hand tools Theory 1 hr Practical 3 hrs Steps Terminal performance Related Technical objectives Knowledge 10 11 12 Obtain the work piece drawing Read drawing thoroughly Obtain the metal sheet of required size and required sheet metal t
202. ing wave in square butt joint welding Procedure of deposition of filler rod in TIG welding beads with filler rod Safety Precautions e Avoid using torch with broken handle e Always check the connection of torch Shield and Grips e Keep away the inflammable material e Always place the torch on hanger after welding e Keep the workplace dry 325 Duty 3 WELD IN FLAT POSITION 3 2 Weld square butt joint with temporary backing bar with filler rodin Time 9 0 hrs Flat position Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow set up welding equipment of TIG no 1 to 3 Condition Clamp the work return lead to a clean Fully equipped workshop Introduction of welding are of table with TIG welding AC DC wave of TIG Welding Keep the material in welding position rectifier tungsten rod wire with temporary bar accessories pieces of Procedure of deposition of Refer and follow surface weldin peat Are a pia a e DIG welds beads wath with filler rod 3 to 4 8 different filler material temporary backing bar with filler rod Restore the tools and equipments Task Clean the working area Weld square butt joint with temporary backing bar with filler rod in Flat position Standards Transverse welding wave in square butt joint welding Procedure of deposition of filler rod in TIG welding beads with temporary backing bar with filler rod
203. initially setting Projected representative lines Design the view with axially at required angle compass Give name on each point according to top view basis in to twelve horizontal point Project the projection line horizontally front cutting plane point Maintain the uniformity of Give same name when same projection line thickness line intersect the each of view Maintain the line joints Joint the drawn points Maintain the neatness and Erase projection lines if draw it cleanliness Represent the dimensions with symbol require Give darkness for necessary lines Clean up the drawing sheet Draw the views Safety Precautions 171 DUTY 1 DEVELOPMENT OF SHEET METAL Time 2 0 hrs 1 5 Draw Pyramid Development Exercise 2 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Determine the length breadth and height of the box to be develop Draw a reference vertical line leaving the left border margin and horizontal line on T ask bottom information column Calculate the total area of the box including edge folding margin Fully equipped Classroom with Drawing board T set and drawing instrument Draw pyramid development Draw the area Standards Divide the area from center for length breadth and height Mark and draw the line in based folding line for excess folding margin outside t
204. ite jaw where the pointer Clamped equal force in is beyond all 4 jaw chuck Align the work piece opening and tightening the opposite jaws checking concentricity with height gauge pointer Tighten all the jaws equally Construction of four jaw chuck Set up round square workpiece on four jaw chuck e Concentricity set with hight gauge points Clamped workpiece on 4 jaw leaving the working length outside Safety Precautions e Avoid opening the adjacent jaws together e Avoid projecting the part of jaws beyond the chuck periphery e Use a wooden block on lathe bed when installing removing the chuck e Follow the same safety precautions of the task setting up round workpiece on three jaw chuck 84 Duty SET UP MACHINE Time 2 0 hrs 1 2 Set up Machined Workpiece on Collet Chuck Exercise 0 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain machined workpiece Condition Introduction of collect Identify the diameter as per size of the chuck Adapter and collect chuck Draw in bar Obtain collect chuck with draw bar Set the speed change gear lever into low Fully equipped workshop with Center lathe machine Set of collet chuck and Draw bar Importance of using speed position collect chucks Remove the lathe chuck if necessary Clean the spindle nose with cotton waste Process of clamping Insert draw bar from behind the head stock Task work on collect chuck
205. ition 1 Set up oxygen gas cylinder and regulator Gas welding nozzles and to rubber hose Fully equipped workshop their types with Gas welding equipments with different sizes of Regulators and hose nozzles fittings Set up acetylene gas cylinder generator and regulator to rubber hose Set up torch handle to attach the nozzle Identify set up the nozzle to be attached Adjust the regulators to pressures suited to the nozzles in use Check all the fittings are leak proof Tasks Set up welding nozzles Standards Connect oxygen gas cylinder to rubber hose Adjust the regulators to obtain desired pressure on the pressure gauge Safety Precautions e Avoid hanging a torch with its hose on regulator or cylinder valves e Avoid relighting a blown out torch without first closing both torch valves e Stop using acetylene at pressure over 15 P S I e Avoid opening the valve too much that the flame separates from the tip e Ifthe nozzle tip is dirty use a tip cleaner of the proper diameter e The orifice or hole in the tip may be worn by constant cleaning and will not give a round nosed inner cone 308 Duty 1 SET UP GAS WELDING EQUIPMENT Time 4 hrs 1 3 Adjust neutral flame Exercise 3 hrs Demo 1 hrs Steps Terminal Performance Related Knowledge Objective Check all the fittings Condition Place all the tools equipment and materials Fully equipped workshop Types of flames Adjust t
206. ition of casement section Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Perform benchworks cutting drilling and punching Perform assembly works required as e Introduction of casement e Design of casement section partition design Tasks Check the dimensions Fix partition of casement Store it in safe and special place secioni Standards Joints are fixed Fixed partition of casement is checked as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 299 Duty 4 FABRICATE PROJECT STRUCTURES Time 6 0 hrs 4 3 Fix partition with sliding door Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Perform benchworks cutting drilling and punching e Types of door e Advantages
207. ive Related Knowledge Set rpm lever for lowest speed Condition Types of cutter 2 Clean the taper shank of short arbor and the holding devices spindle nose Fully equipped workshop with Short arbors Insert taper shank into the Vertical head shell end mill cutter stub arbor spindle nose amidst Vertical Horizontal and Hold short arbor in position and screw in Universal Milling machine draw in bar Tighten draw in bar lock nut Tasks Unscrew the cutter holding screw on the arbor Set up milling cutter on short Insert the cutter on short arbor aligning the arbor in vertical milling key way and hold until screwed Tighten the cutter holding screw with special Standards wrench provided Set r p m lever according to cutter diameter RPM should be set according to and material of workpiece cutter tool diameter Arbor is tightened securely on draw in bar Different types of milling cutters that can be fitted on the short arbors Safety Precautions e Follow the similar safety precautions of task set up milling cutter on long arbor in Horizontal milling Use Fly cutter in order to avoid breaking of the multi toothed cutter 220 Duty 1 SET UP MACHINE Time 2 hrs 1 6 Set up milling cutter in collect chuck Exercise 1 hrs Demo 1 hrs Steps Terminal Performance Objective Related Knowledge Obtain required size of End mill cutter of Condition parallel shank Select collect according to
208. ject The Controller of Examination of CTEVT will conduct final examination after completion of the course For each subject 60 of the weight age will be allotted to the internal assessment and the rest of the 40 to the final examination The overall mark comes from adding the weight age score from the internal assessment and mark from the assessment Only the trainees who have passed the internal assessment can appear in the final exam A candidate who fails in the final exam can appear in the re test scheduled by CTEVT After completion of the final examination On the Job OJT will be administered The course grading will be as follows Overall Marks Grading a 80 and above Distinction b 75 to lt 80 First Division C 65 to lt 75 65 Second Division d Passed below 65 Pass Division Trainers qualification BE in mechanical engineering or equivalent for instructor Diploma in mechanical engineering for assistant instructor TSLC in mechanical engineering for workshop assistant teaching aid 5 The objective of the on the job training 1 2 3 4 To gin knowledge and skills related to mechanical engineering by engaging the reel world of work To practice skills acquired from school in the real field To develop self confidence in the skills acquired in the training institutions To ensure the standard of the training to keep pace with the requirement of the employer The total marks for on the job t
209. jection isometric view drawing Draw three views drawing in Introduction of types of Draw side view third angle projection projection in drawing Draw top view Erase projection lines if draw it Standards Give darkness for necessary lines oe Maintained symmetry Projection line should be visible Line should be appropriate Third angle projection symbol should be placed Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 76 Duty DRAW ORTHOGRAPHIC PROJECTION Time S 0 hrs 5 3 Find and Draw Missing Views Exercise 8 0 hrs Demo 0 0 hrs Objective Knowledge eds Condition ae Obtain missing view drawing of object Se Process of finding Prepare a drawing sheet missing view through Identify the missing front side or top view projection line and given Draw it in rough paper drawing Check the find out view with instructor Calculate the space from drawing area so that the drawing should come in the center Task of the sheet Se Draw all 3 views referring the steps of draw 3 view drawing in first angle projection Erase projection lines if draw it Give darkness for necessary lines Fully equipped Classroom with Drawing board T set and drawing instrument Find and draw missing views Standards All the line of missing view should be drawn Projection line should be visible Maintained symmetry Safety Precautions 77 Du
210. k grind Grind grooving tool Facing corner tool in HSS bit 10 Check the angles with the gauge or bevel Standards protractor Angle of grooving tool 11 Deburr the edges using oilstone should be match with given drawing Cutting tip should be match with given drawing Safety Precautions Too much depth may coloured the tip and may cause short hardness e Any damage to the grinding wheel if noticed should be reported to the instructor e When switching on the grinding machine stand aside until the wheel reaches full speed e Refer the same safety precautions of the task grind twist drill 205 Duty 4 PERFORM OFF HAND GRINDING 4 5 Grind Thread Cutting Tool Time 5 0 hrs Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain Bench or Pedestrian grinding machine Obtain HSS tool bits Obtain Safety goggles Bevel protractor or grinding gauge Dress the wheel 1f necessary Set up tool rest 1f necessary Identify the shape of tool to be grind Identify the angles of tool to be grind Wear safety goggles Refer and follow the steps of the task grind Facing corner tool in HSS bit 10 Check the angles with the gauge or bevel protractor 11 Deburr the edges using oilstone Safety Precautions Condition Fully equipped workshop Introduction with Bench or Pedestrian Type of thread cutting grinding machine Safety tool goggles HSS Tool bits Process of re
211. ks cutting drilling Tasks and punching Perform assembly works pressing gaskets as required as design Check the dimensions Store it in safe and special place Gasket is pressed uniformly Perform gasket pressing Standards Gasket is pressed all corner as required by design Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 303 Duty 5 FINISH THE FABRICATE MEMBERS Time 1 5 hrs 5 4 Perform silicon filling Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Related Knowledge Objective Condition Introduction Purpose of silicon material Obtain details of instructional drawing Prepare work piece materials Fully equipped workshop with Confirm the process of fitting hand tools and punches and Obtain the machine or tools equipments to punching facilities Types of silicon fabricate the materials material Perform benchworks cutting drilling Tasks and punching Perform assembly works fitting glass board as required as design Check the dimensions Store it in safe and special place Silicon is filled uniformly Perform silicon filling Standards Silicon filled on as required as design Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work
212. kshop with Types of bending Confirm the process of bending Hot and cold forging work Hold the work piece manually placing on facilities the anvil Hold a steel hammer on other hand T A Process of bendin asks 8 Strike on marked line ES manually Repeat striking both side of the mark line Perform Bending manually simultaneously Check the radius of the bend at finishing curve Continue striking until the curve shaped Radius of bending should be as as per drawing read specied Align the level of the curve and rest of the part Introduction of bending Equipments and tools of bending Standards Safety Precautions Never use broken or loose handle fitted hammer e Use safety gloves e Perform hot work far as possible Never beaten on top of the vice or any clamping devices 274 Duty 2 PERFORM COLD FORMING THE MATERIALS Time 3 0 hrs 2 2 Perform Twisting manually Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain prepared work piece material Mark layout line on the work piece Fully equipped workshop with Confirm the process of twisting Hot and cold forging work Types of Twists Clamp one end of work piece in vice and facilities Introduction of Twisting Equipments and tools of hold the work piece manually Twisti wisting Insert and clamp other end tap handle N ae Tasks Start
213. l edge speed Move the electrode in a straight line and complete the bead at the other edge of the plate Remove the slag from the weld bead Repeat the exercise till you achieve good result Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 133 Duty PERFORM ELEMENTATY WELDING Time 7 0 hrs 1 3 Grind Off welds surface Exercise 6 0 hrs Demo 1 0 hrs Task and Steps Terminal Performance Related Objective Knowledge Obtain instruction Condition Obtain pre welded workpiece material Obtain accessories and tools required Fully equipped workshop Set the workpiece with Arc welding f Wear safety equipments transformer and Hand vice Connect electrical line to machine e Bonde Hold workpiece material into vice Grind the surface of weld as per the Task drawing 1 2 3 4 5 6 7 8 Grind off surfaces welds Standards Re uses the material Prepare the edges for groove weld Chamfer the burrs Grinds the welding beads to prepare re weld Safety Precautions 134 Duty PERFORM FLAT POSI
214. l diagram according to the Task plan diagram A Prepare motor control electrical accessorles as per plan diagram Interpret Power amp Control diagram Standards Introduce plan diagram Prepared power and control diagram according to the plan diagram Prepared motor control electrical accessories as per plan diagram Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 261 Duty 2 READ HANDLE ELECTRICAL INSTRUMENTS Time 3 0 hrs 2 1 Read amp Handle Multi meter Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain Multi meter Condition Insert probe jack into positive terminal and negative terminal Connect multi meter probe in respective supply Read measured Volt Task Note down the measurement Process of reading and Follow the steps from 3 to 6 for adjusting Read amp Handle Multi meter handling Multi meter selector switch to Ampere Follow the steps from 3 to 6 for adjusting selector switch to Resistance Standards Clean and store the meter in safe and N sound place e Multi meter reading should be between 1 Introduction and types of Full i d Electrical uny eo Eppes AI cHiIca Multi meter workshop with Mul
215. l no on work piece 15 Store the work piece and tools Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Beading machine and dies Materials GI Sheet Safety Take care of marked lines folds must not be collecting together Aware from clamping the finger by machine jaw To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover The mark for beading should be between the dies of machine Avoid over tightening of dies which may tear sheet 116 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 6 hrs Task 14 Perform soldering joint Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w p drawing Condition Given e Introduction of 2 Study the drawing thoroughly e Well equipped workshop soldering joints 3 Obtain the sheet metal as per required size with set of hand tools in e Characteristics of 4 Obtain required tools tool box soldering lead 5 Heat the soldering iron e Drawing instruction and e Soldering method 6 Clean up the soldering areas with zinc work piece e Characteristics of chloride soldering flux 7 Apply flux in all areas to be soldered e Causes of soldering 8 Join the areas together and support them defects 9 Hold soldering lead in one hand and
216. lain shaping 6 8 2 Groove shaping 6 8 3 Angular shaping Welding Theory II 12 7 1 Oxy Acetylene Welding 7 1 1 Introduction 7 1 2 Gas welding and cutting safety 7 1 3 Gases used in gas welding 338 7 1 4 Acetylene generator 7 1 5 Selection of gas welding nozzles 7 1 6 Types and setting of gas welding flames 7 1 7 Position and motion of the gas torch 7 1 8 Introduction argon welding and types 1 2 Tungsten Inert Gas Welding 7 2 1 Introduction and Safety Precautions hide Type of TIG electrode eee TIG welding equipments and tools 1 2 4 Welding current 1 2 5 Shielding gas uses in TIG welding 7 2 6 Setting up a welding machine with water cooling system 71 2 1 Torch angle and filler metal movement 7 3 Metal Inert Gas Welding 7 3 1 Introduction and Safety Precaution 1 3 2 Shielding gas uses in MIG welding 7 3 3 Filler metal and deposition rate 7 3 4 Power supply 7 3 5 MIG welding equipment and tools 7 3 6 Weaving pattern Grinding 8 1 Introduction and Safety 8 2 Types of Grinding 8 2 1 Emery sheet paper 8 2 2 Oil Stone 8 2 3 Hand surface Grinder 8 2 4 Cutting off grinder 8 2 5 Pedestal Bench Grinder 8 2 6 Swing Grinder 8 2 7 Belt type Grinder
217. late by unitary method 9 1 Concept of Unitary method 9 2 Variance and types 9 3 Chain rule 9 4 Estimate time money and number of worker for any job 9 5 Examples and Exercise Calculate stretched lengths 10 1 Stretched length 10 2 Complete ring 10 3 Partial ring 10 4 Angular frames 10 5 Examples and Exercises Calculate Trigonometric functions 13 Time hrs 4 12 13 14 15 16 17 18 19 20 21 11 1 Dependency 11 2 Side ratio 11 3 Relationships 11 4 Examples and Exercises Calculate areas regular quadrilaterals 12 1 Square 12 2 Rhombus 12 3 Rectangle 12 4 Parallelogram 12 5 Examples and Exercises Calculate Areas 13 1 Triangle 13 2 Trapezium 13 3 Circle 13 4 Sector 13 5 Circular ring 13 6 Examples and Exercises Calculate Sheet metal requirements and wastage 14 1 Division 14 2 Wastage 14 3 Examples and Exercises Calculate rivets 15 1 Calculate the length of rivet shank for riveting 15 2 Shearing force of rivet 15 3 Bearing pressure of rivet 15 4 Examples and Exercises Calculate volume of right bodies 16 1 Concept of cube prism and cylinder 16 2 Cube 16 3 Prism 16 4 Cylinder 16 5 Examples and Exercises Calculate volume of pointed and truncated bodies 17 1 Cone Pyramid 17 2 Truncated cone Pyramid 17 3 Summary 17 4 Examples and Exercises Calculate taper and inclination 18 1 Concept of taper and taper ratio 18 2 Taper ratio 18 3 Ratio of inclination 18 4 S
218. lding Technotogy t e ole 6 o 24 234 o 150 10 Fi Workshop Technology 1 Tt sfo 3 a7 o a7 as o a Cf a a0 a0 ao 390 aero 1560 250 750 1000 Second year een eek Total Class Year Full Marks i C Titl Nat IA a al E E A E EE E EE RENA 3 Engineering Drawing Drawing Engineering Drawing Entrepreneurship MON EN Development EM Lathe Operation H 234 2834 234 0 150 150 e rase e O e pa Ning amp Shape Operon FP 0 ON se se E E AENA Sic Fabricas ENERO A O E 10 Welding Technology II 234 234 150 150 Gas TIG MIG Aaa papa HA Air On The Job Training S No Subjects Nature Hours Weeks Total Full Marks Hours 1 On the job training P 20 800 500 Grand Total 1 year 2 year OJT 3920 2500 First Year Subjects Applied English Applied Math I Applied Nepali Bench Work Computer Application Engineering Drawing Lathe Operation I Material Science I Sheet Metal Fabrication Welding Technology I Workshop Technology I Rh OANANNNBWN Unit sub unit Applied English Total 78 hrs Class week 2 hrs Areas and Topics Introduction Noun Verb Adjective and Adverb words Auxiliary and main verbs uses Word identification and practical use Subject verb agreement S V 0 Drill mechanical words Glossaries of mechanical Tense and sentence stru
