Post Diploma in Computer Aided Tool Design

 

 

1)      Introduction to the Center

The last decade has witnessed revolutionary changes in industry and business especially in tool & Die making. CNC based machines have replaced all the conventional machines in order to meet the speed, accuracy and intricacy. Latest advances have taken place in designing and manufacturing of the mould and dies. Conventional drafting board is replaced by various design software/packages through which we can develop the moulds and dies with ease and accuracy. Unlike making number of corrections in the mould, today we are having various simulation software like mould flow and rapid prototyping techniques by which we can analyze all features and working of the moulds before actual making of the mould thereby avoiding various correction in mould and dies. Hence, to cater to these needs of industries, Indo Danish Tool Room has been established in 1991 at Jamshedpur on bilateral agreement between Govt. of India and Govt. of Denmark. The main objective of the center is to provide consistent, reliable, quality service for Industries growth based on its trained, skilled and innovative manpower capabilities backed by the state of art Technology. 

 

Conscious of the need to upgrade the skills of the technical personnel in the industry, IDTR has launched multifarious short term courses-both regular & tailor made to meet the specific demands of the industry.

 

IDTR has been constantly striving to redesign its courses to meet the challenges of change keeping pace with global advancement in technology. 

 

 

2. ABOUT THE COURSE:     

Mechanical Engineering has been undergoing some radical changes in the recent years. To stay competitive (and remain in business), companies are being forced to shorten the time it takes to design and manufacture new products and to reduce total costs. Companies simply cannot compete in a global marketplace by continuing to use old methods.

To meet the goal of reducing the design time, many companies today are changing the method of organizing the engineering process. A parallel or concurrent process is needed where the different disciplines within an organization (such as design, analysis, manufacturing, administration, etc.) work together more closely as in integrated team.

A foundation to this is “Solid Modeling”, where the complete product geometry is modeled in a 3-D solid from in a computer instead of starting with detailed line drawing. This geometric model can then be shared by the entire design team for many different uses as mass properties calculation, interference studies, stress analysis and manufacturing planning.

 

 

3. Aims   & Objective:

  • Design and / or manufacturing of Tools and Components conforming to the desired specifications and deliver in right time.
  • To maintain high standard of training in the field of tool Engineering, CAD/CAM and other related areas.
  • To identify the scope and provide consultancy services in the field of tool Engineering and its related area to SSI units in the region.

 

 

4. Who can avail this opportunity:

Diploma in Mechanical / Production/Mould Making/ Automobile engineering or equivalent are eligible for taking admission. The company sponsored candidates will be preferred. Unemployed/Fresh Diploma holders and those final year students awaiting   result can   apply.

 

 

5. Duration:

·         6 months full time.

·         Candidates will be required to work on flexible hours. (6days a week)

 

6. Fee:   Rs. 36,000/- (To be paid   in 4 Installments)

 

                At    the    time   of     registration    -    Rs 1000/- (part of the course fee)

  • First  installments      -    Rs 9000/- (On or before starting of  course)                                               
  • Second installment    -    Rs.9000/-(On or before completion of 1.5 Month.)
  • Third installments      -    Rs .9000/-(On or  before  completion   of  3rd month)
  • Fourth installments      -    Rs .8000/-(On or  before  completion   of  4.5 month)

 

  (* Fees ones deposited will neither refundable nor transferable to another any candidate)

 

7. CAUTION MONEY

 Caution Money Rs. 1,000/- has to be deposited by the candidate, which is refundable after successful completion of the course.

 

8. HOSTEL

                Dormitory accommodation may be arranged in IDTR’s trainees Hostel subject to availability of the same. The dormitory accommodation charges will be Rs. 1000 or Rs. 1500 per month per candidate. For this candidate has to submit the total Hostel fees (i.e. month of staying) on the starting date i.e. Rs. 6,000/-. In the hostel cot, mattress & pillow will be provided. For fooding mess is available on approx. monthly charge of Rs.1550 or Rs. 1700. Mess is compulsory for hostellers.

 

 

9. How to apply

     Send the filled up application form along with attested Xerox copies of your certificates to  Manager (Training-STC) with DD of  Rs. 1000/- in favour of Indo Danish Tool Room, payable at Jamshedpur. In the event of selection   this money will be adjusted in the course fee.

