Production Technology

Model Curriculum for

B.Voc. / D. Voc.

in

Production Technology

All India Council for Technical Education

Nelson Mandela Marg, New Delhi

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1. Introduction

All India Council for Technical Education (AICTE) Ministry of HRD, Government of India has
introduced Entrepreneurship oriented Skill development courses of B.Voc. /D. Voc. /Skill
Diploma. These courses will be run by AICTE approved institutes by using available
infrastructure and facilities. In these courses the institute will conduct general education
content and sector specific skills will be imparted by Skill Knowledge Providers/ Training
Providers/ Industries.

1.1 Key Features:

Objectives

 To provide judicious mix of skills relating to a profession and appropriate

content of General Education.
 To ensure that the students have adequate knowledge and skills, so that they
are work ready at each exit point of the programme.
 To provide flexibility to the students by means of pre-defined entry and
multiple exit points.
 To integrate NSQF within the undergraduate level of higher education to
enhance employability of the students and meet industry requirements. Such
student apart from meeting the needs of local and national industry are also
expected to be equipped to become part of the global workforce.
 To provide vertical mobility to students admitted in such vocational courses.
 The certification levels will lead to Diploma/Advanced Diploma/B. Voc. Degree
in Production Technology and will be offered by respective affiliating
University/Board of Technical Education.
 Students may be awarded Level Certificate/Diploma/Advance Diploma /Degree
as out-lined in the Table below:

Award Duration after class X Corresponding NSQF level

Level 3 Certificate 1 Year 3
Level 4 Certificate 2 Year 4
Diploma 3 Year 5
Advance Diploma 4 Year 6
B.Voc. Degree 5 Year 7

2. Course Objectives

After successfully completing the vocational course, the student would have acquired
relevant appropriate and adequate technical knowledge together with the professional
skills and competencies in the field of Production Technology so that he/she is properly
equipped to take up gainful employment in this Vocation. Thus he/she should have
acquired:

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 Production Technology

A. Understanding of
(a) The relevant basic concepts and principles in basic science subjects (Physics,
Chemistry and Mathematics) so that he/she is able to understand the different
vocational subjects.
(b) The basic concepts in engineering drawing.
(c) Different manufacturing processes.
(d) The concepts, principles of working different Machine tools.
(e) Importance of Production Technology.
(f) The knowledge of Production Processes.
(g) The production environment in the industry
(h) The concepts and principles used in Mass Production.

B. Adequate Professional Skills and Competencies in

(a) Selecting the raw material for the required Production according to the end
product.
(b) Developing the devices required for mass production.
(c) Preparing the production layout according to the procedures involved in
manufacturing
(d) Locating the fault at production level due to improper process, scheduling etc. and
its rectification.

C. A Healthy and Professional Attitude so that He/ She has

(a) An analytical approach while working on a job.
(b) An open mind while locating/rectifying faults.
(c) Respect for working with his/her own hands.
(d) Respect for honesty, punctuality and truthfulness

D. NSQF compliant skills in Qualification developed by sector skill council in Capital

Goods Sector.

3. Course Structure
The course will consist of combination of practice, theory and hands on skills in the Capital
Goods Sector.
Curriculum
The curriculum in each of the years of the programme would be a suitable mix of general
education and skill development components.

Skill Development Components:

 The focus of skill development components shall be to equip students with
appropriate knowledge, practice and attitude, to become work ready. The skill
development components will be relevant to the industry as per its requirements.
 The curriculum will necessarily embed within itself, National Occupational Standards
(NOSs) of specific job roles within the industry. This would enable the students to
meet the learning outcomes specified in the NOSs.

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 The overall design of the skill development component along with the job roles
selected will be such that it leads to a comprehensive specialization in few domains.
 The curriculum will focus on work-readiness skills in each of the year of training.
 Adequate attention will be given in curriculum design to practical work, on the job
training, development of student portfolios and project work.