219. le in contact with dial test nuts and bol lever on parallel block 12 Move ram slowly by hand wheel at the starting end for dial test lever 13 Observe the indicator 14 Set the indicator lever into zero 15 Move the ram to other end of the parallel block 16 Align the vice hammering opposite to the indicating line 17 Repeat steps no 12 amp 16 until the indicating lever does not show zero at both ends of the parallel block 18 Tighten fully all the nuts Safety Precaution e Always clamps the nut with washer e Always use same size of spanner e Always disconnect the dial test lever before hammering in the vice e Always clean the surfaces where magnetic stand will magnetize e Dial test indicator must not be dropped and should not be exposed to severe shocks 239 Duty 1 SET UP MACHINES HOLDING DEVICES 1 2 Hold HSS Cutting Tool bit on Tool Post Time 1 5 hrs Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Objective Related Knowledge Obtain ground HSS cutting tool bit Obtain 2 nos of MS T shape packing Insert both the packing in tool post PIDAN Insert HSS cutting tool bit between packing facing the cutting edge towards the vice 5 Tighten the tool tightening screw protruding tool enough to cut 6 Set the clapper box at angle if needed Condition Fully equipped workshop with Ground HSS shaping tool with Shaping machine Tasks Hold HSS cutti
220. le or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 263 Duty 3 REPAIR ELECTRICAL WIRING Time 6 0 hrs 3 2 Repair one bulb control by two way switch Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain instruction layout diagram Prepare wiring diagram Obtain electrical accessories as per diagram Mark the layout on the board as per diagram Task Introduction of one bulb Full ipped Electrical Ury equppe CEEA control by two way switch workshop with Multi meter Prepare the auxiliary accessories as per diagram measurement e Repair one bulb control by Install the auxiliary accessories on the two way switch board Lay wire according to the wiring diagram Standards Connect all electrical accessories according to the wiring diagram Bulb should be glow Clean and store the electrical instrument used in safe and sound place Connection should be tight and no beared wire seen Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 264 Duty 4 REPLACE COMMON ELECTRICAL ACCESSORIES AND MATERIALS Time 6 0 hrs Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowle
221. lectrodes Set workpiece material together butt joint maintaining the gap as required Spot weld maintaining short arc Standards Repeat same process in interval of 10 to 15mm down Perform momentary weld join Safety Precautions e Avoid using electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 140 Duty PERFORM FLAT POSITION WELDING Time 17 hrs 1 10 Weld V butt joint with backing Exercise 16 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Obtain work piece Material Condition Refer and follow the steps of surface weld from 4 to 9 Fully equipped workshop with Arc welding transformer welding accessories and different electrodes Position the work piece on the welding table with supporting in a flat position Perform tack weld on both ends Check and re set the position Strike the arc on a rough piece for trail Strike the arc on the work piece at one Task edge Move the electrode developing welding Weld V butt joint with arc following the edges of both w piece backing and
222. length Move the electrode developing welding Perform surface weld arc following the edges of both w piece and complete the bead at other end of the Standards plate Remove the slag from the weld bead Repeat the exercise till you achieve good result Maintain joining of two metals Maintain welding distortion Maintain welding penetration Follow welding procedure of Horizontal position welding Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 142 Duty PERFORM HORIZONTAL POSITION WELDING Time 7 0 hrs 2 2 Perform square butt joint weld Exercise 6 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional drawing Condition Obtain work piece Material Refer and follow the steps of surface weld from 3 to 9 except 4 Set the work piece on the welding stand accessories and different with clamps and supports in a horizontal codes Penetration of welding in position parallel to nose Horizontal position Refer and follow the steps of surface welding of horizontal position from 5 Task to 9 Move the electrode devel
223. les e Maintain the length of the rivet as per the thickness of the work 292 Duty 2 FABRICATE WINDOWS Time 6 hrs 2 1 Fabricate casement windows panel Exercise 5hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and e Different sections and fabricate the materials punching facilities profiles of panel Perform benchworks cutting drilling member and punching e Introduction of aluminium Tasks Perform assembly works required as design Fabricate casement windows Check the dimensions panel Store it in safe and special place Standards Joints are fixed Casement window is as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 293 Duty 2 FABRICATE WINDOWS Time 6 hrs 2 2 Fabricate multi panel sliding windows frame Exercise 5hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Designs of casement Confirm the process of fabrication Fully equipped workshop with windows panel Obtain the machine or tools equipments to hand to
224. lever 14 Set the depth of cut 15 Position the coolant pipe 16 Start the machine and take cut 17 Check the depth 18 Take further cut as per depth require 19 Index the workpiece by moving the crank 20 Reset the indexing lever 21 Repeat machining and indexing until the hexagonal shape obtained 22 Remove burrs from edges Standards Produced hexagon is checked as given measurement head length width chamfer Safety Precautions e Be ensuring the cut should always be up milling e Lock the table after each and every setting Be ensuring the cutter should not touch the Indexing head and Tail stock 235 Duty 9 PERFORM PROJECT WORK Time 18 hrs 9 1 Manufacture a Clamp Exercise 18 hrs Demo hrs Steps Terminal Performance Related Knowledge Objective Position 1 Ruler Condition e Specific tolerance Obtain workshop drawing of machine parts Obtain workpiece material Refer and Follow the steps of Mill Square block in vertical milling Reclamp the workpiece Refer and follow the steps of Mill groove in a workpiece Remove the workpiece and check the two adjacent surfaces are right angle Reclamp the workpiece Standards Refer and follow the steps of Produce angular surface tilting vertical head on both sides Measure the dimension and take further cuts as required 10 Remove the workpiece Deburr the edges and chucks the final measurement Fully equipped w
225. ll maintained of the drawing sheet Fully equipped Classroom with Drawing board T set and drawing instrument ges OL op necHte lines and its applications Safety Precautions e Rotate the pencil while drawing the lines to maintain the same thickness 61 Duty HANDLE INSTRUMENTS Time 2 0 hrs 1 4 Write Engineering Letter Exercise 1 hrs Demo 1 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board Condition 2 Prepare a drawing sheet Scaled and mark on the drawing sheet for spacing height Importance of writing engineering letter Method of writing Fully equipped Classroom with Drawing board T set and drawing instrument Draw horizontal lines for approximately 26 engineering letters letters and 10 numbers Types of case in letter Set up the compass for 70 inclined line Task writing Draw dividend lines Hold the pencil vertically and start writing Write engineering letter the Capital letters A to Z and numbers 1 to 10 along the inclined line Standards Write the small letters a to z along the sree neal d be block inclined line same as above step aire Jean Ensure the letters and numbers are dark gt enough 10 Clean up the drawing sheet Safety Precautions 62 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 2 0 hrs 2 1 Bisect Straight line Divide line Exercise 1 5 hrs Demo 0 5 hrs Steps Terminal Perfor
226. ll scratch the reamed hole Use Vice covers to protect the finished surfaces Apply oil to get good surface finish Refer also the safety precautions of task Drill a hole 35 Duty 5 PERFORM OFF HAND GRINDING Task 1 Grind Center Punch Time 4 hrs Theory 1 0 hrs Practical 3 hrs Steps Terminal performance objectives Related Technical Knowledge 20 10 11 13 14 15 16 17 18 19 20 Obtain workshop drawing Read drawing thoroughly Obtain Bench or Pedestrian grinding machine Obtain blunt center punch Obtain Safety goggles Bevel protractor or grinding gauge Check the grinding wheel abrasive type trueness of wheel and cracks Dress the wheel if necessary Check the tool rest set up if necessary Hold blunt center punch left hand side pointing the tip towards wheel Wear safety goggles Run the machine 12 Touch the angular part of tip on face of wheel holding left hand side so that it can be turn freely by right hand side Give feeding slightly Rotating the punch Check the angle with gauge or Bevel protractor Repeat the grinding until desired angle and sharpened tip obtained Check the final measurement Clean oil and chips Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing ins
227. ller till required shape 13 Open the upper roller to remove job 14 Check dimensions of the completed job 15 Punch the roll no on work piece 16 Store the work piece and tools Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Rolling machine Materials GI Sheet Safety e Take care of marked lines folds must not be collecting together e Aware from clamping the finger by machine jaw e To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover 110 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 6 hrs Task 8 Groove single seam Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece drawing Condition Given e Introduction of Read drawing thoroughly e Well equipped workshop joint Fastening oe 10 11 12 13 14 15 16 17 18 Obtain the metal sheet of required size and required sheet metal tools Straighten and de burr the sheet metal Layout the pattern Layout the folding lines by marking with marking scriber Check the layout for accuracy Notch and cut the unnecessary part Fold the edges as per drawing and form the job to shape Hook the folds together Place the work piece on a suitable stake Flatten the
228. llow surface welding filler rod without filler rod 3 to 8 Task Restore the tools and equipments Clean the working area Perform surface welding with filler rod Standards Transverse welding wave in TIG welding Procedure of deposition of TIG welding beads with filler rod Safety Precautions e Avoid using torch with broken handle e Always check the connection of torch Shield and Grips e Keep away the inflammable material e Always place the torch on hanger after welding e Keep the workplace dry 324 Duty 3 WELD IN FLAT POSITION Time 9 0 hrs 3 1 Weld square butt joint without temporary backing bar with filler rod Exercise 8 0 hrs in Flat position Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of set up welding equipment of TIG no 1 to 3 Condition Clamp the work return lead to a clean Fully equipped workshop Introduction to welding area of the table with TIG welding AC DC wave of TIG Welding Keep the material in welding position rectifier tungsten rod wire without temporary bar accessories and different Procedure of deposition of filler material TIG welding beads with Refer and follow of surface weld filler rod with filler rod 3 to 4 Restore the tools and equipments Task Clean the working area Weld square butt joint without temporary backing bar with filler rod in Flat position Standards Transverse weld
229. m 3 2 5 Specification of steels according to code and classification AISI SAE ISI specification 3 3 Alloy steel 4 3 3 1 Definition of alloy steel 3 3 2 Classification of alloy steel 3 3 3 Effect of alloying elements in steel 3 3 4 Properties and uses of common alloy steels Stain less Steel High Speed Steel Tool Steels Spring Steels Structural Steels 3 4 Cast Iron 4 3 4 1 Introduction and definition 3 4 2 Types properties and uses of cast iron Gray white amp Malleable amp alloy cast iron 3 4 3 Alloying elements in cast iron 4 Heat treatment 6 4 1 Introduction definition amp objectives 101 4 2 Heat treatment process 4 2 1 Annealing 4 2 2 Normalizing 4 2 3 Hardening 4 3 4 Tempering 4 3 5 Case surface hardening Total 39 102 Sheet Metal Fabrication Total 156 hrs Class week 4 hrs Duty Task Duties and Tasks Time hrs Demo Practical Duty 1 Perform Cutting Folding and Rolling 6 18 Task 1 Cut metal sheet in straight with snip 2 3 Task 2 Cut metal sheet in round shape with snip 0 2 Task 3 Cut metal sheet in irregular segment with snip 0 3 Task 4 Fold metal sheet by hand tools 1 3 Task 5 Roll metal sheet by hand tools 1 3 Task 6 Fold
230. m horizontal line as decided angles and triangles length Task Draw a vertical perpendicular line at the center of the line Set the protractor as decided angle and mark with pencil point Align the set square with end point of line and pencil point Standards Repeat it for another side inclined line e Dimen ion should bemie t 10 Joint the corners according to given 11 Erase projection lines if draw it Line thickness should be in 12 Give darkness for necessary lines standard Draw triangle using T set set square and protractor Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 67 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 4 0 hrs 2 6 Construct Ellipse Exercise 3 5 hrs Demo 0 5 hrs Objective Knowledge Draw a rhombus that side is diameter of Condition circle in 30 Fully equipped Classroom Drawing ellipse type Draw a line from the obtuse corner to 3 Construct methods of 4 f with Drawing board T set a center point of both side so that the drawn ee ellipse f and drawing instrument line should made 90 to the rhombus side Draw a line from other obtuse corner to Task center point of side oa Obtain compass and set the leg along with Construct ellipse obtuse corner to center point of both opposite sides Draw an arc Standards Draw another arc with same compass set up from opposite corner to center point of sides Maintain the line joints Re se
231. mance Related Technical Objective Knowledge Condition Set paper in drawing board 2 Prepare a drawing sheet f f Fully equipped Classroom Decide the length of Straight line to be with Drawing board T set bisect and drawing instrument Scaled and mark on the drawing sheet Draw straight line AB with centre A and radius greater than half AB draw arcson Task 1 nstruments that uses to both sides draw arcs in drawing Introduction of Geometrical Elements Uses of Compass in workshop drawings Draw arcs intersecting the each other at C To Bisect Straight line and D Draw a line joining C and D and cutting AB Standards at E Obtain the line AB AE EB e Line should be according to provided dimension uniform neat and clear edge Bisect CD at right angle Safety Precautions 63 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 2 0 hrs Exercise 1 5 hrs 2 2 Bisect an angle Demo 0 5 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board Condition Prepare a drawing sheet Fully equipped Classroom Uses of Compass and in Decide an angle to be bisect q 3 workshop drawings with Drawing board T set Scaled and mark on the drawing sheet ver and drawing instrument Instruments that uses to Draw an angle ABC with B as centre and draw circles in drawing any radius Draw an arc cutting AB at D and BC atE Ta
232. margin 11 Erase projection lines if draw it 12 Represent the dimensions with symbol require Maintain the uniformity of 13 Give darkness for necessary lines line thickness 14 Clean up the drawing sheet Maintain the line joints Maintain the neatness and cleanliness Fully equipped Classroom with Drawing board T set and drawing instrument Draw cylinder T joint development Projected representative lines Design the development Draw the views Safety Precautions 173 DUTY 2 DRAW MACHINE ELEMENT Time 4 0 hrs 2 1 Draw Hexagon Nut Exercise 2 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition i Prepare a drawing sheet i Standards of threads Determine the size of nut in mm Fully equipped Classroom Identify the standards of nut with Drawing board T set Draw the center line crossing X and Y axis and drawing instrument Draw the circle of 2xd dithered size in mm of the center 7 Draw a hexagon in the circle using compass Task Draw 34 circle major diameter of thread size d on the center Draw hexagon nut 9 Draw small circle of minor diameter on same circle 10 Draw circle width size of hexagon 11 Draw a rectangle height of nut in above the hexagon at same vertical center line 12 Divide the rectangle corresponding the line Projected representative from hexagon corner lines 13 Mark a point on vertical center line down Design th
233. mer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety De burr the metal sheet edges Place snips and material on bench Avoid carrying scriber in pockets Open the blades as far as possible for your hand and using the throat of the snips Start the cut at the edge of the material Avoid sharp corners Avoid leaving jagged edges cut the material by closing the blades just short of their full length 125 Duty PERFORM PROJECT WORK Time 6 hrs Task 21 Fabricate a Cylindrical Container Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain an instruction drawing Condition Given e Concept of pattern of gt Obt in an instruct n e Well equipped workshop cylindrical object 3 Obtain workshop drawing with with set of hand tools in development tool box 4 Select the stock material as specified Drawing instruction and 5 Obtain workshop drawing with work piece development 6 Select the stock material as specified 7 Lay out for the cylinder on the metal 8 Lay out the allowance for the grooved seam and soldered seam 9 Check the pattern for accuracy Tasks What 10 Cut out and notch the metal Fabricate a cylindrical 11 Bend the folds for the grooved seam in container bar folder 12 R
234. metal sheet by folding machine 1 2 Task 7 Roll metal sheet by rolling machine 1 2 Duty 2 Perform Fastening Heming and wire edging gt sd Task 1 Groove single seam 1 5 Task 2 Groove edge seam Hem 1 2 Task 3 Perform wire edging 1 5 Task 4 Perform Straight Beading 1 4 Task 5 Perform Round Beading 1 4 Task 6 Perform Bottom Flashing 1 10 Task 7 Perform soldering joint 1 5 Task 8 Perform Riveting joint 1 5 Duty 3 Develop Pattern s A Task 1 Develop Pattern of rectangular box 1 3 Task 2 Develop Pattern of Cylindrical Container 1 5 Task 3 Develop Pattern of Truncated Cylindrical 1 5 Container Task 4 Develop a pattern of funnel 1 5 Dung Perform project work E sa Task 1 Fabricate a Rectangular Box 1 5 Task 2 Fabricate a Cylindrical Container 1 5 Task 3 Fabricate a Funnel 2 16 Task 4 Fabricate a Bucket 2 16 Task 5 Fabricate a cylindrical 90 elbow 2 10 Total 26 130 Total 156 103 TASK ANALYSIS Duty PERFORM CUTTING FOLDING AND ROLLING Time 5 hrs Task 1 Cut metal sheet in straight with snip Theory 2 hr Practical 3 hrs Steps Terminal performance Related Technical objectives Knowledge HOWE Dy ww 11 12 13 14 15 Obtain the work piece drawing Obtain instruction Study the drawing thoroughly Obtain the piece of sheet metal as per drawing size Obtain required tools Straighten and de burr the sheet metal Layout
235. n representation with given scale Safety Precautions Avoid using damaged drawing board e Avoid using damaged T set 69 DUTY 3 DRAW IN SCALE 3 2 Represent the Dimension in Detail Time 4 0 hrs Exercise 3 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Set paper in drawing board 2 Prepare a drawing sheet Introduction of Fully equipped Classroom 3 Decide the drawing that has to be draw with f Dimension and terms of P with Drawing board T set f dimension in detail Paes dimensions and drawing instrument ine Scaled and mark on the drawing sheet General principles and Refer and follow the steps of drawing three rules in dimensioning view isometric or sectional view to draw Task Method of execution the view as needed ae et Arrows depth and length Draw the dimension lines and arrow heads Represent the dimension in of arrow head in all independent shape and sizes which detail included in the object it may required to present in many views Write the dimensions including tolerances Standards ifany e Draw the views and Erase projection lines if draw it dimension representation Give darkness for necessary lines with given scale and 10 Clean up the drawing sheet t l rance Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 70 DUTY 3 DRAW IN SCALE 3 3 Be familier with limit fits and toleran
236. n the lathe bed Set up the RPM gear lever as center drill size Run the machine Arrange coolant flow over center drill standard Give feed from tailstock hand wheel until lt Center dalled aci bigger taper diameter mark on the work piece finished Take off the tailstock stop the machine and then go to further operation Perform center drilling Standards e Depth of center drill is in Safety Precautions e Avoid giving continuos feeding while center drilling e Keep away the tool post from the Head stock e Apply coolant fluently e Always wear safety goggles e Avoid projecting the center drill tailstock spindle too long e Check the center of facing surface and tip of Center drill is matched 89 Duty PERFORM TURNING OPERATIONS Time 3 0 hrs 2 3 Perform drilling Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Refer and follow all the tasks and steps to perform center drilling operation Hold the drill bit on drill chuck Boring tailstock near to work piece Set up RPM according to drill size Run the machine Fully equipped workshop with Center lathe machine Facing tool Drill chuck sleeve drill bits and Center drill Types of drill machine Types of sleeve Arrange coolant flow over center drill Process of drilling Give feed from tailstock hand wheel until required depth is not meet 1 to 12mm Remove drill chuck from