 

 

10. CONTACT PERSON

         For more information or any other queries please contact Mr. M. K Gupta (Mobile no. 9431301686) during office hours on working days. (Sunday closed)

 

 

11. Course Content

(A)     AutoCAD

  • Introduction to computer.
  • System requirements for AutoCAD.
  • Graphics Screen of AutoCAD.
  • Menu Area Setup for drawing.
  • Creation of 2D Drawings: - Point, Line, construction line, multiline, polyline, ray, arcs, circle, rectangle, polygons, ellipse, spline, etc.
  • Modification 2D Drawing: - Fillet, chamfer, trim, mirror, scaling, stretch, copy, move, offset, array, lengthen, extend, break, join, etc.
  • Assigning of different line type to objects: - Dashed line, hidden line, center-line, dotted line, border line, gas line, tracks, zig zag, etc.
  • Transparent Overlay (Layer).
  • Tables, Text, Hatching, Gradient.
  • Block, W Block, Design Center.
  • Modeling 3D Objects: - with the help of box, cylinder, sphere, cone, torus, wedge, extrude, revolve, slice, section, interference, etc.
  • Editing 3D Objects: - with the help of union, intersect, subtract, extrude faces, rotate faces, offset faces, delete faces, move faces, imprint, shell, etc.  
  • Assign different colors to different types of object.
  • Generation of orthographic & isometric views for a 3D component with different scales.
  • Application of layers and demonstrating the same along with application of slide show.
  • Creation of 2D drawing & 3D Objects.

 

 

(C) CATIA

·         Sketch: - Introduction to Sketch mode, Constraining and its types, Animate constraining and automatic constraining, Creation of Basic Sketch Tools, Usage of Relimination Tools, Transformation Tools, 3D-Geomtery tools, Creating of Design Table, Usage of formulas, Catalog and Catalog editor.

·         Part: - Creating of different bodies, Sketch based features, Dress-up Features, Surface Based Features, Transformation Features, Boolean operations, How to use power copy and Instantiate from document.

·         Assembly: - Different types of Constrain tools like, Coincidence, Contact, Offset, Angle, Fix together, Fix, Views etc., Compute clash, Sectioning Degrees of freedom status.

·         Drawing: - Creating different views, Creating drawings, Creating Bill of Materials, Creating Annotations, Creating Dress up Features.

·         Sheet Metal: - How to create sheet metal parameters, Bends, Swept walls, unfold and fold, She pocket, Stampings, patterns, Corners etc.

·         Core and Cavity: - Importing model, creating pulling direction, creating parting surface, Transferring elements, and wire frame tools and operation tools.

·         Mould Tool Design: - How to create mould base components, Guiding Components, Locating components, Fixing components, Ejection components, Injection components, Miscellaneous components etc.,

·         Prismatic machining: - PPR, Machining operations like: - Pocketing, facing, profile countering, curve following, point to point machining, Auxiliary operations like: - Post Processing Instructions, Documentation for shop floor.

·         Surface machining: - Machining operations like: - Sweep Roughing, Roughing, Penciling,

·         Z-Level machining, Profile contouring etc., Auxiliary operations like: - Post Processing Instructions, Documentation for shop floor.

·         DMU fitting: - Sequence and actions, Simulation, animation and mechanism.

·         DMU Kinematics: - How to create new mechanism, Different types of joints, Fixed part, How to use formulas, How to simulate, compile of simulation, Replay and How to replay mechanism etc.,

 

(D) UNIGRAPHICS

·         Introduction - Introduction to CAD/CAM Software, Scope of  Unigraphics  as higher end software, Required hardware & software, High and & low end software, Commands.

·         Drafting - Creating geometry and modifying geometry, Creating dimension and Constraining

·         Modeling  - Introduction, 3D modeling, Plane creation, 3D Curve , Extruding, Revolving,  Part modification, Using history access, Surfacing, Shell, Fillet, Draft, Sweep & Through Curve, Free form feature.

·         Assembly - Introducing assembly, Part constraining and B.O.M.

·         Manufacturing - 2D & 3D Tool path generation, Post processing, Contouring, Facing, Drilling etc

 

 

(F) PRO/ENGINEER –Wildfire

  • Introduction - Introduction to Pro/E software, CAD/CAM through Pro/E, Area & advantages of Pro/E.
  • 2D Sketching - 2D Sketching tools and their uses, Practices
  • 3D Solid Modeling - Set up, Change of datum plane name, Unit Change,Mapkeys,Relations,Family Table etc.
  • Protrusions Making - Extrusion, Cut, Different type of cuts and Practices
  • Producing of Features - Round and its different Type, Chamfer and Hole features, Straight, Standard and Sketched hole features and Practices.
  • Protrusion Making - Revolve, Sweep, and Blend options, Revolve cut, Sweep cut and Practices.
  • Advance options for Modeling - Variation sec. Sweep, Swept blend, helical sweep and Practices.
  • Tweak - Draft, Offset, Dome etc.
  • Sheet metal – wall making , bending of sheets , forming operations , deform area
  • Assembly - Assembly of project by using all options like Mate, Mate offset, Orient, insert, Align etc.
  • Pro-Details - Draw set up, Creating drawings, Automatic dimensioning, Tolerance etc
  • Pro-Data - Export-import of files.