General Education Component:

 The general education component adheres to the normal senior secondary and
university standards. It will emphasize and offer courses which provide holistic
development. However, it will not exceed 40% of the total curriculum.
 Adequate emphasis is given to language and communication skills.
The curriculum is designed in a manner that at the end of year-3, year-4 and year-5,
students can meet below mentioned level descriptors for level 5, 6 and 7 of NSQF,
respectively:

Professional
Level Process required Professional skill Core skill Responsibility
Knowledge
Communication
written and oral
with minimum
required clarity, Under close
Person may carry Recall and
Basic facts, skill of basic supervision
put a job which may demonstrate
process and arithmetic and some
Level require limited practical skill,
principle applied algebraic responsibility
3 range of activities routine and
in trade of principles, for own work
routine and repetitive in narrow
employment personal banking, within defined
predictable range of application
basic limit
understanding of
social and natural
environment
Language to
Recall and communicate
demonstrate written or oral,
practical skill, with required
Factual
Work in familiar, routine and clarity, skill to
knowledge of Responsibility
Level predictable, routine, repetitive in basic arithmetic
field of for own work
4 situation of clear narrow range of and algebraic
knowledge or and learning
choice application, using principles, basic
study
appropriate rule understanding of
and tool, using social political and
quality concepts natural
environment

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A range of cognitive
Desired
and practical skills
mathematical skill, Responsibility for
Knowledge of facts, required to
Job that requires well understanding of own work and
principles, processes accomplish tasks and
developed skill, with social, political and learning and
Level and general solve problems by
clear choice of some skill of some
5 concepts, in selecting
procedures in familiar collecting and responsibility for
a field of work or and applying basic
context organizing other’s works and
study methods, tools
information, learning
materials
communication.
and information

Reasonably good
Demands wide in mathematical
range of specialized A range of calculation,
Responsibility
technical skill, Factual and cognitive understanding of
for own work
clarity theoretical and practical skills social, political
and learning and
Level of knowledge and knowledge in broad required to generate and reasonably
full
6 practice in broad contexts within a solutions to specific good in data
responsibility for
range of activity field of work or problems in collecting
other’s works
involving standard/ study a field of work organizing
and learning
non-standard or study information, and
practices logical
communication
Good logical and
mathematical skill
Requires a Wide range of understanding of
Wide ranging,
command of wide cognitive and social political
factual and
ranging specialized practical skills and natural Full
theoretical
Level theoretical and required to generate environment good responsibility for
knowledge in broad
7 practical skill, solutions to specific in collecting and output of group
contexts within a
involving variable problems in organizing and development
field of work or
routine and non- a field of work information,
study
routine context or study communication
and presentation
skill

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Curriculum

Level Code Educational Component Credit Marks

Theory
3.GE.01 Language – I 3 50
3.GE.02 Applied Chemistry 3 50
3.GE.03 Applied Physics 3 50
3.GE.04 Applied Mathematics-I 3 50
3 Lab/Practical
3.GP.01 Applied Chemistry Lab 1.5 50
Semester
I 3.GP.02 Applied Physics Lab 1.5 50
On-Job-Training (OJT)/Qualification Packs
Operator – Conventional Turning (CSC/Q0110)
Fitter – Fabrication (CSC/Q0303)
(Any one) 15 200
Operator – Conventional Milling (CSC/Q0108)
Assistant MMAW SMAW Welder (CSC/ Q 0202)
Theory
3.GV.01 General Foundation Course –I 3 50
3.GV.02 Basic Electricity 3 50
3.GV.03 Basic Electronics 3 50
3 3.GV.04 Applied Mathematics – II 3 50
Lab/Practical
Semester
3.VP.01 Basic Electricity – Lab 1.5 50
II
3.VP.02 Basic Electronics – Lab 1.5 50
On-Job-Training (OJT)/Qualification Packs
One more QP to be opted from the QPs mentioned in
(Any one) 15 200
Level 3 first semester
Theory
4.GV.01 Engineering Science 3 50
4.GV.02 Manufacturing Technology – I 3 50
4.GV.03 IT Tools 3 50
4 4.GE.05 Language – II 3 50
Lab/Practical
Semester 4.VP.01 Workshop Practice – I 1.5 50
I 4.VP.02 IT Tools (Practical) 1.5 50
On-Job-Training (OJT)/Qualification Packs
CNC Operator – Turning (CSC/Q0115)
Operator – Surface Grinding machines (CSC/Q0109)
(Any one) 15 200
Fitter – Mechanical Assembly (CSC/Q0304)
Draftsman – Mechanical (CSC/Q )