237. nal line as per drawing an sectional represent based on center line and name it Construct a sectional view Draw visible outlines and edges with continuous thick line Draw hidden outlines and edges if any 10 Draw hatching lines on cutting surface 11 Erase projection lines if draw it 12 Give darkness for necessary lines 13 Clean up the drawing sheet Safety Precautions Condition Fully equipped Classroom with Drawing board T set and drawing instrument e Introduction of sectional views e Types of section drawing d Task Draw half section views Standards Line thickness and angle of hatching line should be according to criteria Maintained symmetry 79 Duty 6 DRAW SECTIONAL VIEWS Time 6 0 hrs 6 3 Draw Part Section Views Exercise 6 0 hrs Demo 0 0 hrs Objective Knowledge Set paper in drawing board Condition e Importance of part 2 Prepare a drawing sheet f section Determine the projection view in which wih a maximum sizes can be figure out and drawing ent Scaled and mark on the drawing sheet Construct the view Draw the sectional line as per drawing and Task sectional represent and name it gt Construct a sectional view Draw visible outlines and edges with continuous thick line Draw hidden outlines and edges if any Standards 10 Draw hatching lines on cutting surface 11 Erase projection lines if draw it Maintain the line spacing 12 Give darkness for
238. nce Related Knowledge Objective Introduction of emery Types of emery Grade of emery 1 Obtain pre fabricated structures Condition Obtain instructions Chips off the surfaces by chisels or chipping hammer Fully equipped workshop with Bench work Drilling machine welding machine and Denting 4 Cut and fold emery as required size Painting facilities Rub the surfaces repeatedly until the surface free from oxides Tasks Clean the rub surfaces by brush Pme eset Standards Rusted surfaces of the structural fabrication work should be cleaned Oiled surfaces should be cleaned The steel fabrication is protected from corrosion Safety Precautions e Use safety gloves e Use chipping hammer to clean the welding spatters and welding beads e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 279 Duty 5 FINISH THE STRUCTURE Time 5 0 hrs 5 2 Grind the surface Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain pre fabricated structures Condition Obtain instructions Introduction Chips off the surfaces by chisels or Fully equipped workshop with Grinding types chipping hammer Bench work Drilling machine Types of grinding welding machine and Denting machine Set the grinding machine with flexible Painting facilities Types of wheel abrasive wheel as required
239. nd Key ways in a Round Measurement of key workpiece ways Process of milling a key ways in a round Produced key way is checked as workpiece given measurement of groove Safety Precautions e Refer and follow the safety of Mill end Key way 234 Duty 8 INDEX MILLING Time 10 hrs 8 1 Mill Hexagonal Shape Around the Periphery of Round Workpiece Exercise Shrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Obtain pre machined round w p Condition Obtain Direct indexing head amp tail stock Obtain end mill cutter as per width to be cut Fully equipped workshop with Introduction of Mount the cutter in collect chuck Universal Milling machine indexing Set up Indexing head and tail stock so that the length of work piece will come at the middle Direct indexing of the table as well as in between Tasks method Set up workpiece in 3 jaw chuck of the a indexing head checking concentricity Mill Hexagonal shape around the Indexing calculation Set the machine controls periphery of round workpiece Set the worktable to position the table so that Process of index the cutter is close to the top of the workpiece milling Place a piece of thin wet paper on the workpiece 10 Start the spindle using the hand vertical feed raise the table until the cutter just remove the piece of paper 11 Set the vertical scale to zero 12 Move along cutter from cross feed 13 Set up the crank
240. nd Multiline Text MTEXT Explain Style name Font Name Style and Height Describe Font effect Width factor and Oblique angle Explain the procedure for creating text styles 0 50 1 00 Add Single Multiple line text to a drawing 0 25 1 00 Edit text using these commands and methods Multiline Text Editor e Character e Properties e Line spacing e Find replace import text Layer and symbol 0 25 1 00 Hatch the sectional area Define hatching Differentiate ISO Hatch Pattern User Defined Hatch Pattern Pre Defined Hatch and Associative Hatch Explain Boundary set copying of hatch properties pick point hatch angle scale pattern and object selection modify the hatched pattern 0 50 2 00 Create Block Definition Name Pick point selection 0 25 1 00 164 S N Task Statements Related Technical Knowledge Time hrs T P Add dimensions to a drawing Interpret dimension elements dimension text lines and arrowheads leader extension lines units tolerance and center marks Describe dimension types linear aligned ordinate radius diameter angular baseline and continue Dimension dialog box Lines and arrow Dimension and text Fit Unit Tolerances Modify Dimension style Dimension in isometric drawing 0 50 2 00 Sub total 3 00 10 00 Module 6 Create output S N
241. nd welding beads e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 281 Duty 6 PERFORM THE PAINTING Time 2 0 hrs 6 1 Paint enamel coating by brush Exercise 2 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Introduction of paint enamel Types of paints Function of turpentine Obtain pre primer coated fabricated Condition structures Fully equipped workshop with Bench work Drilling machine welding machine and Denting Painting facilities Obtain instructions Obtain desired color enamel paint painting brush flat screw driver kerosene oil cotton waste gloves and turpentine oil Open the lid of enamel paint Stir the paint thoroughly to mix Faint enamne coanne DY Dash uniformly Add turpentine oil to thinner the paint as Standards required Painted surface should be Dip the brush and side splash to control smooth over flow Cleaned the painting area or Brush the surface up and down ward from zone the left upward corner Continue the brushing from the end of the painting enamel until finish the complete structure Clean up the brush with kerosene oil Cover the lid tightly and store in safe place Safety Precautions e Wear safety gloves safety goggles and safety helmet e Clean the over floated paints on surface or painting zone e Use flat screw driver or iron rod to stir the paint 2
242. necessary lines for hatching 13 Clean up the drawing sheet Draw part section views Draw the section views Projected representative lines Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness Safety Precautions 80 BIBLIOGRAPHY SN Name Author Publication l Engineering Drawing P S Gill S K Kataria amp Sons 2 Engineering Drawing for Instructional Material for Mechanical Trade Vocational Training India 3 Elements of Mechanical Samual Yaslov Delmar Publishers Drafting 4 Engineering Drawing N D BHATT Charotar Publishing House Pvt Ltd 5 Machine Drawing 1 Er R K DHAWAN S CHAND Angle Projection 6 81 Lathe Operation I Total 156 hrs Class week 4 hrs Unit sub unit Duties and Tasks Time hrs Demo Practical 1 Set Up Machine 1 1 Set up round work piece on three jaw chuck 2 1 2 Set up Round Square Workpiece on Four Jaw Chuck 3 E 2 a 1 3 Set up Machined Workpiece on Collet Chuck 1 4 Set up turning tool on tool post 2 1 5 Set up machine controls 2 2 Perform Turning Operations 2 1 Perform facing 1 4 2 2 Perform center drilling 1 2 2 3 Perform drilling 1 4 2 4 Perform plain turning 2 13 2 5 Perform step turning 2 14 2 6 Perform grooving 2 7 2 7 Perform chamfering 2 4 2 8 Perform taper tur
243. ng e Follow the safety of Bench work 284 Duty 8 FABRICATE PROJECT STRUCTURES Time 11 hrs 8 2 Fabricate Helical fixed stair Exercise 10 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition e Designing of Helical Obtain details of instructional Helical Fixed Fixed stair stair drawing Fully equipped workshop with Prepare work piece materials Bench work Drilling machine e Fabrication of Helical Prepare re formed designed materials Grinding machine and welding Fixed stair Obtain the machine or tools equipments to facilities fabricate the materials Perform drilling on required size Tasks Perform assembly works tacking welding joints as design Check the dimensions Perform full welding Store it in safe and special place Dimension of stair shouldbe match with given drawing Fabricate Helical Fixed stair Standards Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Welding e Follow the safety of Bench work 285 8 3 Fabricate Collapsible gate Steps Terminal Performance Related Knowledge Objective Obtain details of instructional Collapsible gate drawing Prepare work piece materials Prepare re formed designed materials Obtain the machine or tools equipments to fabricate the materials Perform drilling on required size Perform assembly
244. ng Attachments 5 6 1 Vertical Head 5 6 2 Slotting Head 5 6 3 Rotary Table 5 6 4 Indexing Head and it types 5 6 5 Indexing method 5 7 Cutting Speed Feed and Depth of Cut 5 8 Milling Fundamentals 5 8 1 Up milling and down milling 5 8 2 Face and peripheral milling methods amp operation 5 9 Milling Cutters and operations 5 9 1 Shank type cutter 5 9 2 Bore type cutter 5 9 3 Fly cutter 5 10 Milling Operations 5 10 1 Plain milling by shell end plain milling cutters 5 10 2 Step milling by end mill shell end 5 10 3 Slot milling by end mill key way T slot 5 10 4 Angular milling by single and double angular milling cutter 5 10 5 Key way cutting by key way cutter 5 10 Gear milling and gear cutter Gear wheel dimension 5 11 Indexing calculation Shaper machine 6 1 Introduction and Safety 6 2 Types of machine 6 3 Parts and their function 6 3 1 Ram 6 3 2 Column 6 3 3 Tool post 6 3 4 Clapper box 6 3 5 Table 6 3 6 Base 6 4 Stroke adjustment Feed mechanism 6 5 Quick return mechanism 6 6 Work holding devices 6 6 1 Machine vice 6 7 Shaping tool 6 7 1 Roughing tool 6 7 2 Corner tool 6 7 4 Finishing tool 6 8 Shaper Operation 6 8 1 P
245. ng Operations II O V T Association Turning manual 7 Sharpening of cutting tools MIR Publishers MOSCOW 211 Material Science II Areas and Topics 1 Mechanical Tests 1 1 1 2 1 3 1 4 15 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 Definition and types Destructive tests Tensile Test Bend Test Hardness testing Impact test Non destructive tests Visual examination Magnetic particle test X ray test Radiographic test Ultra sonic test Dye penetrate test 2 Corrosion 2 1 2d 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 Introduction Specific types of corrosion Atmospheric corrosion Underground corrosion Microbiological corrosion Uniform corrosion Crevice corrosion Stress corrosion Control and prevention of corrosion Metal and alloys Catholic precaution 3 Non Ferrous Metals 3 1 3 2 3 3 3 4 3 5 3 6 3T 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 Aluminium and its alloys Introduction and its properties Aluminium alloys Applications Copper and its alloys Introduction and its properties Copper alloys Applications Lead and its alloys Introduction and its properties Lead alloys Applications Zinc and its alloys Introduction and its properties Zinc alloys Applications Tungsten and powder metallurgy Introduction Manufacturing process 212 Total 39 hrs Class week 1 hr Time hrs 7 3 2
246. ng board Uses of T set Align drawing paper with T set Task Overview of drafter mini Hold on drawing paper with drawing tape drafter Set up paper in drawing board Standards The bottom edge of paper should be parallel to the T set drawing edge Hold the drawing paper without stretch Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 59 Duty 1 HANDLE INSTRUMENTS Time 3 hrs 1 2 Draw Title Box Using T Set and Set Square Exercise 2 hrs Demo 1 hrs Steps Terminal Performance Related Technical Objective Knowledge Set up paper in drawing board Condition 2 Mark a point at top remaindering margin with scale by pencil Set square and its uses Full ipped Cl ully equipped Classroom Drawing sheet Title Box ith Drawing board T set l Attach the T set on ebony working edge so laa drawing dl Paper size that a horizontal line can draw on the stent Layout the drawing sheet marked point Particulars of title blocks Draw a line of full length Mark the point at both sides remaindering margins Task Place the Set square aligning the working edge of T set so that a vertical line can Prepare a drawing sheet draw on side marked point using T set and Set square Draw a line of full length Repeat the same steps for next vertical line Repeat the steps of top horizontal line for bottom horizontal line Standards 10 Erase the lines over drawn on every corner
247. ng tool bit on tool post Standards e Clamped cutting edge facing towards the vice hanging the tool bit e Placed both side packing s on clamping screw e Introduction of tool post e Use of clapper box e Process of Holding HSS cutting tool bit on tool post Safety Precaution e Avoid holding the tool over hanging Make sure that the cutting edge of the tool is facing towards the vice e Avoid tightening the tool without T shaped MS packages e Avoid using over sizes Spanner or Slide wrenches 240 Duty 1 SET UP MACHINE amp HOLDING DEVICES Time 1 5 hrs 1 3 Adjust Stroke Length Exercise 1 hrs Demo 0 5 hrs Steps Terminal Performance Related Objective Knowledge 1 Clamp the work piece material Condition 2 Hold shaper cutting tool on tool post Fully equipped workshop With Process of 3 Move ram extreme behind by hand A adjusting stroke eee s Shaping machine and stroke 4 Inserta handle in stroke adjusting spindle OS length i adjusting handle 5 Loosen the spindle turning clockwise direction 6 Turn half of the round nut covering spindle Tasks by hand AAA 7 Turn spindle anti clock wise to move the Adjust stroke length tool near to the work piece 8 Turn hand wheel if possible to check the stroke length Standards 9 Repeat turning spindle until the stroke s Str ke lengths according to en adele the length of work piece 10 Tighten the round nut covering spindle by 5
248. nical objectives Knowledge 1 Obtain w p drawing Condition Given e Introduction of Dies 2 Read drawing thoroughly e Well equipped workshop and Dieing 3 Obtain w p material with set of hand tools in Required blank size for 4 Obtain required hand tools file caliper tool box external thread threading die die handle check nut e Drawing instruction and 5 Mark square at the end face as per thread amater work piece 6 File roughly using the procedure of filing a square block 7 File round bar of black using the steps of taste File external radius 8 Check the blank size with hole gauge 9 Re file until the blank diameter is obtained Tasks What 10 Chamfer 45 at the end of the blank EE OS 11 Fix the die in die handle MISAS ies 12 Re clamp the w p on vice projecting the blank upward above the vice in 90 with the horizontal 13 Place the leading side of the die on the chamfer of the w p 14 Ensure the die is fully open by tightening the centre screw 15 Hold the die handle close to the centre 16 Apply pressure on die handle evenly and Standard How well turn clockwise to advance the die on the e Dieing work piece bolt blank should be match with 17 Ensure the thread starts by the time reverse given drawing frequently at about every quarter turn e Tolerances of 18 Cut thread until the die is fully down the dimensions are within length to be threaded the 0 5 mm 19 Increase the depth of cut gradually
249. ning 2 14 2 9 Perform plain boring 2 6 3 Perform Project 3 1 Manufacture bush 10 3 2 Manufacture shaft with stepped surface 16 3 3 Manufacture fittings of stepped parts 22 3 4 Manufacture a spindle with bearing journal 14 sub Total 26 130 Total 156 82 TASK ANALYSIS Duty SET UP MACHINE Time 2 0 hrs 1 1 Set up Round Workpiece on Three Jaw Chuck Exercise 0 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Obtain round workpiece Obtain chuck key Set the speed change gear lever into neutral position Clean the jaws with cotton waste Bring the jaws slightly bigger than Construction of Three workpiece diameter with the help of chuck jaw chuck key Task De burrs the workpiece if necessary Process of clamping amp Insert the workpiece on three jaw leaving the Set up round workpiece on truing the work piece working length outside three jaw chuck Tighten the jaws slightly Obtain height gauge Set the pointer of height gauge to workpiece diameter Standards Turn the chuck freely by hand Observe concentricity Hammer on the side as necessary Check the concentricity again and align same Clamped equal force in all process till the workpiece turn truly 3 jaw chuck Tighten all the jaws equally Fully equipped workshop with Center lathe machine and Three jaw chuck Introduction of Lathe machine e Aligned the conce
250. ns available in mirror command f Describe options available for 5 Duplicate object using Offset a Olerdsane 0 25 100 command Through Differentiate Rectangular Array and Polar Array 6 Dupheate Ones Explain Rows Columns ad 0 25 1 00 command A Distance Center point number angle and rotation Modify object using trim Define Cutting edge 7 command Explain the options available for o 0 25 0 50 trimming object project edge undo Modify object using extend Define Boundary edge 8 command State the procedure for modifying object using Extend 0 25 1 00 command Modify object using fillet 9 command Differentiate Chamfer and Fillet j Explain the options available for 0 25 0 50 filleting object i e fillet radius 10 Modify object using chamfer Explain the options available for command chamfering object i e Distance 0 25 0 50 angle Sub total 2 50 7 00 163 Module 5 Annotate a drawing with Text layer lock Hatching and Dimensioning S N Task Statements Related Technical Knowledge Time hrs T P Create a Layer Define Layer Explain different attributes and properties of a Layer Line type line weight Global Scale Factor Current Object Scale Names Of Off Freeze Thaw Lock unlock Color Plot style Plot don t plot Explain the procedure for creating a layer 0 75 2 00 Create text styles Differentiate Single line text TEXT a
251. nter square 20 20 Task 6 Manufacture Divider 30 30 Task 7 Manufacture Hand Hacksaw Frame 50 50 Total 34 395 429 16 TASK ANALYSIS Duty 1 PERFORM FILLING Task 1 Familiarize with mechanical hand tools and o hrs eory 2 hrs equipments Practical 4 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain tools materials and Condition Given e Bench work tools and equipment as per list equipments 2 Introduce tools materials e Tool materials and e Definition and equipment Equipments as per e Objective 3 Explain objectives given list e Working principle 4 Explain working principle e Well equipped Uses 5 Explain safety precaution workshop e Importance 6 Exp lain care and e Handling and caring maintenance Tasks What 7 State work using tools Sae prevaukan material equipments 8 Store the tools e Familiarize with mechanical tools materials and Equipments Standard How well e Tools equipments and material should be identified as per given list e Applied different tools equipment and materials safely e Explained the functions of different tools equipment and materials Tools and Equipments Steel rule Different types of file Back square Marking scriber Center punch Hammers Hand hack saw Materials Mild steel Carbon steel Tool steel Safety e Handle the tools carefully e Store the tools and material
252. ntricity in clamping Clamped workpiece on 3 jaw leaving the working length outside Safety Precautions e Avoid leaving Chuck key on the three jaw chuck e Always remove burrs before clamping the workpiece Keep the carriers away from the head stock e Switch off the main electrical line while setting up the workpiece e Pre set enough lighting in machine area e Always keep the machine and its surroundings neat and clean 83 Duty SET UP MACHINE Time 3 0 hrs 1 2 Set up Round Square Workpiece on Four Jaw Chuck Exercise 0 0 hrs Demo 3 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain round square workpiece Uses of four jaw independent Obtain chuck key chuck Set the speed change gear lever into Fully equipped workshop neutral position with Center lathe machine Clean the jaws with cotton waste Four jaw chuck and Bring the jaws slightly bigger than Height gauge workpiece size in the center of spindle Process of clamping and truing with the help of chuck key individually a workpiece on 4 jaw De burrs the workpiece if necessary Task independent chuck Insert the workpiece inside the jaws leaving the working length outside Tighten the jaws slightly one by one Obtain height gauge Set the pointer of height gauge to the periphery of workpiece Standards Turn the chuck freely by hand Observe concentricity Open the jaw where the pointer is far Tighten the oppos
253. ntroduction of forward Fully equipped Electrical reverse motor starter workshop with forward Install the auxiliary accessories on the Task board Lay wire according to the control and e Connect forward reverse power diagram motor control Connect all electrical accessories according to the control and power Standards diagram ee Re check all control and power circuit Clean and store the electrical instrument used in safe and sound place e Forward reverse motor control should be connected as per drawing Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 267 Duty 5 PERFORM PROJECT WORK OF ELECTRICAL REPAIR Time 32 0 hrs Exercise 32 0 hrs 5 3 Project work of electrical repair Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain instruction plan control and power diagram Obtain electrical hand tools as required Find diagnose faults Switch off the main connection Different type of motor Replace and connect the accessories Task starter Check the faults repairs Switch on the main connection e Project work of electrical Re check all control and power circuit repair Clean and store the electrical instrument used in safe and
