Semester 1:
Professional Knowledge (Theory)
1. Safety and Environment:
- Importance of workplace safety.
- Personal protective equipment (PPE).
- Safety signs, emergency exits, and fire extinguishers.
- First aid procedures in case of burns, cuts, and electric shocks.
2. Introduction to Hand Tools:
Types of hand tools (hammers, chisels, hacksaws, files).
Proper handling and maintenance of tools.
3. Measuring Instruments:
Vernier calipers, micrometers, steel rules, and gauges.
Units of measurement (metric and imperial).
Measurement techniques and accuracy.
4. Basic Fitting Operations:
Marking and layout techniques using scribers, punches, and surface plates.
Filing, sawing, chiseling, and grinding to size and shape.
Drilling, reaming, and tapping of metals.
Concepts of limits, fits, and tolerances.
5. Engineering Materials:
Properties of materials: ferrous (steel, iron) and non-ferrous (aluminum, brass, copper).
Introduction to heat treatment processes (annealing, hardening, tempering).
6. Fasteners and Threads:
Types of screws, bolts, nuts, and rivets.
Thread types (metric, imperial, BSP).
Tools for threading and thread gauges.
Trade Practical
Safety Practices:
Identification and use of fire extinguishers.
Workshop housekeeping and safe disposal of waste.
Hand Tools:
Practice in using hammers, chisels, and files for fitting operations.
Demonstration and practice of sawing, filing, and finishing.
Measurement:
Measurement of parts using micrometers and vernier calipers.
Practical exercises to measure dimensions accurately.
Fitting Operations:
Marking out workpieces using scribers, punches, and surface gauges.
Practice on drilling, tapping, and filing to precise dimensions.
Thread Cutting:
External and internal thread cutting using taps and dies.
Semester 2:
Professional Knowledge (Theory)
1. Advanced Fitting Operations:
Precision filing and fitting.
Assembling and dismantling of mechanical components.
Practice on precise limits, fits, and tolerances.
2. Welding Techniques:
Introduction to arc welding, gas welding, and brazing.
Types of welding joints: lap, butt, corner, and T-joints.
Safety precautions for welding.
3. Sheet Metal Work:
Introduction to sheet metals, gauges, and types.
Operations like bending, cutting, and shearing.
Tools for sheet metal work: snips, shears, bending machines.
4. Heat Treatment of Metals:
Principles of annealing, hardening, tempering.
Testing of materials before and after heat treatment.
5. Bearing and Lubrication:
Types of bearings: ball, roller, bush bearings.
Lubrication methods and maintenance of bearings.
Trade Practical
Fitting and Filing:
Practical fitting and filing to match precise tolerances.
Filing angular and curved surfaces.
Welding:
Arc welding and gas welding of simple joints.
Brazing and soldering metal components.
Sheet Metal Work:
Cutting and forming sheet metal to desired shapes.
Practice in bending, forming, and riveting sheet metals.
Heat Treatment:
Practical demonstrations on annealing, hardening, and tempering.
Testing hardness before and after heat treatment.
Bearing Assembly:
Dismantling, fitting, and lubricating bearings.
Inspection and maintenance of bearings in machines.
Semester 3:
Professional Knowledge (Theory)
1. Lathe Operations:
Introduction to lathe machines.
Operations: turning, facing, taper turning, and threading.
Selection and grinding of lathe cutting tools.
2. Drilling Machine Operations:
Types of drilling machines and drill bits.
Operations: drilling, counterboring, countersinking, and reaming.
3. Milling Machine Operations:
Introduction to milling machines and cutters.
Operations: plain milling, face milling, angular milling.
4. Shaping and Slotting Machines:
Introduction to shaping and slotting machines.
Operations: external and internal shaping and slotting.
5. Power Transmission:
Introduction to belt drives, chain drives, and gear drives.
Concepts of couplings, keys, and clutches.
Trade Practical
Lathe Operations:
Practical exercises in turning, facing, taper turning, and threading.
Practice on setting cutting tools and adjusting speeds.
Drilling Machine Operations:
Drilling, reaming, and boring workpieces.
Practice on precision drilling.
Milling Machine Operations:
Milling operations on flat and angled surfaces.
Cutting keyways, splines, and gears.
Shaping and Slotting:
Practical shaping and slotting of metal workpieces.
External and internal slot cutting.
Assembly and Dismantling of Power Transmission:
Fitting and dismantling of belt drives, chain drives, and gear drives.
Practice in coupling and clutch alignment.
Semester 4:
Professional Knowledge (Theory)
1. Precision Instruments:
Usage of dial gauges, height gauges, sine bars, and slip gauges.
Measurement and inspection techniques using precision instruments.
2. Introduction to CNC Machines:
Basics of CNC (Computer Numerical Control) machines.
Introduction to CNC programming and operations on CNC lathe and milling machines.
3. Maintenance of Machines:
Preventive and breakdown maintenance of mechanical systems.
Alignment, leveling, and lubrication of machines.
4. Hydraulics and Pneumatics:
Introduction to hydraulic and pneumatic systems.
Components: pumps, valves, cylinders, and actuators.
5. Project Work and Industrial Visits:
Working on industrial projects involving fitting, assembly, and maintenance.
Visits to industries for practical exposure to machine operations.
Trade Practical
Precision Measurement:
Using height gauges, slip gauges, and dial gauges for inspection.
Practice in measuring complex components to precise tolerances.
CNC Operations:
Basic CNC lathe and CNC milling operations.
Programming and execution of simple parts on CNC machines.
Machine Maintenance:
Practice on preventive maintenance of lathes, milling machines, and drilling machines.
Machine alignment and leveling exercises.
Hydraulics and Pneumatics:
Practical exercises in assembling hydraulic and pneumatic circuits.
Operation and troubleshooting of hydraulic and pneumatic systems.
Final Project Work:
Hands-on project related to fitting and machine assembly.
Practical exposure to industry-standard practices through visits.