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Level Code Educational Component Credit Marks

Theory
4.GV.04 General Foundation Course –II 3 50
4.GV.05 Material Science & Materials 3 50
4.GV.06 Manufacturing Technology - II 3 50
4 4.GV.07 General Mechanical Engineering -I 3 50
Semester Lab/Practical
II 4.VP.03 Material Science Lab. 1.5 50
4.VP.04 Workshop Practice – II 1.5 50
On-Job-Training (OJT)/Qualification Packs
One more QP to be opted from the QPs mentioned in
(Any one) 15 200
the Level 4 first semester
Theory
5.GV.01 Machine Tool Technology 3 50
5.GV.02 General Mechanical Engineering - II 3 50
5.GV.03 Production Technology 3 50
5.GV.04 Metrology and Measuring Instruments 3 50
5 Lab/Practical
5.VP.01 Metrology and Measuring Instruments Lab 1.5 50
Semester 5.VP.02 Machine Tool Technology Lab. 1.5 50
I
On-Job-Training (OJT)/Qualification Packs
Metal Arc Welding (CSC/Q0204)
MIG MAG or GMAW Welder (CSC/Q0209)
Assistant TIG Welder (CSC/Q0212) (Any one) 15 200
CNC Setter Cum Operator (CSC/Q0120)
CNC Operator – VMC (CSC/Q0116)
Theory
5.GV.05 Industrial Management 3 50
5.GV.06 Total Quality Management 3 50
5 5.GV.07 Entrepreneurship 3 50
Lab/Practical
Semester
II 5.VP.03 Project 6 150
On-Job-Training (OJT)/Qualification Packs
One more QP to be opted from the QPs mentioned in
(Any one) 15 200
the Level 5 first semester
Theory
6.GV.01 Metal Casting Technology 3 50
6
6.GV.02 Production Automation & Computer Integrated Mfg. 3 50
Semester 6.GV.03 Fundamentals of Mechatronics 3 50
I
6.GV.04 Machining and Machine Tools 3 50
Lab/Practical
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Level Code Educational Component Credit Marks

6.VP.01 Metal Casting Technology Workshop 1.5 50
6.VP.02 Mechatronics Lab 1.5 50
On-Job-Training (OJT)/Qualification Packs
Service Engineer – Installation (CSC/Q0501)
Quality Inspector – Forged, Casted or Machined Component
(CSC/Q0601)
(Any one) 10 200
CNC Programmer (CSC/Q0401)
Maintenance Fitter – Mechanical (CSC/Q901)
CNC Setter Cum Operator – VMC (CSC/Q0123)
Theory
6.GV.05 Mass Production Devices 3 50
6.GV.06 Agile and Lean Manufacturing Systems 3 50
6 6.GV.07 Metal Forming Processes 3 50
6.GV.08 Non-conventional Machining 3 50
Semester Lab/Practical
II
6.VP.03 Tool and Die Making Lab - Practical 3 100
On-Job-Training (OJT)/Qualification Packs
One more QP to be opted from the QPs mentioned in the Any one) 15 200
Level 6 first semester
Theory
7.GV.01 Reliability, Maintenance & Safety Engineering 3 50
7.GV.02 Plant Layout and Product Handling 3 50
7.GV.03 Product Design for Manufacturing 3 50
7
7.GV.04 CAD & CAM 3 50
Semester Lab/Practical
I 7.VP.01 CAD & CAM Lab - Practical 3 100
On-Job-Training (OJT)/Qualification Packs
Tool & Die Maker (CSC/Q0306)
Designer – Mechanical (CSC/Q0405) (Any one) 15 200
Service Engineer – Breakdown Service (CSC/Q0503)
Theory
7.GV.05 Rapid Prototyping and Reverse Engineering 3 50
7.GV.06 Production Planning & Control 3 50
7
Lab/Practical
Semester 7.VP.02 Project Work 9 200
II
On-Job-Training (OJT)/Qualification Packs
One more QP to be opted from the QPs mentioned in the
(Any one) 15 200
Level 7 first semester