254. nts with gas place different sizes of nozzles y e Types of acetylene gas 4 Open main cover 5 Remove the calcium carbide tray en 6 Clean up all parts and cylinder e Main parts and their 7 Fill up the water in tank up to the marked Task functions of cylinders level 8 Fill up required amount of calcium carbide Prepare Acetylene gas in carbide bucket 9 Put inside the water tank on cylinder 10 Put inside the carbide bucket in water tank 11 Tighten the main cover 12 Open main valve 13 Check the manometer for increments of the e Substitute of acetylene gas Standards e Use Calcium carbide gas level e Prepare acetylene gas 14 Connect acetylene rubber hose pipe from calcium carbide 15 Check all connection and cylinder lid to ensure not leaking e Check gas level Safety Precautions e Avoid using hammer or wrench to open cylinders valves Ensure with soap water that all connections are tight Never use acetylene at pressure over 15 P S I e When welding is to be stopped temporarily release the pressure adjusting screws of the regulators by turning them to the left It it is to be stopped for long time close the cylinder valves and release all pressure from regulators 307 Duty 1 SET UP GAS WELDING EQUIPMENT Time 6 0 hrs 1 2 Set up welding equipments and nozzles Exercise 4 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective 1 Obtain Instruction Cond
255. o on work piece 16 Store the work piece and tools Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Pointed tool Materials GI Sheet Safety Take care of marked lines folds must not be collecting together Aware from clamping the finger by machine jaw To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover 113 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 5 hrs Task 11 Perform Straight Beading Theory 1 hr Practical 4 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece Condition Given e Introduction beading drawing e Well equipped workshop e Purpose of bead 2 Read drawing thoroughly with set of hand tools in e Introduction of beading 3 Obtain the metal sheet of tool box machine required size and required e Drawing instruction and e Operation of machine sheet metal tools work piece e Selection of dies 4 Straighten and de burr the sheet metal 5 Layout the pattern Tasks What 6 Check the layout for Perform straight beading accuracy 7 Notch and cut the unnecessary part Standard How well 8 Lay out the marks where beads e Bead should be match are to be made 9 Place the single bead rolls on the beading machine and bead the work piece 10 Place
256. o turning tool Manufacture a lathe center Remove all setting and follow the steps 1 to 4 of manufacturing stepped shaft Take rough cut through top slide according Standards to angle set Check the dimensions and angles turned is Exercise of combine skills correct Perform process of Re sharpened the tool if necessary manufacturing a Lathe Take finishing cut with fire surface center Check the angles with a gauge of available same size of sleeve Check Dimensions of the Remove workpiece from the chuck product Remove chuck from the spindle Clean up thoroughly the taper nose of the spindle Insert the manufactured morse taper side of the workpiece in spindle nose Calculate the taper angle Reset the angle Repeat the steps 10 to 13 Check the angles with gauge or bevel protactor Safety Precautions e Refer the task Perform taper turning 208 Duty 5 PERFORM PROJECT WORK Time 12 hrs 5 2 Manufacture a Taper fitting Component Exercise 12 hrs Demo 0 0 hrs Terminal Performance Related Knowledge Objective Condition Refer and follow the complete steps of External taper turning for pos 1 and machine Fully equipped workshop other dimensions as required with Center lathe machine Refer and follow the complete steps of Facing tool turning tool manufacture bush for pos 2 and machine Center drill Drill bits for other dimensions as required guide hole plain boring tool Calculate t
257. oard mouse joystick and scanner output devices monitor printer plotter sound card and speaker central processing unit memory unit Install Computer Peripheral and auxiliary storage devices 0 50 1 00 hard disk CD DVD Blue Ray Pen drive memory card Explain different types of ports Parallel Serial USB IEEE 1394 and Slots Explain the precaution to be taken while installing computer peripheral Explain operating system including its role Describe different types of operating systems MS DOS Windows Unix Linux Enlist the function of DOS Commands COPY REN DIR Install Operating System TYPE CD MD and BACKUP 0 50 4 00 Explain precautions to be taken while installing operating system Make a list of tasks to be performed before during and after installation of MS Window operating system Differentiate application software and driver software Describe the uses of antivirus 0 5 2 00 program Explain the procedure for 3 Install Application Driver Software 53 S N Task Statements Related Technical Knowledge Time hrs T P installing application driver software Describe the features of Control Panel Uninstall Software Application 1 00 Format External Mass Storage 0 50 Sub total 1 50 8 5 Module 2 Prepare Documents using Word Processing Package S N Task Statem
258. of vertical position from 3 to 4 table and accessories MIG welding straight beads in vertical upward Task process position Restore the tools and equipments Clean the working area Weld butt joint in vertical position Standards Transverse welding wave in MIG welding Procedure of deposition of MIG welding straight beads in vertical upward process position Safety Precautions e Avoid using Welding gun with broken handle e Always use Wire brush to clean up the welding beads e Always check the connection of gun Shield and wire end e Avoid using damp MIG wire Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry 333 Duty 3 PERFORM VERTICAL POSITION WELDING Time 13 hrs 3 3 Weld T joint in Vertical position Exercise 12 hrs Demo 1 hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of the steps of set up welding equipment MIG from 1 to 3 Condition Refer and follow the steps of surface Fully equipped workshop Introduction of welding weld in flat position from 2 to 3 with MIG welding DC wave of MIG Welding Tack weld both ends as per the drawing rectifier MIG filler metal Refer and follow the steps of weld in wire welding stand fitted at Procedure of deposition of vertical position from 3 to 4 table and accessories MIG welding
259. oll the cylinder in the slip roll forming machine 13 Groove the seam with a hand groover 14 Make sure that the cylinder is Standard How well completely round 15 Check dimensions of the completed job 16 Punch the roll no on work piece 17 Oil the surface of the work piece 18 Store the work piece and tools e Container should be match with given drawing e Tolerances of dimensions are within the 0 5 mm Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety e De burr the metal sheet edges e Place snips and material on bench e Avoid carrying scriber in pockets e Open the blades as far as possible for your hand and using the throat of the snips e Start the cut at the edge of the material e Avoid sharp corners e Avoid leaving jagged edges cut the material by closing the blades just short of their full length 126 Duty PERFORM PROJECT WORK Time 18hrs Task 22 Fabricate a Funnel Theory 2 hr Practical 16 hrs Steps Terminal performance Related Technical objectives Knowledge NA DU oO 10 11 12 13 14 15 16 17 Obtain an instruction drawing Obtain an instruction Select the stock sheet metal as specified Cut the sheet metal
260. ols and punches and Designs of multi panel fabricate the materials punching facilities sliding windows frame Perform benchworks cutting drilling and punching rakes Perform assembly works required as design Fabricate multi panel sliding Check the dimensions windows frame Store it in safe and special place Standards Joints are fixed Multi panel sliding window is as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 294 Duty 3 FABRICATE DOORS Time 6 0 hrs 3 1 Fabricate flush door panel Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials e Types of door Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Perform benchworks cutting drilling e Design of flush door panel and punching Tasks Perform assembly works required as ER design Check the dimensions Fabricate flush door panel Store it in safe and special place Standards Joints are fixed Flush door is as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Foll
261. on of drawing cut the cutting plane area 10 Project the projection line horizontally from Projected representative the top and base line front view lines 11 Draw a vertical line of reference out any Design the view with point on horizontal projection line axially at required angle 12 Take one part of length from top view by Draw the views divider or compass 13 Mark twelve times from the initially draw reference line by taking length from compass 14 Draw vertical projection line from each Maintain the neatness and point respectively upper projection line cleanliness 15 Give name at each point according to initially given name 16 Project the projection line from cutting plane s point horizontally 17 Give name at same point of projection line intersect to each other respectively 18 Joint each point by French curve 19 Erase projection lines if draw it 20 Represent the dimensions with symbol require 21 Give darkness for necessary lines 22 Clean up the drawing sheet Fully equipped Classroom with Drawing board T set and drawing instrument and French curve Draw truncated cylindrical development Maintain the uniformity of line thickness Maintain the line joints Safety Precautions 169 DUTY 1 DEVELOPMENT OF SHEET METAL Time 2 0 hrs 1 3 Draw Truncated Cone Development Exercise 2 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition Prepare a dr
262. ons e Refer to the Task Weld edge joint 316 Duty 4 PERFORM OXY ACETYLENE FLAME CUTTING 4 1 Cut MS plate by gas welding equipment manually Time 9 0 hrs Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain a work piece material MS Plate Set up all gas welding equipment Place the plate on the cutting table in such a way that the place to be cut comes over the hole or slot in the cutting table Rule a chalk line about 34 from one edge of the plate Select and set up the correct nozzle for the thickness of the metal to be cut Light the torch adjust preheated flame Observe the nature of the cutting flame by pressing down the oxygen control lever The valve is operated either with the thumb or forefinger Adjust the flame if necessary to keep the preheating cones burning with a neutral flame Bring the preheated flame on the edge to be cut amp heat edge to cherry red Press down the oxygen pressure lever Move the torch forward slowly along the chalk line A shower of sparks will be seen to fall from the underside indicating that the penetration is complete and the cut is proceeding correctly Reheat from the beginning if the cut does not seem to go through the metal Blow with hammer to separate the two sections Safety Precautions Condition Fully equipped workshop with Gas welding equipments Flame cutting nozzles with different sizes of g
263. ool box e Drawing instruction and work piece Tasks What Manufacture a Hand Hacksaw Frame Standard How well e Tolerances of dimensions are within the 0 1 mm Tools and Equipments Vernier caliper drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set center punch drill machine welding rod tap set die set handles tap and die Materials MS square Oil Safety 51 Refer the task File flat surface Punch dot and center Saw the metal by hand and Drill a hole and Radius filing BOOK AND REFERENCES S K Hajra Chaudhary Workshop Technology Vol 1 Media promoters Henp Fort Shop Theory Vol 1 Trade School W A J Chapman Workshop Technology Vol 1 Elsevier Science Heinrich Gerling Elementary Metal Course Training Section I ETHIO Arbeitsstelle fur Unterricht und Technik GERMAN Technical Institute Holetta Heinrich Gerling All about MACHINE TOOLS New Wiley Eastern Ltd India 1965 52 Computer Application Total 78 hrs Class week 2 hrs Course Description This course intends to impart the competencies required to prepare document spreadsheets presentations slides and database management sheets by using different computer application packages Module 1 Maintain Computer System Time hrs T P S N Task Statements Related Technical Knowledge Introduction Identify input devices keyb
264. ools Straighten and de burr the sheet metal Layout the pattern Layout the folding lines by marking with marking scriber Check the layout for accuracy Notch and cut the unnecessary part Bend the open folds by mallet soft hammer and hardies Check dimensions of the completed job Punch the roll no on work piece Store the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Fold metal sheet by hand tools Standard How well e Folding work piece should be match with given drawing e Tolerances dimensions the 0 5 mm of are within e Introduction of folding e Hand tools Hardies used in folding metal sheets e Mallet and types Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Oil Safety Take care of marked lines folds must not be collecting together Use only mallet hammer to bend sheet To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover 107 Duty PERFORM CUTTING FOLDING AND ROLLING Time 4 hrs Task 5 Roll metal sheet by hand tools Theory 1 hr Practical 3 hrs Steps Terminal performance Related Technical objectives Knowledge 10 11 12 13 14
265. oping welding arc following the edges of both w piece and complete the bead at other end of the plate Standards Fully equipped workshop Workpiece clamping with Arc welding Wave of welding in transformer welding Horizontal position Welding procedure Perform square butt joint weld Remove the slag from the weld bead Maintain joining of two Repeat the exercise till you achieve good metals result Maintain welding distortion Maintain welding penetration Follow welding procedure of Horizontal position welding Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 143 Duty PERFORM VERTICAL POSITION WELDING Time 9 0 hrs 3 1 Perform surface weld in Vertical position Exercise 8 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Condition Obtain work piece Material iu to Workpiece clamping Refer and follow the steps of surface se I P AE weld from 3 to 9 except 4 dan Wave of welding in Place the work piece on th weldins transformer welding Vertic
266. ore the work piece and tools Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Grind marking scriber Standard How well e Marking scriber should be match with given check list e Tolerances of dimensions are within the limit provided e Features of Marking Scriber e Procedure of re sharpen marking scriber Tools and Equipments Bench or Pedestrian grinding machine Safety goggles Bevel protractor or grinding gauge Blunt Marking Scriber Oil can Number punch Bench cleaning brush Dust pan Materials Blunt marking scriber Oil Safety Move the work across the full face of the wheel to prevent uneven wearing off of the grinding wheel Refer the same safety precautions of the task grind center punch 38 Duty 5 PERFORM OFF HAND GRINDING Time 6 hrs Task 4 Re sharpen twist drills Theory 1 hrs Practical 5 hrs Steps Terminal performance Related Technical p objectives Knowledge oe 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Obtain workshop drawing Read drawing thoroughly Obtain Bench or Pedestrian grinding machine Obtain blunt drill bits Obtain Safety goggles Bevel protractor or grinding gauge Check the grinding wheel abrasive type trueness of wheel and cracks Dress the wheel if necessary Set up tool rest if necess
267. ork piece Material iu to Workpiece clamping Refer and follow the steps of surface IS I P ot Aa weld from 3 to 9 except 4 WAL weing Wave of welding in Place thew srk piece onthe weldine transformer welding overhead position accessories and different stand with clamps and supports in a electrodes Welding in overhead overhead position position Check and re set the position Strike the arc on a rough piece for trail Task Strike arc and start welding from left to right maintaining short arc length Perform surface weld Remove the slag from the weld bead Repeat the exercise till you achieve good Standards result Maintain welding distortion Welding procedure Maintain welding Follow welding procedure of overhead position welding Safety Precautions e Avoid using Electrode holder with broken handle e Always use Chipping hammer and Wire brush to clean up the welding slags e Always check the connection of Holder Shield and Grips e Avoid using damp electrodes e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the holder on hanger after welding e Keep the workplace dry 146 Duty PERFORM OVERHEAD POSITION WELDING Time 14 0 hrs 4 2 Perform square butt joint Exercise 13 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Obtain instructional drawing Con
268. orkshop with Universal and Vertical Milling machine Tasks Manufacture a Clamp Produced rectangular is checked as given dimension in workshop drawing Produced groove is checked as given dimension in workshop drawing Produced angular surface is checked as given dimension in workshop drawing Safety Precautions Deburr sharp edges when handling workpiece Clean up the vice jaws and parallel blocks every time when resetting the workpiece Check that the cutter is sharp edge and undamaged before setting Select the RPM slightly lower than the higher Be ensure the parallel blocks are tighten sufficiently when use Check that the main switch is put off and clean off whenever you leave the machine 236 Duty 9 PERFORM PROJECT WORK Time 24 hrs 9 2 Manufacture Slide Rule in Vertical milling Exercise 24 hrs Demo hrs Steps Terminal Performance Related Knowledge Objective Position 1 Ruler Condition e Application of slide Obtain workshop drawing rule Obtain workpiece material Refer and Follow the steps of Mill Square block in vertical milling Reclamp the workpiece Refer and follow the steps of Mill Blank Key way in a round workpiece Tasks Remove the workpiece and check the two adjacent surfaces are right angle Manufacture Slide Rule in Reclamp the workpiece Vertical milling Refer and follow the steps of Produce angular surface tilting vertical head on both sides
269. otal 10 68 Total 78 Total A B 117 78 195 270 Task Analysis Duty 1 PREPARE MATERIAL 1 1 Saw the Metal by Hacksaw Timer rae Exercise 2 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain work piece material Obtain Steel scale Obtain Marking scriber Condition Obtain center punch Hammer Obtain Hand hacksaw frame with blade Fully equipped fitting Mark the symmetrically lines workshop Tool room with Punch dotted on marked line Hand hacksaw frame Blade Clamp the work piece so that the marked and bench vice line must be outside from the vice Introduction of Hacksaw amp blade Types of hacksaw and blade Holding different sections of work piece for hack sawing ADUANA 9 Check the blade Procedure of sawing 10 Set up the blade on the hacksaw frame Tasks the metal by hand 11 Take a small triangular file 12 Mark a small vee notch at starting point Saw the metal by Hacksaw 13 Hold hacksaw frame as for the rough file 14 Start cutting slowly moving the blade forward Standards 15 Apply pressure only during the forward Set blades on Hacksaw frame stroke 16 Return the blade faster without touching blade Apply reciprocating motion to 17 Repeat the same motion to complete the complete the cutting stroke stroke as for filling 18 Check the cutting ways that goes straight down Follow safety precaution 19 Move slows
270. ottoming tap Tap no 3 Remove the chips from thread Clean oil and chips Clean the vice Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Cut internal thread using hand taps Tapping Standard How well Tapping work piece should be match with given drawing e Introduction thread and its types e Introduction of tap and tapping e Types of tap e Thread nomenclature e Selection of drill bit for required tapping 29 Tools and Equipments Drill m c Sets of twist drills Bench vice Set of hand tap Cutting oil can Countersink 60 and 90 Centre punch Steel hammer Number punch Bench cleaning brush File brush Dust pan files tap handle checking bolt Materials MS Flat Oil Safety 1 Use cutting fluid while cutting threads to avoid heat 2 Avoid applying side pressure without giving turning motion to tap 3 Tap alignment should be correct since starting of thread to avoid breaking of taps 4 Tap handle should be chosen as per tap size 5 Chips after cutting threads must be cleaned out from the hole and vice 30 Duty 3 PERFORM CUTTING Task 5 Cut external thread using threading dies Dieing Time 6 hrs Theory 1 hrs Practical 5 hrs Steps Terminal performance Related Tech