·     Pro/mechanica - Pro/Mechanica basics, Structural Analysis, Thermal Analysis and Practice.
  • Mechanism
  • Pro Manufacturing - Mould Designing, core cavity extraction, Pro-Mfg-Mill, Pro-Mfg-Turning, Post Processing.

 

(G) CNC Turning (FANUC)

 

·         Introduction to CNC Technology

·         Advantages & Disadvantages

·         NC & CNC Machine

·         Elements of CNC Machine

·         Positional Data (Absolute & Incremental Dimensioning)

·         Introduction to Programming Words

·         Functions of G- Code  & M- Code.

·         Tool Selection  & Tool Offset, Tool Nose Radius Compensation (TNRC)

·         ISO Specification for Insert, Cutting Parameters.

·         Data Input Panel & their uses

·         Canned Cycles - Roughing, Drilling, Peck drilling, etc.

·         Boring Cycle 

 

(H) CNC Milling (HAIDENHAIN ISO)

 

·         Data Input Panel & their Functions

·         Axis Definition, Main function of M – Code & G - codes

·         Dimensional Programming

·         Programming of Work piece Contour

·         Tool Offsets

·         Tool Radius Compensation & Tool Definition

·         Path Functions

·          Contour programming

  • Machining Practice: Concepts Of Operating a CNC Machine, Operating Practice on CNC XLTurn (Turning m/c)& CNC Triac (Vertical spindle Milling) Machine, Machine Homing, Work Offset, Tool Offset, Tool Changing, Profile machining etc.

 

(I) Mould Theory & Design

  • Introduction of different Plastic Material and their uses.
  • Processing of Plastic Material
  • Injection Moulding, Blow Moulding, Extrusion, Thermoforming, Compression Moulding, Transfer   Moulding.
  • Injection Mould processing & Machines of Injection Moulding.
  • Constructions of Compression Mould, Core & Cavity dimensions, Shrinkage, Tolerance, Draft of Core and Cavity.
  • Design Principles of Transfer Mould
  • -Pot Type, Plunger Type Transfer mould, Material & H. T of different Parts
  • Injection Mould Construction
  • -Two Plate, Three Plate
  • Different Parts and Function of each parts
  • Design Principles of Injection Mould-
  • -Sprue, Runner and gate design and calculations
  • Ejection System and application in design –
  • Project of Standard Mould design
  • Project of standard two Plate Mould design 

                 

(J) Press Tool Theory & Design

·         Principles of Blanking and Piercing dies.

·         -Introducing   Terminology, Basic Blanking & Piercing Operation., Description of blanking or Piercing die, Critical Stages of Shearing Action on Metal., Typical Appearance Characteristic, Cutting Force, Stripping Force, Clearance

·         Elementary Blank dies and Pierce dies- Construction

·         Bending dies.

·         -Basics of Bending, Estimating Flat Blank length, Simple “V” die for punch press operation, spring back.

·         Compound die- Principal of Operation, Construction.

·         Draw die:- Principal of Operation ,no of Strokes, Press Tool design .

·         Design Practice of Progressive die.

·         Design Practice of Compound die.

·         Design Practice of bending die.

 

 

 

 

(K) Die Casting Theory & Design

 

  • Introduction to die casting processes, gravity and pressure die casting processes such as permanent mould casting, cold chamber and hot chamber processes.
  • Introduction to forging process. Power hammer and their classification. Drop stamping drop forging and their specific use and advantages.
  • Material consideration and their selection for making dies.
  • Design & drawing practice of selected components by die casting processes.
  • Design data and drawing practice of dies for drop forging operations.  

 

(L) JIGS & FIXTURES

  • Introduction
  • Jigs & fixtures
  • Classification of drill jigs and their uses.
  • Classification and Fixtures and their uses.
  • Classification and construction of drill bushes and their application.
  • Clamping devices and their application
  • Degree of devices and their application degree of freedom and principal location (3:2:1 Location System)
  • Limit, Fit and Tolerances.
  • Recommended materials for Jigs & Fixtures.

 

(M) GDPI

·         Group discussion & personality development

                                                              

                                                                         (N) TQM

·         Total quality management