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Detailed Curriculum

Level 3 (Semester I)

(3.GE.01) Language - I

Module 1: Reading comprehension (prescribed texts) and functional grammar

A variety of genres – short stories, expository pieces, biographies, poems, plays, newspaper
and magazine excerpts have been included. Teaching of grammar has been integrated with
the reading texts. The emphasis is on functional grammar.
The following ten prose texts and five poems have been selected for development of
different reading skills.

Prose texts (Prescribed)

1. A warmer or a colder earth (popular science) Arthur – C. Clark
2. The tiger in the tunnel (narrative) – Ruskin Bond.
3. First two or four pages from Sunny Days (autobiographical) – By Sunil Gavaskar
4. Case of suspension (narrative)
5. Big brother (narrative) Shekhar Joshi
6. Father, dear father (news paper article form the Hindu)
7. Face to face (autobiographical) Ved Mehta
8. I must know the truth (narrative) Sigrun Srivastva
9. If I were you (play) Douglas James
10. India, her past and her future (speech) Jawahar Lal Nehru

Poems
1. Leisure – W H Davis
2. The road not taken – Robert Frost
3. Where the mind is without fear- Tagore
4. My grandmother’s house – Kamla Das
5. The night of the scorpion – Nissi, Ezekiel

Non prescribed

In this section learners will be exposed to newspaper, articles, tables, diagrams,

advertisements etc. which they have to read carefully and interpret. In the examination
similar pieces will be used.
Grammar and usage:
The following points of grammar and usage have been selected from the reading passages.
1. Agreement /concord: number – gender etc.
2. Tenses: simple past (negatives/interrogatives) present perfect, past perfect
continuous, past perfect, expressing future time (will and going to)
3. Passive voice (perfect tenses and modals)
4. Modals (must, should ought to, would)
5. Linking words (to like because although, instead of, if, as, since, who, which that,
when however, inspite of)
6. Reported speech, statements, questions (yes/no)

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Module 2: Functional writing and study skills

This module help the learner to write descriptive and narrative paragraph, letters, reports
notices etc. and also practice skills of note making

1. Paragraph writing
 Describing objects
 Describing people
 Narrating events, stories
2. Letter writing
 Application for leave
 Application for jobs
 Asking for information form various agencies (e.g. Last date for getting prospects; price
of items before placing doers etc.)
3. Note making
4. Ending (punctuation, spelling, appropriate vocabulary, structures)

Reference Books:
1. Effective Communication Skills, Kulbhushan Kumar, Khanna Publishing House
2. Business Communications, Varinder Bhatia, Khanna Publishing House

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(3.GE.02)Applied Chemistry

1. Structure of Atom:
Rutherford model of the structure of atom, Bohr's theory of electrons, quantum numbers
and their significance, de-Broglie equation and uncertainty principle, electronic
configuration of 1 to 30 elements
2. Periodic Properties of Elements:
Periodic law, periodic table, periodicity in properties like atomic radii and volume, ionic
radii, ionization energy and electron affinity, Division of elements into s, p, d and f blocks
3. Chemical Bonds:
Electrovalent, covalent and coordinate bond and their properties, Metallic bonding
(electron cloud mode) and properties (like texture, conductance, luster, ductility and
malleability).
4. Fuel and their Classification:
Definition, characteristics, classification into solid, liquid and gaseous fuel, Petroleum and
brief idea of refining into various factions and their characteristics and uses, Calorific value
of fuel, Gaseous fuels- preparation, properties, composition and use of producer gas, water
and oil gas.
5. Water:
Impurities in water, methods of their removal, hardness of water, its types, causes and
removal, disadvantages of hard water in boilers, pH value and its determination by
calorimetric method.
6. Corrosion:
Its meaning, theory of corrosion, prevention of corrosion by various methods using metallic
and non-metallic coatings
7. Plastic and Polymers:
Plastic-thermo-plastic and thermo-setting, Introduction of Polythene. P.V.C. Nylon, synthetic
rubber and phenol-formal-dehyde resin, their application in industry.