271. ow the safety of Bench work 295 Duty 3 FABRICATE DOORS Time 6 0 hrs 3 2 Fabricate swing door panel Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Introduction of door Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Design of swing door Perform benchworks cutting drilling panel Types of panel and punching Tasks Perform assembly works required as Te design Check the dimensions Fabricate swing door panel Store it in safe and special place Standards Joints are fixed Swing door is as per design in drawing sheet Safety Precautions e Use safety gloves helmet and goggles e Follow the safety of Prepare materials e Follow the safety of Bench work 296 Duty 3 FABRICATE DOORS Time 6 0 hrs 3 3 Fabricate glass door panel Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain details of instructional drawing Condition Prepare work piece materials Confirm the process of fabrication Fully equipped workshop with Obtain the machine or tools equipments to hand tools and punches and fabricate the materials punching facilities Perform benchworks cutting drilling Material use
272. pes e Dot punch its included angle and its uses e Dots punch material e Centre punch its included angles and its uses e Centre punches material Tools and Equipments Steel rule marking scriber steel hammer centre punch or dot punch anvil Oil can Number punch Bench cleaning brush File brush Dust pan Materials MS Sheet Oil Safety WA RYN Assure the head of the punch is flat Avoid mushroom head punch Wiper off oily substance if any from the face of the hammer Look at the punch tip not at the head while punching While punching remove bangles and wrist watches 25 Duty 3 PERFORM CUTTING Task 1 Saw metal by hand hack saw Time 20 hrs Theory 2 hrs Practical 18 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the w p drawing Condition Given Introduction of 2 Read drawing thoroughly e Well equipped workshop hacksaw 3 Obtain the w p material with set of hand tools in Types of hacksaw 4 Obtain required hand tools i e steel rule tool box Parts of hack saw marking scriber dot punch hammer and Drawing instruction and Hacksaw blades and E Mae sluts ee mee 6 Punch dotted on marked line Selecting blade for 7 Clamp the work piece so that the marked different materials line must be outside the vice and sections 8 Set the hand hack saw blade on hacksaw Holding different frame making teeth pointing towards sections of w p
273. ps Terminal performance objectives Related Technical Knowledge AS 10 11 12 14 15 16 17 18 19 20 Obtain the w p drawing Read drawing thoroughly Obtain the w p material Obtain steel rule marking scriber steel hammer centre or dot punch Prepare the w p material flat as per required dimension Mark the symmetrical lines as per drawing using steel rule and marking scriber Place the w p on flat anvil Hold the dot centre punch by three fingers of one hand and the hammer on other hand Place the tip of the centre punch at the cross of symmetrical lines Apply trial stroke Assess that the punch is at the correct centre Align if required 13 Punch further stroke to get good impression Take next cross line and punch the centre Move center from self ward while punching numerous dotted in same line Repeat the same steps for other cross lines until finished Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Clean the vice and work shop Condition Given e Well equipped workshop with set of hand tools in tool box e Drawing instruction and work piece Tasks What Punch dot centre on the object Standard How well e Check trial stroke e Punching work piece should be match with given drawing e Tolerances of marking line is within the 0 5 mm e Introduction of punch and its ty
274. quare butt 1 8 Perform V butt joint weld with backing 1 6 4 Perform over head position welding 4 1 perform surface weld 1 8 4 2 perform butt joint 1 13 5 Perform Pipe welding in Flat Position 5 1 Weld pipe to pipe joint in rotated position 1 8 5 2 Weld pipe to flat metal joint 1 8 6 Repair Welding Parts 6 1 Repair of casting and forgings 2 6 2 Fill a large hole 1 8 6 3 Assemble individual weld parts and prepare 32 whole products project work Total 24 210 131 Task Analysis Duty PERFORM FLAT POSITION WELDING Time 7 0 hrs 1 1 Perform Striking Exercise 6 0 hrs Demo 1 0 hrs Task and Steps Terminal Performance Related Objective Knowledge Obtain instruction Condition Obtain workpiece material Obtain accessories and tools required Fully equipped workshop Introduction to welding with Arc welding transformer welding accessories and different sizes of electrodes Use of welding tools Obtain electrode of required size Set the current Clamp the earth line to the workpiece material table 7 Clamp the electrode on electrode holder Striking method Arc welding machines transformers Hold hand shield on one hand and the by Task on holder one Produce arc by striking on the rough Perform Striking piece of metal use tapping method Travel the electrode maintaining the arc right angle Standards Develop non sticking Arc Safety Pr
275. r Drill vice Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials Flat chisel Oil Safety Move the work across the full face of the wheel to prevent uneven wearing off of the grinding wheel Refer the same safety precautions of the task grind center punch 37 Duty 5 PERFORM OFF HAND GRINDING Time 4 hrs Task 3 Grind marking scriber Theory 1 hrs Practical 3 hrs Steps Terminal performance Related Technical P objectives Knowledge Ea 9 10 11 12 13 14 15 16 17 18 19 20 Obtain workshop drawing Read drawing thoroughly Obtain Bench or Pedestrian grinding machine Obtain blunt Marking Scriber Obtain Safety goggles Bevel protractor or grinding gauge Check the grinding wheel abrasive type trueness of wheel and cracks Dress the wheel if necessary Set up tool rest if necessary Hold Marking Scriber by left hand pointing the tip towards wheel Wear safety goggles Run the machine Position the angular part of tip up ward on face of wheel fronting left hand side so that it can be rotate freely by right hand side Give feeding slightly rotating the Marking Scriber Check the angle with gauge or Bevel protractor Repeat the grinding until desired angle and sharpened tip obtained Check the final measurement Clean oil and chips Punch the roll no on work piece Oil the surface of the work piece St
276. r Vernier Regrinding tool bits height gauge Center drill amp Grooving tool Process of holding workpiece for turning Perform facing and then center drilling eccentric operation Remove the workpiece Task Mark eccentric center on both surface with i Vernier height gauge and punch it Manufacture eccentric shaft Make center drilling on both marked center with drilling machine Set up worpiece center to center with lathe Standards Process of turning eccentric operation dog and dog clamp Obtain grooving tool according to the size of the groove Reset the grooving tool on tool post so that the cutting blade is parallel to the work length Identify and mark for groove to be cut Set low RPM than turning same diameter Run the machine Perform grooving Reset the workpiece for another eccentric center Repeat step no 15 and 18 for next eccentric groove Make sure the dimensions are as given in workshop drawing Stop the machine bring back the tool measure all dimensions open the workpiece and tool Collect all tools and store in its place e Eccentric dimensions should be as per given drawing Safety Precautions Take care when center drilling in drilling machine e Refer to the task Set up turning tool Plain turning and Center drilling 198 Duty 3 PERFORM THREAD CUTTING Time 16 hrs 3 1 Cut Threads on Machine Using Threading Die Taps Exercise 12 hrs Demo 4 0 hrs
277. r measurements Tools and Equipments Bevel protractor Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials MS Flat Oil Safety Refer same safety precautions of the task of Check square ness using back square 43 Duty 6 HANDLE MEASURING INSTRUMENTS Task 4 Measure the dimensions using Vernier Caliper Time 12 hrs Theory 2 hrs Practical 10 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain pre machined work piece material Condition Given e Rar 2 Obtain Vernier caliper e Well equipped workshop Vertier 3 Clean the caliper with a clean cloth with set of hand tools in caliper 4 Check that the caliper reads correctly by tool box F Foues of moving the jaws together so that they e Drawing instruction and Verte touch amp checking that scale reads zero work piece li 5 Clean the work piece remove burrs Seis ote e Reading the 6 Measuring outside dimensions scale 7 Set the outside measuring jaws to a o sesof Venice dimension larger than that to be measured caliper 8 Place the fixed jaw against the w p Tasks What gt brad tof 9 Move the sliding jaw so that the work Measure the dimensions using e sa a piece is gripped by the caliper Vernier Caliper E ae ea oe 10 Make sure that the jaws are in full contact Era Pa of and not just their tips ie 11 Read the number of mill
278. r in drawing board Condition 2 Prepare a drawing sheet Obtain the drawing sheet of detail drawing that has to be assembly Identify the assembly Determine the functions of the part which part goes in which part Task Draw free hand sketch in rough paper Ensure the view with instructor Scaled and mark on the drawing sheet Construct the view as the object nature if it Fully equipped Classroom with Drawing board T set and drawing instrument Draw assembly view from detail drawing have cylindrical part start from center line 10 Section the view if it necessary Standards 9 Hatch the lines if it sectioned eae 10 Erase the projection lines drawn Draw the supporting lines 11 Give darkness for necessary lines 12 Clean up the drawing sheet Projected representative lines Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions e Refer the safety precautions of draw three view drawing 179 DUTY 4 DRAW STEEL FABRICATION Time 5 0 hrs 4 1 Draw Steel Windows Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Fully equipped Classroom Measurement obtain Determine the length breadth and height of with Drawing board T set Drawing scale the box to be develop E i Basic config
279. r or with Bench or Pedestrian elements grinding gauge grinding machines Safety Check the grinding wheel abrasive type goggles Blunt drills bits Re sharpening process trueness of wheel and cracks Bevel protractor or Angle of drill bit Dress the wheel 1f necessary gauge Set up tool rest if necessary Angle of ddrill bit tip Hold twist drills lightly between the thumb Tasks and the first finger pointing the tip towards wheel Re sharpen twist drills Wear safety goggles Run the machine Standards Hold the drill level and turn it to 59 to the face of the wheel so that the cutting edge is horizontal and parallel to the grinding wheel face Swing the shank of the drill slightly Lip angle should be equal downward and towards the left Rotate the drill to the right by turning it between the thumb and the finger Apply slight forward motions while swinging down this will help to form the clearance angle Repeat the process from step no 10 to 13 to re sharpen the second cutting edge Check both the cutting edges with a drill angle gauge or Bevel protractor for correctness of the lip angle and equality of the lip length Repeat the grinding until desired angle and sharpened tip obtained Cutting angles and drill angle should be match with drill angle gauge Safety Precautions e All movement made to the drill i e angular turning swinging and forward movements should be well coordinated e Too m
280. r support Decide the position of the cutter to be fitted Standards on the long arbor Remove the unnecessary collars Cutter Tool should be fitted Clean the hole of the cutter and slide away within bed area onto the long arbor so that the arbor key fits Arbor should be tighten into the keyways Slide enough collars on the arbor to extend Cutter Tool should be locked by the edge of the workpiece key Slide on the bush bearing Slide on more collars until they just cover the one or two threads of the arbor screw Screw the arbor nut hand tight only Fix the long arbor support onto the Over arm and to be fitted on the bush bearing Tighten the arbor support nut Tighten the long arbor nut Set r p m Cotter holding devices Long arbor and their uses Different cutter used in horizontal milling machines Safety Precautions Be ensuring the thread of arbor screw is left hand e Cutter should be as close as possible to the spindle nose Make sure that the cutter is facing in the direction of rotation of the cutter spindle The bush bearing should extend equally each side of the arbor support e Use correct size of spanner to tighten or loosen the nuts Hold the arbor support firmly to avoid dropping it on the work table or floor 219 Duty 1 SET UP MACHINE Time 2 hrs 1 5 Mount milling cutter on Short arbor and in Vertical spindle Exercise 1 hrs Demo 1 hrs Terminal Performance Object
281. raighten and deburr the sheet metal e Drawing instruction 5 Lay out the elevation view a half plan and work piece view and the pattern on drawing paper 6 Check the paper for accuracy 7 Cut out the paper pattern 8 Transfer the paper pattern into the sheet metal 9 Cut out the sheet metal Tasks What 10 Folds for the grooved seam in bar e Fabricate a Cylindrical folder 90 elbow 11 Roll both cylinder pieces in the slip roll forming machine 12 Groove the seam with the hand grover 13 Make sure that the both cylinder is completely round 14 Assemble the pieces and tack the seam by soldering 15 Check the angle of the elbow with a protractor 16 Solder the seams on the outside Standard How well 17 Check dimensions of the completed jo e Elbow should be match with given check list e Tolerances of dimensions are within the 0 5 mm Tools and Equipments Rivet head set Ball pin hammer Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials GI Sheet Rivet Aluminum or MS Oil Safety e De burr the metal sheet edges e Place snips and material on bench e Avoid carrying scriber in pockets e Open the blades as far as possible for your hand and using the throat of the snips e Start the cut at the edge of the material e Avoid sharp corners e Avoid leaving jagged edges cu
282. raining is distributed as Bee NAS 200 marks will be awarded by the supervisor of the user agency 200 marks will be awarded by the related training institute 100 marks will be awarded by CTEVT OJT conduction and evaluation scheme will be as per the guidelines of CTEVT Basic Requirements Office Equipment There should be well arranged equipment for training and office management a Desk top Computer b Scanner c Multi media projector d Laser color mono printer e Fax mail f Photo Copy Machine color mono Classroom Equipment There should be well arranged modern facilities for training and instruction management 1 2 3 4 5 White Board Soft Board Multi media projector Chair and desks Overhead projector Library facilities Essential furniture chair table racks books journal and periodicals Curriculum structure TSLC IN MECHANICAL ENGINEERING PRE SLC INTAKE 2014 First year Class Week Total Class Year Full Marks IM A ected tered al IO CE A A CC EE a faam a ajo apor fopojo 3 _ Appliea Nena a olo s o pa so 0 50 Fa Bench Work e off ar ope a9 o as 275 5 Computer Applicaton r of2 2 o 7 7 0 so 50 16 Engineering Drawing e opa o 7 7 ols 75 7 Este Operation t e ola o 156 156 0 100 100 8 Material Seience t r pois pops as o gt 9 Sheet Metal Fabrication P ola 4 o lise 156 0 100 100 Lio We
283. re the work piece and tools Tools and Equipments Steel rule Snips Back square marking scriber steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan smooth file Materials GI Sheet Oil Safety e Place snips and material on bench e De burr the metal sheet edges e Avoid carrying scriber in pockets e Open the blades as far as possible for your hand and using the throat of the snips e Start the cut at the edge of the material 105 Duty PERFORM CUTTING FOLDING AND ROLLING Task 3 Cut metal sheet in irregular segment with snip e o Practical 3 hrs Terminal performance Related Steps objectives Technical Knowledge 1 Obtain the work piece drawing Condition Given e As same as 2 Obtain instruction e Well equipped workshop related 3 Study the drawing thoroughly with set of hand tools in knowledge of 4 Obtain the piece of sheet metal as per tool box Task 1 drawing size e Drawing instruction and 5 Obtain required tools work piece 6 Straighten and de burr the sheet metal 7 Layout Measure and mark the notches and line for cutting 8 Punch the center of radius circle by center punch 9 Check the layout for accuracy 10 Put the work piece on the table Tasks What 11 Place the snip on the edge of marking line Cut metal sheet in irregular 12 Cut the sheet metal according to the drawing segment with snip 13 Deburr and straighten 14 Make a start
284. recautions e Refer to the task Set up tool Plain and Center drilling Apply fluent coolant on machining surface e Take care when drilling the hole from tailstock 96 Duty 3 PERFORM PROJECT Time 10 0 hrs 3 1 Manufacture a Bush Exercise 10 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition e Application of bush Obtain drawing Fully equipped workshop Obtain workpiece as per drawing with Center lathe machine Obtain tools and equipments Facing tool turning tool Clamp the workpiece in 3 jaw chuck Center drill Drill bits for Clamp the turning tool guide hole plain boring tool Face up the surface Drill center drill Drill a hole as much as large diameter Task Set up boring tool Bore the hole until hole diameter obtain Manufacture at bush Chamfer for hole Change turning tool Standards Turn outside diameter Reclamp the workpiece Dimensions of the product Face up reduce the length is as per drawing Chamfer on necessary corner Measure final dimensions to ensure all the dimensions are as required 1 2 3 4 5 6 7 8 9 Surface quality and tolerenced is as specified Machined corners are chamfered Safety Precautions e Refer the task Perform plain boring 97 Duty 3 PERFORM PROJECT Time 16 0 hrs 3 2 Manufacture a Shaft with Stepped Surface Exercise 16 0 hrs Demo 0 0 hrs Objective Knowledge Follow and
285. repeat the steps 1 to 6 of bush Condition e Importance and manufacture application of shaft Reclamp the workpiece clamping min with Center lathe machine Portion inside the chuck supporting Facing tool turning tool revolving center from tailstock Center drill Drill bits for True concentricity Turn out big diameter engaging auto feed Mark small grove for shoulder length Take rough cut to stepped length remains Task 1mm in required diameter lt Change the tool according to the shoulder Manufacture a shaft with shape it necessary stepped surface Take a cut and shaped the shoulder as per exchanged cutting tool Take final and finishing cut Standards Perform chamfers on all required corners Measure dimensions to ensure all the dimensions are as required Reclamp the workpiece turning inside out True concentricity Surface qulity ad tolerence Face the surface reduce the length as is as specified required size Turn out big diameter if required Turn out shoulder if required Perform chamfers on all required corners Measure final dimensions to ensure all the dimensions are as required Fully equipped workshop guide hole plain boring tool Dimensions of the product is as per drawing Machineed corners are chamfered Safety Precautions e Refer the task Perform step turning 98 Duty 3 PERFORM PROJECT Time 22 0 hrs 3 3 Manufacture a fittings of Stepped part Exercise 22 0 hrs Demo 0 0
286. required angle reading swivel scale T and tighten the nuts 11 Reset the sliding length of top slide as per DA OS ISS En o Perform internal tapers taper length 12 Bring and touch gently the cutting tip on the Standards bore edge of the workpiece 13 Set the dial scale 0 on cross slide 14 Run the machine and give depth of cut from cross slide Measurement of taper 15 Give feed manually from top slide slowly angle made should be as 16 Repeat turning taper until the required per drawing dimension obtain giving depth of cut from cross slide respectively 17 Make sure the dimensions is as given in workshop drawing 18 Stop the machine bring back the tool measure the entire dimension open the workpiece and tool 19 Collect all tools and store in its place e Maintained surface quality Safety Precautions e Refer to the task Perform boring and Taper turning 197 Duty 2 PERFORM MACHINING OPERATION Time 20hrs 2 5 Manufacture Eccentric Shaft Exercise 16 hrs Demo 4 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain workshop drawing Condition Obtain workpiece material Obtain required tools and equipment Set up workpiece on three jaw chuck Perform facing Perform center drilling Reset the workpiece in side out on the three jaw chuck Importance and use of eccentric operation Fully equipped workshop with Center lathe machine and turning tool Center punch Hamme
287. ries and tools required j q Fully equipped workshop Introduction to TIG Prepare TIG welding machine with TIG welding AC DC welding Connect the electrical power rectifier tungsten rod wire accessories and different filler material Use of TIG welding Switch the machine tools Connect the torch to the machine C tth linder onnect the gas cylinder Task Fix tungsten electrode 1 2 3 4 5 6 7 8 9 Adjust the gas pressure and voltage Set up welding equipment 10 Take any arrangements as required Standards Connect hose pipe on gas holder Set up current and tungsten wire on holder Safety Precautions e Avoid using torch with broken handle e Always check the connection of Holder Shield and grips e While removing the slag wear safety goggles and chip off in opposite direction e Keep away the inflammable material e Always place the torch on hanger after welding e Keep the workplace dry 322 Duty 2 PERFORM SURFACE WELDING Time 7 0 hrs 2 1 Perform surface welding without filler rod Exercise 6 0 hrs Demo 1 0 hrs Objective Knowledge Refer and follow of set up welding equipment of TIG from 1 to 3 Condition Clamp the work piece and return lead to a clean and of the table Fully equipped workshop Introduction of welding Keep the material in welding position and With TIG welding AC DC wave of TIG Welding clean thoroughly rectifier tungsten rod wire Hold the torch at th