Reference Books:
1. Chemistry, Satyaprakash, Khanna Publishing House
2. Engineering Chemistry, Saiful Islam, Khanna Publishing House

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(3.GE.03) Applied Physics

1. Units & Dimensions: M.K.S. fundamentals & derived units, S.I. base units supplementary
units and derived units, Dimensions of various physical quantities, uses of dimensional
analysis.
2. Surface Tension and Viscosity: molecular forces, molecular theory of surface tension,
surface energy, capillary action, concept of viscosity, coefficient of viscosity, principle and
construction of viscometers.
3. Vibrations: Vibration as simple spring mass system, elementary and qualitative concept of
free and forced vibrations, resonance. Effects of vibrations on building bridges and
machines members.
4. Heat: Temperature and its measurement, thermoelectric, platinum resistance
thermometers and pyrometers. Conduction through compound media and laws of
radiations.
5. Ultrasonics: Productions of ultrasonic waves by magnetostriction and piezo-electric effect,
application of ultrasonics in industry.
6. Optics: Nature of light, reflection and refraction of a wave from a plane surface. Overhead
projector and Epidiascope.

(3.GE.04) Applied Mathematics – I

Sets, Relations and Functions

1. Sets
2. Relations and Functions-I
3. Trigonometric Functions-I
4. Trigonometric Functions-II
5. Relation between Sides and Angles of A triangle

Sequences and Series

1. Sequences and Series
2. Some Special Sequences

Algebra-I
1. Complex Numbers
2. Quadratic Equations and Linear inequalities
3. Principle of Mathematical Induction
4. Permutations and Combinations
5. Binomial Theorem

Co-ordinate Geometry
1. Cartesian System of Rectangular Co-ordinates
2. Straight Lines
3. Circles
4. Conic Sections

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Statistics and Probability

1. Measures of Dispersion
2. Random Experiments and Events
3. Probability

Reference Books:
1. Applied Mathematics-I, J.K. Tyagi, Khanna Publishing House
2. Engineering Mathematics, Reena Garg, Khanna Publishing House

(3.GP.01) Applied Chemistry – Lab

1. Proximate analysis of solid fuel.

2. Experiments based on Bomb Calorimeter.
3. Determination of turbidity in a given sample.
4. To determine the flash and fire point of a given lubricating oil.
5. To determine the viscosity of a given lubricating oil by Redwood viscometer.
6. To determine cloud and pour point of a given oil.

(3.GP.02)Applied Physics – Lab

1. To determine the surface tension of a liquid by rise in capillary.

2. To determine the viscosity of a given liquid.
3. To determine the frequency of tuning fork using a sonometer.
4. To determine the frequency of AC main using sonometer.
5. Time period of a cantilever.

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Level 3 (Semester II)

(3.GV.01) General Foundation Course – I

A. Business Management and Entrepreneurship

(a) Entrepreneurship Orientation
Importance and relevance in real life: Emphasis on self-employment.
(b) Entrepreneurship Values and Attitudes
Innovativeness, Independence, Risk Taking, Analytical ability.
(c) Entrepreneurial Motivation
Achievement Planning, personal efficacy, entrepreneurial goal setting.
(d) Launching of a Business Venture
Identification of project, steps in setting up a business, information about
various institutions providing assistance, project formulation.
B. Computational Skills
(a) Percentage, ratio & proportion, profit & loss, discount, simple and compound
interest, population growth and depreciation of value of articles using logarithm.
(b) Area and volume: rectangle, parallelogram, circle, cube, cone, cylinder & sphere.

C. Environmental Education
(a) Environment and the society.
(b) Environment properties risks in different economic enterprises, in use of
raw materials, in processing / manufacturing and designing.
(c) Poverty and environment.
D. Rural Development
(a) Agriculture, the back bone of Indian Economy.
(b) Rural development projects in India including integrated rural development
programme.
(c) Agro based rural industries.
(d) Community approach to rural development.