288. ring following the same steps of previous filing task 6 Mark the chipping depth using height gauge as per drawing 7 Punch dotted on chipping depth line 8 Clamp the work piece securely in the vice 9 Install chip guard 10 Hold cross cut chisel in left hand Tasks What 11 Position the chisel at about 60 angle Chisel grooved surface 12 Repeat the chiseling process as for flat surface from Step 13 to 18 13 Hold concave chisel 14 Repeat the chipping process as for step 14 15 Repeat the chipping until required ba iS dimension obtain Standard How well Punch the roll no on work piece e Chiseled oor 17 Oil the surface of the work piece ISE SG ees Plees 18 Store the work piece and tools Shou NE tatei aii p f 19 Clean the vice and work shop given check list Tolerances of dimensions the 0 5 mm are within Tools and Equipments Steel rule marking scriber dot center steel hammer flat anvil Cross cut Chisels Concave chisel Oil can Number punch Bench cleaning brush File brush Dust pan files Finishing file Materials MS Flat or MS Square bar Oil Safety Refer as same as Chisel flat surfaces 28 Duty 3 PERFORM CUTTING Task 4 Cut internal thread using hand taps Tapping Time 6 hrs Theory 1 hrs Practical 5 hrs Steps Terminal performance objectives Related Technical Knowledge APS OO ANA 13 14 15 16 17 18 19
289. rite engineering letter 1 1 2 Construct Geometrical Figures 2 1 Bisect Straight line divide line 0 5 1 5 2 2 Bisect an angle 0 5 1 5 2 3 Draw circle using compass 0 5 1 5 2 4 Draw square rectangle 0 5 1 5 2 5 Draw triangle using set square amp protractor 0 5 1 5 2 6 Construct ellipse 0 5 3 5 3 Draw in Scale 3 1 Represent the drawing in scale 1 2 3 2 Represent the dimension in detail 1 3 3 3 Determine the tolerances 1 3 3 4 Draw the symbols 2 2 4 Draw Pictorial Projection 4 1 Draw isometric projection 2 14 4 4 Draw oblique projection 2 6 5 Draw Orthographic Projection 5 1 Draw three view in first angle projection 2 16 5 2 Draw three view in Third angle projection 1 7 5 3 Find and draw missing views 8 6 Draw Sectional Drawing 6 1 Draw full section views 2 8 6 2 Draw half section views 4 6 3 Draw partials section views 6 sub Total 21 96 Total 117 58 TASK ANALYSIS Duty 1 HANDLE INSTRUMENTS Time 2 0 hrs 1 1 Set up Paper in Drawing Board Exercise 1 hrs Demo 1 hrs Objective Knowledge Place the drawing board straightness to the Condition Paper size for drawing left side and designing work Clean up the drawing board Drawing board Set up base paper over drawing board material sizes and Place drawing paper over the base paper application Fully equipped Classroom with Drawing board T set and drawing instrument Set the T set on the drawi
290. rners to notch in 45 at all excess folding margin 11 Erase projection lines if draw it 12 Represent the dimensions with symbol require 13 Give darkness for necessary lines 14 Clean up the drawing sheet Safety Precautions Task Draw square box development Sheet metal pattern development Area calculation Importance of notching Importance of edge folding Sheet metal folding Standards Calculation of drawing area Design the view with margin edge folding and notching Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness 168 DUTY 1 DEVELOPMENT OF SHEET METAL Time 2 0 hrs 1 2 Draw Truncated Cylindrical Development Exercise 2 0 hrs Demo 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Select dimension such as diameter length and cutting angle Draw atop view amp front view of cylinder Divide the circle twelve parts by compass and divider Project the projection line from each of the Task point towards on front view respectively or 7 vertically down ward Give the name where the projection line cuts the upper and lower parts of front view line Cut the front view axially at any desired or Standards required angle on the any desired height from the base f 9 Give same name where the projection line Calculati
291. rough in the work piece e Move the torch from right side of the work piece to left side in manipulating the semicircle e Maintain the inner cone of the flame to touch the work piece or the puddle e Avoid using match to light a torch Use a regulation spark lighter e Wear safety apparel safety goggles working apron leather apron and dark glass e Avoid conditions that may cause a backfire or flashback 310 Duty 1 RUN BEADS IN LINE Time 20 hrs 2 2 Run fusion with filler rod Exercise 16 hrs Demo 4 0 hrs Steps Terminal Performance Related Knowledge Objective Repeat the steps from 1 to 8 of the fusion Condition run without filler rod Fully equipped workshop with j Obtain filler rod a 5 Gas welding equipments filler Hold filler rod at an angle 30 to 40 rod with different sizes of Hold the torch at an angle about 60 to the nozzles plate Characteristics and use of Put one end in of filler rod to the molten filler rod Laying beads with a filler rod Introduction of filler rod Tasks puddle Melt the rod till a bead of 5 to 10 mm wide Ryn fusion with filler rod Left ward welding and 3 mm high is formed techniques Advance the torch and rod along the Standards Right ward welding desired line on the workpiece techniques Withdrawn the torch at the end of the pass Obtain uniform ripple fill the crater by adding filler rod surface Practice running consistent strai
292. ructional drawing Obtain prepared work piece material Fully equipped workshop with e Types and application of Hold both workpiece together securely Bench work tools facilities screws Insert a tip of screw on hole and screw driving on its head y Make full tightening Tasks Perform screwing Standards Screw in on as dimension Screw is straight and insert full Safety Precautions e Never use broken or loose handle fitted on screwdriver e Use safety gloves e Never beaten on top of the handle 291 Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE Time 5 0 hrs 1 6 Perform Riveting Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain instructional drawing Condition Obtain layout or marked work piece material Fully equipped workshop with e Types of Rivets Clamp both workpiece together rivets and riveting tools Drill a hole according to the size of rivet facilities e Introduction of Rivets e Fundamental of riveting diameter Obtain pop riveting machine and insert the nozzle as rivet size Insert a rivet on hole and other end to Perform riveting riveting machine Clamp it fully till the rivet broke down Standards Checked the joint Repeat it till the joint is complete Rivets are on as dimension Joint is securely hold Tasks Safety Precautions e Do not use broken handled hammer e Use safety gloves helmet and gogg
293. ry tool and equipment Drawing instruction and 4 Measure rough dimension and file out work piece side by side to prepare a square block with geometrically 90 5 Mark a layout line on workpiece 6 Punch dots on marking line Tasks What 7 Saw the metals to cut out unnecessary Manufacture a Center Square parts 8 File out the flat even surface 9 File out opposite flat even surface 10 Maintain the thickness required and flat even surface 11 File out the width of blade with Standard How well geometrically 90 12 Drill the holes on side as per given drawing 13 Chamfer and deburr all sharp edges 14 Perform internal thread using hand taps 15 Check the final measurements Position 2 e Tolerances of dimensions are within the 0 1 mm 1 Refer and follow the step of Pos 1 from 4 to 11 Mark the layout line for drilling the holes Punch center on drilling marks Drill the holes as per required size Counter sunk the holes with 60 Chamfer and deburr all sharp edges Check the final measurements Assemble the both parts with countersunk head screws SN Pe Tools and Equipments Vernier caliper drill bits Steel rule marking scriber steel hammer Oil can Number punch Bench cleaning brush File brush Dust pan file set drill machine drill vice center punch Materials MS Flat Oil Safety e Refer the task File flat surface Punch dot and center Saw the metal by hand and Drill a hole and R
294. s and Application 2 Cutting Tool Geometry 1 2 1 Introduction 2 2 Angles of cutting tool 2 3 Effects of angles on cutting tool 2 4 Cutting tool material 2 5 Recommended angles for cutting different materials 3 Precision Instrument 3 3 1 Introduction 3 2 Dial Test Indicator 3 3 Slip gauge 3 4 Ring gauge and plug gauge 3 5 Telescopic gauge 3 6 Micrometer 4 Lathe Machine 4 1 Introduction Occupational Safety 1 4 2 Types of Machine 2 4 2 1 Introduction of Engine Lathe 4 2 2 Introduction of Capstan Lathe 4 2 3 Introduction of Wheel Lathe turret 4 2 4 Introduction of Vertical Lathe 4 2 5 Introduction of Copy Lathe 4 2 6 Introduction of Special Purpose Lathe 4 2 7 Introduction of NC CNC lathe machine 4 3 Parts and Function of machine 1 4 3 1 Head Stock 4 3 2 Tail Stock 4 3 3 Carriage 4 3 4 Bed 4 3 5 Feed Gear Box 4 4 Accessories of machine 2 4 4 1 Work holding devices 4 4 2 Chucks 3 Jaws and 4 jaws self centering amp independent 4 4 3 Face plate 4 4 4 Dog Plate 4 4 5 Mandrel 4 4 6 Sleeves and adaptors 336 4 4 7 Centers 4 4 8 Follower and Steady rest 4 5 Attachments of the machine 4 5 1 Taper turning 4 5 2 Grinding 4 5 3
295. s equally Introduction of Face Full ipped worksh ANNA etter ne plate and its with Center lathe machine Face plate and clamping set Use of counter weight or supports Machining parts should be in center Safety Precautions e Always keep the counter piece of same weight e Always use same size of spanners e Keep the carriers away from the Head stock e Switch off the main electrical line while setting up the workpiece e Pre set enough lighting in machine area e Always keep the machine and its surroundings neat and clean e Use a wooden block on lathe bed when installing removing the chuck e Setting or removing of a chuck or faceplate shall be made with due care not to drop them down 190 Duty 1 SET UP MACHINE Time 3 0 hrs 1 2 Set up Workpiece Center to Center with Lathe Dog and Dog Clamp Exercise 0 0 hrs Demo 3 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain workpiece Obtain facing tool centre drill and drill chuck with key Clamp the workpiece on three jaw chuck Set up the cutting tool on tool post Perform facing operation Perform center drilling operation Perform step no 5 amp 6 for other side of the workpiece Remove three jaw chuck Set up face dog plate with dog stopper Hold the lathe dog on a side of work piece Set up live center on spindle nose Set the tail stock leaving center distance close to the workpiece Fix the work center of
296. s of drill machine Punch dot on marked line Drilling speed Change the drill bit as required Tasks RPM selection Select and set up the RPM Place the panel on the drill vice in such a Perform drilling way that the dot marked should be in spindle center Standards Switch on the machine and start pressing till drill hole through Hold section panel Switch off the machine and change without damaging the countersink on chuck section panel Switch on the machine and start pressing till burrs removed from drill hole Repeat it on other side of the hole Remove job material and countersink Clean the machine table Restore all tools and equipments Fully equipped workshop with Drilling machine and drill bits 1 Ze 3 4 5 6 7 8 Drill hole is circular and as given Dimension Safety Precautions e Wear safety apparels safety goggles safety gloves Safety helmet e Secure vice on machine table with nut and bolts e Frequent apply of coolant e Maintain the RPM of the machine spindle 288 Duty 1 PERFORM BENCH WORK ON ALUMINIUM PROFILE Time 2 hrs 1 3 Perform filling Exercise 2 hrs Demo 0 hrs Objective Knowledge Obtain instruction Condition Introduction Obtain workpiece material Types of file Obtain tools required Fully equipped workshop Filing procedure Set the workpiece with set of files and Bench Wear safety equipments vice Hold file Start filing Make sure the surface is
297. seam slightly with a mallet Place the hand grooves over one end of the seam and strike it with a hammer Groove the other end in the same manner Groove the entire seam by striking the hand groover with the hammer Check dimensions of the completed job Punch the roll no on work piece Store the work piece and tools with set of hand tools in tool box Drawing instruction and work piece Tasks What Groove single seam Standard How well Groove single seam should be match with given drawing Tolerances dimensions the 0 5 mm of are within e Type of fastening e Seam joint and its type e Tools used for making seam joint Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Seam punch Hand groover Materials GI Sheet Safety Take care of marked lines folds must not be collecting together Aware from clamping the finger by machine jaw To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover Use the right number of hand groovers Both pieces must be fitted right together Avoid mushroom head seam punch 111 Duty PERFORM FASTENING HEMING AND WIRE EDGING Task 9 Groove edge seam Hem Time 3 hrs Theory 1 hr Practical 2 hrs Steps Terminal performance objectives Related Technical Knowledge 10
298. sk 7 Draw the arcs with centers D and E any To Bisect an angle convenient radius Draw arcs intersecting each other at F 8 Standards Join the line BF BF bisects the angle ABC e Dimension should be according to criteria Safety Precautions 64 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 2 0 hrs 2 3 Draw Circle Using Compass Exercise 1 5 hrs Demo 0 5 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Set paper in drawing board Prepare a drawing sheet Decide the diameter of circle to be draw Scaled and mark on the drawing sheet Draw cross line and center line in each and every marked centers Obtain a compass set the radius lengthin Task scale as the circle to be draw Uses of Compass and representative of circles in workshop drawings Fully equipped Classroom with Drawing board T set and drawing instrument Instruments that uses to draw circles in drawing Place a needle of compass on the center Draw circle using compass Hold rotator of compass rotate it in clockwise direction compressing towards a Standards pencil Ensure the circle drawn is dark enough Start and end point should not seen All lines should be uniform Radius dimeter should be in given dimension Safety Precautions e Handle compass carefully e Keep the compass in proper place 65 Duty 2 CONSTRUCT GEOMETRICAL FIGURES Time 2 0 hrs 2
299. soldering iron in other hand Tasks What 10 Heat the parent metal Perform soldering 11 Touch the lead by soldering iron until it melts and apply in the joining areas 12 Use the soldering iron frequently to spread melted lead in all joining areas 13 Repeat spreading lead until it covers and joins the pieces Standard How well 14 Allow the soldered area cool for solid e Soldering work piece deposition should be match with 15 Clean up all the areas are tools after given check list completing e Tolerances of 16 Check dimensions of the completed job dimensions are within 17 Punch the roll no on work piece the 0 5 mm 18 Oil the surface of the work piece Store the work piece and tools Tools and Equipments Soldering iron Soldering iron stand Steel rule marking scriber try square snips steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials Zinc chloride soldering lead flux Safety Take care while using zinc chloride Take care while heating the soldering iron Flux should be applied in whole joining areas Avoid overheating of soldering iron Make proper ventilation and well lighted working areas Beware from toxic fumes generated while soldering Use safety goggles Work safety to avoid burn Apply electrical safety prcations 117 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 6 hrs Task 15 Perform Riv
300. sound place Introduction of forward Polly equipped Pecica reverse motor starter plant machines 2 3 4 5 6 7 8 9 Standards e Electrical connections of plant machines should be repaired Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets BIBLIOGRAPHY SN Name Author Publication 1 Industrial Maintenance H P Garg 2 Welding Engineering and Technology Dr P S Parmar 3 Machine Design R S Khurmi and J K Gupta 4 Workshop Technology R S Khurmi and J K Gupta 5 Elements of electrical and Mechanical B L Theraja Engineering 6 Workshop Technology part I and II Hazra Chaudhari 7 Westermann Table of Mechanical Engineering 8 Basic Electrical Engineering M L Adwani CIMI Madras 9 Basic Electrical Engineering Vol I and II P S Dhogal 268 Structural Fabrication Total 195 hrs Class week 5 hrs S No Duties and Tasks Time hrs A Steel Fabrication Demo Practical 1 Prepare material 1 1 Perform Sawing 2 1 2 Cuts the material by Oxy acetylene gas cutting 1 3 1 3 Perform off hand
301. straight beads in vertical upward Task process position Restore the tools and equipments Clean the working area Weld T joint in vertical position Standards Transverse welding wave in MIG welding Procedure of deposition of MIG welding straight beads in vertical upward process position Safety Precautions e Avoid using welding gun with broken handle e Always use Wire brush to clean up the welding beads e Always check the connection of gun Shield and wire end e Avoid using damp MIG wire Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding Keep the workplace dry 334 BIBLIOGRAPHY SN Name Author Publication 1 Job Sheets of Welding Ministry of Japan 2 Welder Trade Manual Kakkar 3 Welding Skill Joseph W Giachino William 4 Welder Trade Theory Central Instructional Media Institute Madras 5 Prinicples of Welding LM Gourd Viva Books Private Technology Limited 6 Welding Engineering and Dr R S Parmar Khanna Publishers Technology 335 Workshop Technology II Total 78 hrs Class week 2 hrs Unit sub unit Areas and Topics Time hrs 1 Lubrication and Cutting Fluid 2 1 1 Introduction 1 2 Characteristic of Lubricants 1 3 Types and Application 1 4 Characteristic of Cutting oil 1 5 Type
302. t be collecting together Aware from clamping the finger by machine jaw To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover 112 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 6 hrs Task 10 Perform wire edging Theory 1 hr Practical 5 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece drawing Condition Given e Introduction of wire 2 Read drawing thoroughly e Well equipped workshop edge 3 Obtain the metal sheet of with set of hand tools in e Purpose of wire edge required size and required tool box e Margin calculation sheet metal tools e Drawing instruction and 4 Straighten and de burr the work piece sheet metal 5 Layout the pattern 6 Layout the folding Tasks What lines margin for wire by Groove edge seam hem marking with marking scriber 7 Check the layout for accuracy 8 Notch and cut the unnecessary Standard How well part e Wire edge should be 9 Fold the edges as per drawing match with given and form the job to shape drawing 10 Place the work piece on a e Tolerances of suitable stake dimensions are within 11 Strike the folding part by light the 0 5 mm hammer until its shape to be round 12 Place the selected wire in the round shaped margin 13 Press the un round edge if any under the wire with the help of any pointed tool 14 Check dimensions of the completed job 15 Punch the roll n
303. t in average of 500 to 600 r p m for Centro fix Be careful when mounting the Centro fix Follow the other safety precautions of previous task 229 Duty 6 MILL GROOVES Time 10 hrs 6 1 End milling a Slot Exercise Shrs Demo 2 hrs Steps Terminal Performance Related Knowledge Objective Prepare a Square block referring the previous Condition tasks Obtain Key way cutter that is smaller than Fully equipped workshop with Set up End mill cutter width of slot to be cut Universal and Vertical Milling in collect chuck Set up the collect chuck in the machine machine spindle Set up work table Mount the cutter in the collect chuck eliminating Re clamp the workpiece material as per the backlashes size Set the machine controls End Milling a Slot Process of end Bring the face of the cutter over the milling a slot machined surface Set the vertical hand feed scale to zero 9 Move along the cutter from cross feed 10 Set depth of cut 11 Bring the periphery of cutter on the side of Dimension should be as per the workpiece drawing 12 Set the cross feed scale to zero 13 Clear out the cutter from work piece moving Surface should be plain and longitudinal movement of table smooth 14 Position the cutter at the slot to be mill 15 Position the coolant pipe 16 Start the machine and mill one side of the slot 17 Check dimension of side machined and further cuts until depth dimension is reached 18 Reset the workt