Reference Books:
1. Environmental Studies, M.P. Poonia & S.C. Sharma, Khanna Publishing House
2. A Textbook of Environmental Sciences, Rimpi Mehani Ne’ Chopra, Khanna Publishing House

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(3.GV.02) Basic Electricity

1. Current Electricity
Definition of Resistance, Voltage, Current, Power, Energy and their units,
Relation between electrical, mechanical and thermal units, Temperature
variation of resistance, Difference between AC and DC voltage and current

2. D.C. Circuits
Ohm’s Law, Series – parallel resistance circuits, calculation of equivalent resistance,
Kirchhoff’s Laws and their applications.

3. Electric Cells
Primary cell, wet cell, dry cell, battery, Li-ion battery, series and parallel connections of cells,
Secondary cells, Lead Acid Cell, Discharging and recharging of cells, preparation of
electrolyte, care and maintenance of secondary cells.

4. Lighting Effects of Current

Lighting effect of electric current, filaments used in lamps, and Tube-light, LED, their
working and applications.
5. Capacitors
Capacitor and its capacity, Concept of charging and Discharging of capacitors, Types of
Capacitors and their use in circuits, Series and parallel connection of capacitors, Energy
stored in a capacitor.
6. Electromagnetic Effects
Permanent magnets and Electromagnets, their construction and use, Polarities of an
electromagnet and rules for finding them.
Faraday’s Laws of Electromagnetic Induction, Dynamically induced e.m.f., its magnitude and
induction, inductance and its unit. Mutually induced e.m.f., its magnitude and direction, Energy
stored in an inductance.
Force acting on a current carrying conductor in magnetic field, its magnitude and direction,
Principles and construction of dynamo.
7. A.C Circuits
Generation of A.C. voltage, its generation and wave shape. Cycle, frequency, peak value
R.M.S. value, form factor, crest factor, Phase difference, power and power factor, A.C.
Series Circuits with (i) resistance and inductance (ii) resistance and capacitance and
(iii) resistance inductance and capacitance, Q factor of R.L.C. series circuits.

Reference Books:
1. Basic Electrical Engineering, Ritu Sahdev, Khanna Publishing House
2. Basic Electrical Engineering, Pradeep Kumar, Khanna Publishing House

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(3.GV.03) Basic Electronics

i) Overview of Atom, Sub-Atomic Particles and CRO

 Brief History of Electronics.
 Atom and its elements,
 Electron, Force, Field intensity, Potential, Energy, current
 Electric field, Magnetic field, Motion of charged particles in electric and magnetic field.
 Overview of CRO, Electronic and Magnetic deflection in CRO, Applications.

ii) Voltage and Current

 Resistance, Ohm’s law, V-I Characteristics, Resistors, Capacitors, Inductors.

 Voltage and Current sources, Symbols and Graphical representation
 Overview of AC, DC, Cells and Batteries, Energy and Power.

iii) Basics of Semiconductor

 Semiconductor materials, Metals and Semiconductors and Photo-electric emission.
 N-type and P-type semiconductor, Effects of temperature on Conductivity of
semiconductor.
 PN junction diode, depletion layer, Forward & Reverse bias, V-I Characteristic, Effects
of temperature, Zener diode, Photo diode, LED, Types and applications of diode.
 Diode as a rectifier, half wave and full wave rectification, Zener diode Regulator.
 Introduction to Filters, Clippers, Clampers

iv) Bipolar Junction Transistor

 Operation of NPN and PNP transistors, Biasing of BJT.

 CB, CE and CC configuration

 Introduction to FET, JFET, MOSFET, CMOS and VMOS

v) Transistor Amplifier and Applications

 Introduction, Single and Multi-stage amplifiers
 Introduction to Oscillators
 Introduction to Thyristors, PNPN diode, SCR, LASCR, DIAC, TRIAC

Reference Books:
1. Basic Electronics, S. Biswas, Khanna Publishing House
2. All in One Electronics Simplifies, A.K. Maini, Khanna Publishing House

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(3.GV.04) Applied Mathematics – II

Algebra-II
1. Matrices
2. Determinants
3. Inverse of a Matrix and its Applications

Relations and Functions

1. Relations and Functions-II
2. Inverse Trigonometric Functions

Calculus
1. Limits and Continuity
2. Differentiation
3. Differentiation of Trigonometric functions
4. Differentiation of Exponential and Logarithmic functions
5. Application of Derivatives
6. Integration
7. Definite Integrals
8. Differential Equations

Vectors and Three Dimensional Geometry

1. Introduction to Three Dimensional Geometry
2. Vectors
3. Plane
4. Straight Line

Linear Programming and Mathematical Reasoning

1. Linear Programming
2. Mathematical Reasoning

Reference Books:
1. Applied Mathematics-II, J.K. Tyagi, Khanna Publishing House
2. Elements of Mathematical Analysis, R. Agor, Khanna Publishing House

(3.VP.01) Basic Electricity Lab

1. Verify that resistance of conductor is directly proportional to resistivity

and length and inversely proportional to cross- sectional area of the
conductor.
2. Verification of Ohm’s Law.
3. Verification of temperature co-efficient of resistance:
(i) Positive for Tungsten and Nichrome and
(ii) Negative for carbon.

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4. Study of series resistive circuits.

5. Study of parallel resistive circuits.
6. Study of series and parallel connection of cells in circuits.
7. Preparation of Electrolyte for lead acid battery and its charging and
measurement of Specific gravity with the help of hydrometer.
8. To find heat efficiency of an electric kettle.
9. Charging and Discharging of a capacitor.
10. Verification of magnetic field of a Solenoid with:
(i) Iron core and
(ii) Air core.
11. Verification of Faraday’s Laws of electromagnetic induction.
12. Verification of Torque development in a current carrying coil in magnetic field.
13. Study of R.L. series circuit and measurement of power and power factor.
14. Study of R.C. series circuit and measurement of power and power factor.
15. Study of R.L.C. series circuit and measurement of power and power factor.
16. Study of R.L.C. series circuit for calculation of inductive reactance,
capacitive reactance, impedance and Q- Factor.
Instruments Required

 Trainer kit for verifying ohm’s law,

 Trainer kit for measuring TCR
 Lead acid battery,
 Hydrometer,
 Electric kettle,
 Trainer kit for measuring power and power factor in RLC circuits

(3.VP.02) Basic Electronics – Lab

1. Study of current and voltage measurement using Ammeter and Voltmeter.

2. Study of current and voltage measurement using Galvanometer.
3. Study of current, voltage and resistance measurement using of Multi-meter
4. Study of Power and Energy measurement using Wattmeter and Energy meter.
5. Study of working principle of Signal Generator and measurement of amplitude,
time period and frequency of signal using Oscilloscope.
6. Study of V-I Characteristic of Diode.
7. Study of V-I Characteristic of Zener Diode. And use of Zener Diode as voltage
regulator.
8. Study of Half wave rectifier with and without filter circuit.
9. Study of Full wave rectifier with and without filter circuit.
10. Study CE configuration for NPN and PNP transistors and measurement of voltage
and current gain.
11. Study CB configuration for NPN and PNP transistors and measurement of voltage
and current gain.
12. Study CC configuration for NPN and PNP transistors and measurement of voltage
and current gain.
13. Study of working of single layer PCB manufacturing
14. Study of working of double layer PCB manufacturing.
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15. Design of 7 segment display using LED and bread board.

Instruments Required
 Ammeter
 Voltmeter,
 Multi-meter,
 Galvanometer,
 Energy Meter,
 CRO,
 Diode Trainer kit
 Zener diode Trainer kit
 Rectifier trainer kit
 Transistor characteristics trainer kit,
 PCB manufacturing Lab
 Bread board trainer kit to design 7 segment displays.