304. t the compass from cross point of center line to both center point of sides Draw another arc Draw another arc with same compass set up from opposite crossed point of center line to center point of sides 10 Erase the rhombus and center lines 11 Give darkness for drawn ellipse Ormity of line thickness Maintain the neatness and cleanliness Safety Precautions e Keep the compass in safe position to other people e Do not drop the compass on the ground Do not over press on the needle leg of the compass while drawing an arc 68 DUTY 3 DRAW IN SCALE Time 3 0 hrs 3 1 Represent the Drawing in scale Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Set paper in drawing board Prepare a drawing sheet Definition of scale Decide the drawing for proper scale Calculate the drawing measurement Scaled and mark on the drawing sheet Refer and follow the steps of drawing Types of scale three view isometric or sectional view to Task Fully equipped Classroom with Drawing board T set General principles and and drawing instrument rules of scale draw the view as needed 7 Write the actual dimensions including tolerances if any 8 Write the name of using scale in title bock 9 Erase projection lines 1f draw it 10 Give darkness for necessary lines Standards 11 10 Clean up the drawing sheet Represent the drawing in scale e Draw the views and dimensio
305. t the material by closing the blades just short of their full length 129 BOOK AND REFERENCES S K Hajra Chaudhary Workshop Technology Vol 1 Media promoters Henp Fort Shop Theory Vol 1 Trade School W A J Chapman Workshop Technology Vol 1 Elsevier Science PS Gill Engineering Drawing S K Kataria amp Sons Heinrich Gerling Elementary Metal Course Training Section I ETHIO Arbeitsstelle fur Unterricht und Technik GERMAN Technical Institute Holetta Heinrich Gerling All about MACHINE TOOLS New Wiley Eastern Ltd India 1965 130 Welding Technology I Total 234 hrs Class week 6 hrs Duty Task Duties and Tasks Time hrs Shielded Metal Arc Welding SMA W Demo Practical 1 Perform Flat Position Welding 1 1 Perform striking 1 6 1 2 Perform surface weld 1 6 1 3 Grind off welding surfaces 1 6 1 4 Perform multi run straight beads 1 6 1 5 Weld corner joint 1 6 1 6 Weld edge joint 1 6 1 7 Weld Lap joint 1 6 1 8 Weld square butt from both sides 1 8 1 9 Perform tack weld for V butt joint 1 6 1 10 Weld V butt joint with backing 1 16 2 Perform Horizontal Position Welding 2 1 Perform surface weld 1 12 2 2 Perform square butt joint 1 6 Perform V butt joint weld with backing 1 10 Perform fillet joint weld 1 6 3 Perform Vertical Position Welding 3 1 Perform surface weld 1 8 3 2 Perform s
306. tail stock Fit the taper shank drill bit to the appropriate sleeve Fix the drill bit with sleev in tailstock spindle Repeat step 3 to 7 until required diameter is not get Take off the tailstock stop the machine and then go to further operation Task Perform drilling Standards e Depth and diameter of the drilling is measured according to given dimension Drilled surface is finished Safety Precautions e Sleeve and drill shank should be oil or grease free e RPM should be set according to diameter of drill bits e Workpiece and drill bits should be clamped tightly 90 Duty PERFORM TURNING OPERATIONS Time 18 0 hrs 2 4 Perform Plain Turning Exercise 16 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Condition Set up round workpiece on three jaw chuck Set up turning tool on tool post Fully equipped workshop Process of Plain Set up machine control turning operation Perf faci with Center lathe machine Nee ee re eh and cutting tools Perform center drilling if necessary Identify the length amp diameter to be machined l Task Start the machine Bring the cutting tool at the end edge of the workpiece Take a first cut giving depth as facing opposite direction Standards Bring back the tool Give rough depth of cut Peripheral surface is fine Feed the tool forward to the Head stock as surface required slowly moving hand wh
307. tailstock offset 1 2 2 6 Repair coolant pipe lines 2 2 3 Project work of Machines repair 37 Total 13 65 Total 78 B Electrical Maintenance Demo Practical 1 Interpret Electrical Symbol amp Drawing 5 8 1 1 Schematic Diagram 1 2 1 2 Layout Diagram 1 2 1 3 Wiring Diagram 1 2 1 4 Power and Control Diagram 2 2 2 Read amp Handle Multi meter 2 1 Multi meter 1 2 3 Repair Electrical Wiring 2 10 3 1 One bulb control by one way switch 1 5 3 2 One bulb control by two way switch 1 5 4 Replace common electrical Accessories amp 1 5 materials Repair motor control and installation system 4 8 5 1 Connect direct on line starter DOL 2 4 5 2 Connect forward reverse motor starter 2 4 6 Project work of Electrical repair 32 Total 13 65 Total 78 Total A B 78 78 156 246 TASK ANALYSIS Duty 1 PREVENTIVE MAINTENANCE Time 3 0 hrs 1 1 Schedule Maintenance Plan Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Obtain instructional manual Condition Read the pages of maintenance instructions Introduction of List down with maintenance intervals Fully equipped Machining shop preventive Draw a wall chart with maintenance tools and maintenance Collect all material as required materials Prepare recycle Follow the instruction at very first time maintenance chart Clean the working surroundings Task Read instructional Restore all remaining materials manual 1 2 3
308. tain electrical accessories as per line starter workshop with line starter diagram DOL and Multi meter i Mark on the board as per plan diagram POL ee Mune Introduction of 3 phase Prepare the auxiliary accessories as per supply system diagram measurement Task Install the auxiliary accessories on the board e Connect direct on line starter Lay wire according to the control and DOL power diagram Connect all electrical accessories according to the control and power diagram els e DOL should be connected Re check all control and power circuit as per drawing Clean and store the electrical instrument used in safe and sound place Standards Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 266 Duty 5 PERFORM MOTOR CONTROL AND INSTALLATION SYSTEM Time 6 0 hrs 5 2 Connect forward reverse motor control Exercise 4 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective ez Condition Obtain instruction plan control and power diagram Obtain electrical accessories as per digri reverse motor control and Mark on the board as per plan diagram Multi meter Different type of motor Prepare the auxiliary accessories as per starter diagram measurement I
309. tal grinding different tools used Set up tool rest if necessary machine Safety goggles HSS in Fly cutter Identify the shape of tool to be grind Tool bits Bevel protractor or Identify the angles of tool to be grind Angle gauge Method of grinding Wear safety goggles a single tip tool for Refer and follow the steps of the task grind Tasks Fly cutter Facing corner tool in HSS bit Check the angles with the gauge or bevel Grind Single Tip tool for Fly protractor cutter 10 Deburr the edges using oilstone Standards Ground shape and angle is according to Fly cutter tool bit Safety Precautions Too much depth may overheat the tip and may cause short hardness e Any damage to the grinding wheel if noticed should be reported to the instructor e When switching on the grinding machine stand aside until the wheel reaches full speed 222 Duty 2 MILL PLAIN SURFACE Time 15 hrs 2 1 Mill Plain Surface on Horizontal Milling Exercise 12 hrs Demo 3 hrs Objective Knowledge Obtain workpiece material Condition 2 Obtain set of parallel blocks as per working dimensions Fully equipped workshop with Fundamental of Set up workpiece as per the size Horizontal and Universal Milling milling Set up plain milling cutter on long arbor in machine Horizontal spindle Process of milling a Set up machine controls Plain surface Bring the table so that the cutter is close to top of the workpiece Place a thin pi
310. tally to join the lines Standards 11 Draw thin line onto thread length asa pitch of the thread size Draw the supporting lines 12 Draw the chamfer size at the thread end 13 Represent hexagon at head referring the steps no 12 to 20 of draw hexagon nut 14 Give dimensions 15 Erase the projection lines if drawn 16 Ensure the rectangle or square drawn is Maintain the uniformity of dark enough line thickness 17 Clean up the drawing sheet Maintain the line joints Maintain the neatness and cleanliness and lines Screws Bolts Studs Square amp trapezoid Fully equipped Classroom with Drawing board T set and drawing instrument Draw hexagon bolts Projected representative lines Design the view Draw the views Safety Precautions e Avoid using damaged drawing board e Avoid using damaged T set 175 DUTY 2 DRAW MACHINE ELEMENT Time 3 0 hrs 2 3 Draw Gear Drawings Exercise 0 0 hrs Demo 3 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Prepare a drawing sheet Determine the size of drawing Scaled and mark on the drawing sheet Draw a center line Representation of Mark horizontally on center line for different types of gear drawing Application of different Draw a vertical lines on every marked dots Task gear Condition Introduction Fully equipped Classroom Types of gear with Drawing board T set and drawing instrument 8 Mark from cent
311. the drawing sheet 6 7 8 Erase all projection lines Standards 9 1 Projected representative lines Design the view Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions 182 DUTY 5 SKETCH FREE HAND DRAWING Time 6 0 hrs 5 1 Construct Workshop Drawing from Sample Real Object Exercise 6 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition Prepare a drawing sheet Obtain the sample or real object Determine the view in which all Fully equipped Classroom with Drawing board and drawing instrument dimensions can be represent Construct necessary views Section the view if it necessary Task Hatch the lines on sectional area Erase the projection lines drawn Represent the dimensions with symbol Construct workshop drawing from sample real object require 10 Give darkness for necessary lines 11 Clean up the drawing sheet Standards Projected representative lines Design the view Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions e Refer the safety precautions of draw three view drawing BIBLIOGRAPHY SN Name Author Publication 1 Engineering Drawing P
312. the sheet between the beading dies of the machine 11 Clam the sheet in the die of machine 12 Roll the dies of machine with the help of handle 13 Straightening the work piece 14 Check dimensions of the completed job 15 Punch the roll no on work piece 16 Store the work piece and tools with given drawing e Tolerances of dimensions are within the 0 5 mm Tools and Equipments Steel rule marking scriber try square snips hardies steel hammer Mallet Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Beading machine and dies Materials GI Sheet Safety e Take care of marked lines folds must not be collecting together e Aware from clamping the finger by machine jaw e To avoid damage on surface of sheet insert a protecting jaw of aluminum or vice jaw cover e The mark for beading should be between the dies of machine e Avoid over tightening of dies which may tear sheet e Beads first the inside circle and finish the outside circle if it is required 114 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 5 hrs Task 12 Perform Round Beading Theory 1 hr Practical 4 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain the work piece drawing Condition Given e Introduction 2 Read drawing thoroughly e Well equipped workshop beading 3 Obtain the metal sheet of required with set of hand toolsin e Purpose of be
313. thout filler rod Exercise 16 hrs Demo 2 0 hrs Steps Terminal Performance Related knowledge Objective Obtain instructions Obtain work piece material MS Sheet Condition Set up welding equipment and nozzle Fully equipped workshop gt Procedure for running a Adjust pressure on regulator suitably with Gas welding line of fusion or puddling Clean up the surface of work piece equipments with different without a filler rod material sizes of nozzles Light the torch and adjust till neutral flame is obtained Hold the torch on the work piece at an Tasks Backfire and flashback angle of 60 Maintain the inner core of the flame should be about 3 to 5 mm above the metal surface Standards 9 Move the torch in a semi circle of about 5 mm radius Obtain neutral flame 10 Form a puddle of molten metal 11 Maintain the depth of the puddle as much as the thickness of the work piece Play fusion wave on 12 Advance the torch slowly along the melting zone required line with semicircular oat movements Maintain the depth of the 13 Let the molten metal left behind solidifies puddle in the form of nipples Produce uniform width 14 Repeat till lines of beads of uniform width and pattern penetration and pattern are produce Position and motion of the torch Run fusion without filler rod Hold gas welding torch Safety Precautions e Maintain a consistent travel speed to prevent burn th
314. ti meter Advantage of using Multi meter Handle and care of Multi meter Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cable or wire to disconnect the plug e Never place bare wire seen on plugs and sockets 262 Duty 3 REPAIR ELECTRICAL WIRING Time 6 0 hrs 3 1 Repair one bulb control by one way switch Exercise 5 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Obtain instruction layout diagram 2 Prepare wiring diagram Obtain electrical accessories as per diagram Mark the layout on the board as per diagram Task Introduction of one bulb Full ipped Electrical Ury equppe CEEA control by one way switch workshop with Multi meter Prepare the auxiliary accessories as per diagram measurement e Repair one bulb control by Install the auxiliary accessories on the one way switch board Lay wire according to the wiring diagram Connect all electrical accessories according Aeon Hasta er e Bulb should be glow Clean and store the electrical instrument Connection should be tight used in safe and sound place Sid no baked wire sen Standards Safety Precautions e Handle all electrical apparatus and equipment carefully e Replace broken switches and plugs immediately as and when seen e Never pulls the flexible cab
315. to avoid breading of drill Use cleaning brush to clean out the chips 32 Duty 4 PERFORM DRILLING Task 2 Countersink a hole Time 4 hrs Theory 1 hrs Practical 3 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain workshop drawing Condition Given e Introduction to 2 Read drawing thoroughly e Well equipped workshop countersink 3 Obtain previously drilled w p with set of hand toolsin e Types of countersink material tool box e Importance of 4 Obtain countersink as per the e Drawing instruction and countersinking required size work piece e Safety 5 Mount the same size of twist drill on drill spindle on drill chuck 6 Clamp the w p in drill vice or hold by hand placing at the m c table 7 Align the centre of m c spindle with the drilled hole to cut uniform angle 8 Change countersink on drill machine chuck 9 Set the RPM 10 Start machine 11 Check the alignment giving feed by hand 12 Re align if necessary Tasks What 13 Give feed as per depth required Countersink a hole 14 Stop the machine 15 Remove the work piece from vice 16 Chamfer De burr if necessary 17 Check the final measurement 24 Clean oil and chips Standard How well 25 Punch the roll no on work piece e Countersinked work 26 Oil the surface of the work piece piece should be match 27 Store the work piece and tools with given check list Tolerances dimensions the 0 1 mm
316. truction and work piece Tasks What Grind Center Punch Standard How well e Center punch should be match with given drawing e Tolerances of dimensions are within the limit provided e Introduction of center punch e Uses of Center punch e Procedure of grinding center punch e Introduction of off hand grinding e Type of grinding wheel e Material Component of grinding wheel Tools and Equipments Bench or Pedestrian grinding machine Safety goggles Bevel protractor or grinding gauge Blunt centre punch steel hammer Oil can Number punch Bench cleaning brush Dust pan Finishing file Materials Blunt center punch Oil Safety Make sure the grinding wheel guards are in place Always wear safety goggles Avoid working on grinding wheels which are loaded or glazed It is dangerous to working cracked or improperly balanced wheels Adjust the tool rest as close to the wheels as possible The maximum recommended gap is 2mm Small jobs should be held with pliers or other suitable tools Never holds jobs with cotton waste or similar materials Use gloves while grinding heavy jobs Avoid grinding on the side of the grinding wheels 36 Duty 5 PERFORM OFF HAND GRINDING Time 4 hrs Task 2 Grind Flat Chisel Theory 1 0 hrs Practical 3 hrs Steps Terminal performance Related Technical P objectives Knowledge Ea 9 10 11 12 13 14 15 16 17 18
317. ts as with maintenance tools and required materials Re check the errors Run the machine Task Restore all remaining materials A Repair machine Standards Machine is repaired Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 257 Electrical Repair and Maintenance Duty 1 INTERPRET ELECTRICAL SYMBOLS AND DRAWINGS Time 3 0 hrs 1 1 Interpret Schematic Diagram Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge Obtain the instruction Condition Prepare the drawing instruments Introductions of Prepare the drawing sheet Fully equipped Drawing electrical symbols Draw a schematic diagram of one bulb control classroom with drawing Electrical by one way switch instrument schematic wiring Wipe off unnecessary drawing lines and layout Submit the drawing to instructor for Task evaluation E Interpret Schematic Diagram Standards Schematic drawings should be followed Simple diagram of one bulb control by one way switch should be drawn as per given drawing Safety Precautions e Follow the safety precautions of Technical drawing subject 258 Duty 1 INTERPRET ELECTRICAL SYMBOLS AND DRAWINGS Time 3 0 hrs 1 2 Interpret Layout Diagram Exercise 2 0 hrs Demo 1 0 hrs Objective Knowledge 1 Obtain the instruction Condition 2 Obtain the layout diagram Introductions of 3 Prepare electrical accessories as per layo
318. ttitudes related to the field of mechanical engineering This curriculum focuses on basic mechanical skills and knowledge related to mechanical engineering to be used in related mechanical workshop and industries Aims e To produce competent lower level workforce in the field of mechanical engineering who will be able to provide services in different related plants and industries e To produce competent workforce who will get an opportunity to be self or wage employed in the related national and international market Objectives After the completion of the training program the graduates will be able to Perform basic mechanical works carried out in mechanical workshops Perform basic computer applications Perform mechanical drawings drafting Design and perform sheet metal steel and aluminum fabrications Operate lathe milling and shaping machines Repair and maintain mechanical devices Course Description This curriculum includes skills and knowledge related to the core subjects like applied English mathematics and Nepali as well as disciplinary subjects like Bench work Engineering drawing lathe operation material science sheet metal welding technology computer aided drafting milling and shaping operation structural fabrication and repair and maintenance This course also imparts with computer application and entrepreneurship development This course also includes on the job training OJT so as to provide
319. tware down menus screen icons command line and dialogue boxes Modify display Introduce and arrange toolbar Managing unit limit Start organize and save file Explain how to start drawing from scratch using wizard and using and creating a template 2 Setup a Drawing file 0 25 0 5 Describe setting preferences units angle direction area Manage toolbar Standard tool bar Draw tool bar 3 A MOS 0 25 0 5 Dimensioning tool bar Other Sub total 1 50 2 00 Module 3 Construct 2 D drawing using CAD Software Time hrs S N Task Statements Related Technical Knowledge gt Different system Relative Cartesian and absolute coordinate system l Start and end point of a line Draw Des Different methods of drawing a oe Ed line in CAD Options available in drawing line in CAD Undo Close Corner points first and other 2 Options available in drawing Draw rectangle rectangle chamfer fillet 0 25 0 50 Chamfer distance Fillet radius 161 S N Task Statements Related Technical Knowledge Time hrs T P Draw arc Identify arc among various types of geometric shapes Describe different options for drawing arc 3 points method Start Center method Start End method Center Start method 0 25 0 75 Draw circle Describe different options for drawing arc Center Radius method Center Diameter method 2P method 3P method Tan Tan Radi
320. ty 6 DRAW SECTIONAL VIEWS Time 10 0 hrs 6 1 Draw Full Section Views Exercise 8 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board Condition 2 Prepare a drawing sheet Importance of drawing eae sde Os Fully equipped Classroom Determine the projection view in which with Drawing board T set in section maximum sizes can be figure out Types of sectional views Scaled and mark on the drawing sheet Construct the view Draw the sectional line based on center line Task and drawing instrument and name it Construct a sectional view Draw visible outlines and edges with continuous thick line Draw hidden outlines and edges if any Standards 10 Draw hatching lines on cutting surface eer arte 11 Erase projection lines if draw it 12 Give darkness for necessary lines 13 Clean up the drawing sheet Draw full section views e Line thickness and angle of hatching line should be according to criteria Maintained symmetry Safety Precautions 78 Duty 6 DRAW SECTIONAL VIEWS 6 2 Draw Half Section Views Time 4 0 hrs Exercise 4 0 hrs Demo 0 0 hrs Steps Terminal Performance Related Technical Objective Knowledge Set paper in drawing board 2 Prepare a drawing sheet Determine the projection view in which maximum sizes can be figure out Scaled and mark on the drawing sheet Construct the view Draw the sectio
321. ty and dimension obtain given drawing 17 Punch the roll no on work piece o of 18 Oil the surface of the work piece A ROBin 19 Store the work piece and tools haan O 20 Clean the vice and work shop Tools and Equipments Hand Hacksaw frame Hacksaw blade steel rule marking scriber steel hammer flat anvil Chisels dot center punch Oil can Number punch Bench cleaning brush File brush Dust pan Triangular file Finishing file Materials MS Flat or MS Square bar Oil Safety 1 While chipping remove bangles and wrist watches 2 Wear safety goggles 3 The chisel head must be free from mushroom formation 4 While chipping look at the cutting edge of the chisel and not at the head of the chisel 5 Wipe off oily substances if any from the face of the hammer 27 Duty 3 PERFORM CUTTING Task 3 Chisel grooved surface Time 12 hrs Theory 1 hrs Practical 11 hrs Steps Terminal performance Related Technical objectives Knowledge 1 Obtain drawing Condition Given Pee eee wenn ee 2 Read drawing thoroughly e Well equipped workshop anid its types 3 Obtain work piece material with set of hand tools in nr 4 Obtain Cross cut chisel Concave chisel tool box chipping Height gauge Center punch Steel rule e Drawing instruction and Use ofchisels marking scriber Center punch Steel work piece Procedure f e oe on groove 5 Prepare rectangular block as per drawing refer
322. uch depth may colour the tip and may cause short hardness e Any damage to the grinding wheel if noticed should be reported to the instructor e When switching on the grinding machine stand aside until the wheel reaches full speed 202 Duty 4 PERFORM OFF HAND GRINDING Time 5 0 hrs 4 2 Grind Facing Corner Tool in HSS Bit Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Obtain Bench or Pedestrian grinding Condition machine Obtain HSS tool bits Fully equipped workshop Importance of cutting Obtain Safety goggles Bevel protractor or with Bench or Pedestrian geometry of lathe tools grinding gauge grinding machine Safety Dress the wheel if necessary goggles HSS Tool bits Too angle of facing and Set up tool rest if necessary Bevel protractor or Angle corner tool Identify the shape of tool to be grind gauge Identify the angles of tool to be grind Process of re sharpening Wear safety goggles Tasks the facing and corner Run the machine tool Hold HSS tool left hand in between the Grind facing corner tool in thumb fore and the middle finger so that HSS bit Wheel dressing process front clearance and first cut shape of the tool to be produce Standards Rest the left finger amp tool on the tool rest All the angel should be as Apply a slight forward motion Move the tool across full face of the wheel with the help of right hand Cutting tip should be Dip frequently on
323. uipped workshop with workshop drawing of step block HSS tool parallel blocks and Shaping machine Tasks Manufacture a step block Standards e Produced step block is as per given dimension and within tolerance in workshop drawing Safety Precaution Follow the same safety precaution of task produce 90 Right angle corner step surface BIBLIOGRAPHY SN Name Author Publication 1 Fitter trade Practical CIMI Madras 2 Mechanical engineering ILO learning element 3 All about MACHINE TOOLS Heinrich Gerling 4 Elementary Metal Course BBE Training Section I 5 Mechanical Engineering ILO LEARNING Milling ELEMENT 6 Milling Operation Overseas Vocational WORKSHOP MANUAL of Training Association Japan 245 Repair amp Maintenance Total 156 hrs Class week 4 hrs Course Stage Duties and Tasks Time A Mechanical Maintenance Demo Practical 1 Preventive Maintenance 5 8 1 1 Schedule maintenance plan 1 2 1 2 Manage stock spare components 1 2 1 3 Apply lubricants and lubrication 1 2 1 4 Maintain history card and machine records 2 2 2 Breakdown Maintenance 8 20 2 1 Diagnose find faults 1 2 2 2 Replace change gear 1 2 2 3 Adjust replace V and Flat belts 1 2 2 4 Overhaul gear box 2 10 2 5 Align Lathe
324. uminum or vice jaw cover The mark for beading should be between the dies of machine Avoid over tightening of dies which may tear sheet 115 Duty PERFORM FASTENING HEMING AND WIRE EDGING Time 11 hrs Task 13 Perform Bottom Flashing Theory 1 hr Practical 10 hrs Terminal performance Related Technical Steps ee objectives Knowledge 1 Obtain the work piece drawing Condition Given e Introduction 2 Read drawing thoroughly e Well equipped workshop bottom flashing 3 Obtain the metal sheet of required with set of hand tools in e Process of flashing size and required sheet metal tool box tools e Drawing instruction and 4 Obtain an instruction drawing work piece 2 Cut the sheet metal on the squaring shears from stock material 3 Straighten and Deburr the sheet metal Tasks What 5 Lay out the center by marking the Perform bottom flashing sheet metal piece with diagonal lines 6 Punched the centers by center punch 7 Lay out the pattern for the bottom on Standard How well the metal e Bottom flash should be 8 Lay out the allowance for the burred match with given edge drawing 9 Cut out the bottom with combination Tolerances of ee dimensions are within 10 Deburr the edge on the bottom with a the 0 5 mm mallet 11 Place the bottom in the cylinder and tack it in place with solder 12 Solder the seam on the inside of the job 13 Check the dimensions of the completed job 14 Punch the rol
325. un on hanger after welding e Keep the workplace dry 328 Duty 2 PERFORM FLAT POSITION WELDING Time 10 hrs 2 2 Weld butt joint in Flat position Exercise 10 hrs Demo hrs Steps Terminal Performance Related Objective Knowledge Refer and follow of the steps of set up welding equipment MIG from 1 to 3 Condition Tack weld the materials at both ends Fully equipped workshop Introduction to welding witi pon gotgap with MIG welding DC wave of MIG Welding Refer and follow the steps of surface rectifier MIG filler metal weld in flat position from 2 to 8 wire and accessories Procedure of deposition of Restore the tools and equipments MIG welding beads Task without filler rod Clean the working area Weld butt joint in flat position Standards Transverse welding wave in MIG welding Procedure of deposition of MIG welding straight beads in Flat position Safety Precautions e Avoid using welding gun with broken handle e Always check the connection of Holder Shield and wire end e Avoid using damp MIG wire e Use cutting pliers to cut fusion tipped at wire end e Keep away the inflammable material e Always place the gun on hanger after welding e Keep the workplace dry 329 Duty 2 PERFORM FLAT POSITION WELDING Time 13 hrs 2 3 Weld lap joint in Flat position Exercise 12 hrs Demo 1 0 hrs Objective Knowledge Refer and follow of the steps of set up welding equipment
326. uration of and drawing instrument A Draw a reference vertical line leaving the Steel windows left border margin and horizontal line on bottom information column Task 5 Sketch out the rough design of steel windows with dimensions in extra sheet Calculate the Scale of drawing to be drawn Draw the supporting lines Draw steel windows Darken all objective lines 2 Represent the dimensions with symbol Draw the supporting lines require 13 Give darkness for necessary lines 14 Clean up the drawing sheet 6 7 8 Erase all projection lines Standards 9 1 Projected representative lines Design the view Draw the views Maintain the uniformity of line thickness Maintain the line joints Maintain the neatness and cleanliness and lines Safety Precautions 180 DUTY 4 DRAW STEEL FABRICATION Time 5 0 hrs 4 2 Draw Steel Stairs Exercise 4 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Knowledge Objective Set paper in drawing board Condition 2 Prepare a drawing sheet Fully equipped Classroom Measurement obtain Determine the length breadth and height of with Drawing board T set Basic configuration of the box to be develop SE i Steel Stairs and drawing instrument Draw a reference vertical line leaving the left border margin and horizontal line on bottom information column Task Sketch out the rough design of steel Stairs with dimensions in extra sheet
327. ure that the clamps clear the area where the key way is to be machined Always debur the corners of machined surface before taking measurement Make sure that the contact faces keys and slots are clean and free form burrs It is safe to drill slot size at the starting point before milling keyways Always check the rotating direction before taking cut Add the radius of the cutter diameter when setting the position and milling longitudinal Lock the table as far as possible before taking cut 233 Duty 7 MILL KEY WAYS Time 6 hrs 7 2 Mill blind Key way in a Round W p Exercise 5hrs Demo 1 hrs Steps Terminal Performance Related Knowledge Objective 1 Refer and follow the steps of Mill end Key way up to step 17 2 Lower the table 3 Move table distance for starting of Key way 4 Change the Centro fix to Center drill 5 Make a center drill on starting spot 6 7 8 9 Condition Vee Block setting on Fully equipped workshop with work table Universal and Vertical Milling machine Position to bring the cutter at the center of Check the distance Tasks round work piece Change drill bit of key width size Drill a blank hole as key depth Change Key way cutter 10 Start machine applying depth maintain 11 Feed the table as it clamped on table Standards 12 Stope and measure the manufactured key Sooty way 13 Deburr the edges of the keyways 14 Check the depth and length of the keyways Mill Bli
328. us method Tan Tan Tan method 0 25 0 50 Draw polygon Describe different options for drawing polygon center edge 0 25 0 50 Manage lines Line properties Line weight Line color Line loading 0 25 0 50 Draw an isometric drawing Concept Isometric snap and rectangular snap Setting of isometric snap 0 50 1 00 Draw ellipse Ellipse in rectangular snap e Center Radius method Center Diameter method Ellipse in isometric snap 0 50 0 75 Sub total 2 00 4 00 Module 4 Edit drawing using CAD Software S N Task Statements Related Technical Knowledge Time hrs T P Relocate object using Move command Different methods of selecting objects for editing such as window crossing fence all e Base point Second point of displacement 0 25 0 50 Relocate object using rotate command Define rotation angle Explain Reference Point 0 25 0 50 162 Time hrs S N Task Statements Related Technical Knowledge z Differentiate Multiple copy and E Single copy 3 Duplicate object using Copy Explain the procedure for 0 25 0 50 command ae A duplicating object using copy command State the purpose of Mirror Explain First point and Second 4 Duplicate object using Mirror point of mirror line 0 25 1 00 command Second point of mirror line Describe optio
329. ustment knob nut or bolt 11 Turn on switch the machine Standards 12 Keep all tools and equipment on their specified place Belt is replaced and re adjusted Belt transmission ratio is true Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 253 Duty 2 BREAKDOWN MAINTENANCE Time 12 hrs 2 4 Overhaul Gear box Exercise 10 hrs Demo 2 0 hrs Objective Knowledge Obtain instructional manual Condition Read the pages of Gear box Introduction types Confirm the gear box of a machine Fully equipped Machining shop and application of Collect the required repair tools with maintenance tools and gear transmission Switch off the machine and de fuse if possible materials Chart of different Drain out the gear oil model of gear box Disconnect gear connecting shaft Task as manual Remove plug screw to drain out all gear out Safety knowledge Check the lever connection for reconfirming Overhaul Gear box of machine the gear positioning components used in 10 Sketch a drawing of a gear and shaft position gear boxes 11 Remove bearings seals circlip and pin from Standards the shaft connection CONDANNE Gear oil is not leaking 12 Remove all gears and bathed on kerosene oil 13 Clean up all gears shaft and machine components in kerosene oil and make dry 14 Checks the condition of all dismantled Gear lever turned smoothly Variable spe
330. ut Fully equipped Electrical Layout diagram diagram workshop with different Introduction of electrical accessories electrical accessories Task Interpret Layout Diagram Standards Layout diagram should be interpreted Different electrical accessories should be identified Safety Precautions 259 Duty 1 INTERPRET ELECTRICAL SYMBOLS AND DRAWINGS Time 3 0 hrs 1 3 Interpret Wiring Diagram Exercise 2 0 hrs Demo 1 0 hrs Steps Terminal Performance Related Objective Knowledge 1 Obtain the instruction Condition 2 Obtain the Wiring diagram Introductions of 3 P lectrical A e Fully equipped Electrical irine di aan electrical accessories as per wiring workshop with different wiring diagram electrical accessories Use of electrical accessories Task Interpret Wiring Diagram Standards Wiring diagram should be interpreted Different electrical accessories should be used Safety Precautions e Carefully handle electrical accessories 260 Duty 1 INTERPRET ELECTRICAL SYMBOLS AND DRAWINGS Time 4 0 hrs 1 4 Interpret Power amp Control Diagram Exercise 2 0 hrs Demo 2 0 hrs Objective Knowledge 1 Obtain the instruction Condition 2 Obtain the Plan diagram Introductions plan 3 Prepare motor control electrical accessories as Fully equipped workshop with diagram per plan diagram Vertical Horizontal and Prepare power and Universal Milling machine contro
331. versal and Vertical Milling work table machine Position to bring the cutter at the center of round work piece Measurement of key Set the machine controls in a Round Workpiece ways Stick a piece of thin wet paper on the periphery of the workpiece Process of milling a 10 Start the spindle move the table very slowly Standards key ways in a round until the cutter just removes the paper workpiece 11 Set the cross feed scale to zero Produced Key ways is checked as 12 Lower the table until the cutter clears w p given measurement of groove 13 Move the table to bring the cutter clear of the end of the workpiece 14 Raise the table so that the cutter is above the level of the top of the workpiece 15 Move the table so that the center of the cutter is in line with the center of the workpiece 16 Place a piece of paper at the end of the w p 17 Repeat step no 11 using longitudinal feed 18 Set the scale to zero 19 Lower the table so that cutter is above the starting position for the key way 20 Raise table until the cutter just touches w p 21 Set the vertical scale to zero 0 22 Move along and set the depth of cut using vertical hand feed 23 Mill away to the required length 24 Stop the spindle and lower the table until the cutter clear from the work 25 Deburr the edges amp check the keyways Safety Precautions Vee blocks should be such that the sides of workpiece contacts the vee at about the center Make s
332. w a wall chart with maintenance tools and lubrication Collect all material as required materials Properties and Follow the instruction at very first time application of Clean the working surroundings Task lubricants Restore all remaining materials aha Read user s ADO Bu n manual Sample lubrication chart of a machine Apply lubricants and lubrication Standards Lubricants should be applied as per lubrication point Lubrication chart of machine should be followed User s manual should be referred Safety Precautions e Follow the safety of Occupational Safety and Health Administration OSHA 249 Duty 1 PREVENTIVE MAINTENANCE Time 4 0 hrs 1 4 Maintain History card and Machine record Exercise 2 0 hrs Demo 2 0 hrs Objective Knowledge Obtain instructional manual Condition Read the pages of maintenance instructions Introduction of List down with maintenance intervals Fully equipped Machining shop history card Prepare a A4 size History card Log sheet with maintenance tools and Prepare history Collect all material as required materials card Follow the instruction at very first time Important of Clean the working surroundings Task keeping records of Restore all remaining materials ES machines 1 2 3 4 5 6 7 8 Maintain History card and machine record Standards History card should be prepared Machine record should be maintained
333. with Try square Re align if necessary Turn the tap handle in a clockwise direction applying a slight downward pressure at the same time Apply pressure evenly at both ends of the tap handle Ream the hole through Ensure that the taper lead length of the reamer comes out well and clear from the bottom of the work Remove the reamer with an upward pull until the reamer clear the hole Clean the hole Check the accuracy with the required cylindrical pins Check the final measurement Clean oil and chips 23 24 25 Punch the roll no on work piece Oil the surface of the work piece Store the work piece and tools Condition Given Well equipped workshop with set of hand tools in tool box Drawing instruction and work piece Tasks What Ream Drilled Hole Using Hand Reamers Standard How well e Reaming work piece should be match with given drawing e Tolerances according to the basic hole system Introduction of reamer Determine the drill size for reamer Procedure of using hand reamer Tools and Equipments countersink 60 and 90 Drill m c with drill chuck key and drill bits centre punch steel hammer Reamer Countersink Drill vice Oil can Number punch Bench cleaning brush File brush Dust pan Finishing file Materials MS Flat Oil Safety Turn the tap handles steadily and slowly maintaining the downward pressure Avoid turning the reverse direction for it wi
334. xplain the procedures to insert Text Pictures Objects Sound and Charts Graphs 0 50 2 00 19 Animate the content of slide Define animation Explain the procedure to apply animation to the content of slide Differentiate between transition and animation 0 50 1 00 20 Perform On screen Presentation Explain the procedure to perform on screen presentation State the precautions to be taken while connecting computer with Multimedia Projector for presentation 0 50 2 00 Sub total 2 50 6 00 Module 5 Maintain Database Management System using Database Package S N Task Statements Related Technical Knowledge Time hrs T P 21 Create Database Table Define Database Explain the purpose of Database Management System Interpret the interface of Database Package including tools menu Differentiate Table Query Form and Report Enlist the procedure to create database table 1 00 2 00 22 Create Query Explain the procedure to create query 0 50 1 00 23 Generate report State the procedure to generate report Explain the procedure to print report 0 50 1 00 Sub total 2 00 4 00 56 Module 6 Manage e mail internets Time hrs S N Task Statements Related Technical Knowledge 7 5 Differentiate among web server web browser w
335. y of gear blank complete Give further depth of cut Repeat taking cut same as step 19 Stop the machine remove workpiece Check the final measurement Safety Precautions e Refer and follow the task Mill Hexagonal shape in round workpiece 238 B Shaper Machine Operation Duty 1 SET UP MACHINE amp HOLDING DEVICES Time 3 0 hrs 1 1 Set up Shaper Vice on Machine Table Exercise 2 0 hrs Demo 1 0 hrs St Terminal Performance Related Knowledge eps ae Objective 1 Obtain shaper vice 2 Obtain T bolts nuts and washer Condition e Introduction of 3 Obtain large size parallel block shaper machine 4 Obtain dial test indicator with magnetic Fully equipped workshop with lt Introduction of dial stand Shaper vice T bolts Nuts and tet indicar 5 Clean machine vice and machine table Washer amp Shaping machine along tee slot thoroughly e Use and care of 6 Apply thin film of oil at the bottom of dial test indicator machine vice l l Tasks a Peceiu ot i ee machine a le un ee Sd up shaper vice on machine setting a Shaper positioning the jaw in table ran machos lengthwise parallel to the ram fable movement 8 Tighten lightly all nuts i 9 Hold dial test indicator on magnetic Standards stand then magnetized on tool head 10 Clamp the parallel block between the Vice jaw is parallel to ram vice projecting more than 1 2 of the movement width RV Tighten the Shaper vice with all 11 Bring the tab
336. ylindrical T joint development 2 Draw the Machine Elements 2 1 Draw hexagon nuts 2 2 2 2 Draw hexagon bolts 2 2 2 3 Draw gear drawings 3 Draw Assembly Views 3 1 Copy simple assembly views 2 10 3 2 Draw detail from assembly view 10 3 3 Draw assembly view from detail drawings 8 Draw Steel Fabrication 4 1 Draw Steel windows 1 4 4 2 Draw Steel Stairs 1 4 4 3 Draw Roof Truss it 6 Sketch Freehand Drawings 5 1 Sketch workshop drawing from sample 6 real object Sub Total 14 64 Total 78 167 DUTY 1 DEVELOPMENT OF SHEET METAL Time 4 0 hrs 1 1 Draw Square Box Development Exercise 2 0 hrs Demo 2 0 hrs Steps Terminal Performance Related Knowledge Objective Condition Types of sheet metal development Parallel line and Radial line Sheet metal development Set paper in drawing board 2 Prepare a drawing sheet Determine the length breadth and height of the box to be develop Fully equipped Classroom with Drawing board T set and drawing instrument Draw a reference vertical line leaving the left border margin and horizontal line on bottom information column Calculate the total area of the box including edge folding margin Draw the area Divide the area from center for length breadth and height Mark and draw the line in based folding line for excess folding margin outside the box area on all 4 side Mark and draw the line for edge folding margin on 4 edges 10 Mark and draw all co

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