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Level 4 (Semester I)

(4.GV.01) Engineering Science

i) Soldering and Brazing

General characteristics of soldering, brazing joints, processes and their characteristics, brief
description of soldering and brazing tools equipment, types of solders and fluxes and their
uses, soldering defects and their remedies, brazing materials, advantages and
disadvantages of soldering and brazing. Introduction to PCB, PCB designing, wet etching,
dry etching, track correction, wiring, single sided and double sided PCB.

ii) Measuring Instruments

Construction and working principles of moving iron and moving coil voltmeters and
ammeters, dynamometer type wattmeter, ohm meter, megger and induction type energy
meter- their circuit connection and application for measurement of electrical quantities.

iii) Electrical Engineering Drawing

Schematic and wiring diagram for domestic simple wiring, symbols used for different
electrical devices and equipments.

iv) Electrical wiring

Types of wiring – cleat wiring, casing and capping, C.T.S./T.R.S. wiring, metal sheath wiring,
conduit wiring and concealed wiring – their procedure. Factors of selection of a particular
wiring system, importance of switch, fuse

v) Earthing
Earthing of wiring system, types of faults, their causes and remedies, Types of earthing-
plate earthing and Pipe earthing, their procedure and application. Methods of finding
numbers of circuits and circuit distribution by distribution board system loop in system of
wiring connections IE rules related to wiring.

Reference Books:
1. Environmental Studies, M.P. Poonia & S.C. Sharma, Khanna Publishing House
2. A Textbook of Environmental Sciences, Rimpi Mehani Ne’ Chopra, Khanna Publishing House

(4.GV.02) Manufacturing Technology -I

UNIT 1
(A) General Introduction: (a) Scope of subject "Workshop Technology" in engineering (b)
different shop activities and broad division of the shops on the basis of nature of work done
such as (i) Wooden Fabrication-carpentry (ii) Metal Fabrication (shaping and Forming,
Smithy, sheet metal and Joining-welding, Riveting, Fitting and Plumbing).

(B) Carpentry: (a) Fundamental of wood working operations (b) Common Carpentry Tools-
Their classification, size, specification (name of the parts and use only): (i) Marking and
measuring tools (ii) Holding and supporting tools: (iii) Cutting and Sawing Tools: (iv)
Drilling and Boring Tools (v) Striking Tools-Mallet and Claw hammer (vi) Turning Tools &
Equipment (vii) Miscellaneous Tools

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UNIT 2

(A) Joining of Timber Components for Fabrications Works: Assembly of joints (Preparation
steps and tools used only) Mortise, Tenon, Rivet, Groove, Tongue, Dowel, operations in
assembly-simple lap and butt, Mortise, Tenon, Dovetail, Miter & briddle joints. Metal
Fabrication.

(B) Metal Shaping-Smithy: (i) Operations involved (concept only) (ii) Tool and equipment
used (Names, size, specification for identification only) (iii) Heating and fuel handling
equipment (iv) Holding and supporting tools (v) Striking Tools (vi) Cutting tools (vii)
Punching & Drifting Tools (viii) Bending Tools and figures (ix) Forming & Finishing Tools (x)
Defects Occurring & its remedy

UNIT 3
Sheet metal working-Tools and operation: (1) Operations involved (Names and concept
only) (2) Sheet metal joints (3) Tools and equipment used (Name, size, specifications for
identification only) (4) Marking tools (5) Cutting and shearing Tools (6) Straightening tool
(7) Striking Tools (8) Holding Tools (9) Supporting Tools (10) Bending tools (11)
Punching-Piercing and Drafting tools (12) Burring Tools-Files (13) Defects Occurring & its
remedy

UNIT 4
(A) Metal Joining During Fabrication-
(a) Permanent Joining: (i) Welding methods (ii) Electric welding
(b) Soldering & Brazing: (i) Its concept, comparison with welding as joining method and
classification (ii) Soldering operation (iii) Materials Used (iv) Defects Occurring & its
remedy
(B) Riveting-
(i) Its comparison with welding as joining method. (ii) Rivets and Materials. (iii) Operation
involved (iv) Tools and equipment used (Names, Size, specification and uses)), Elementary
knowledge about working of pneumatic, hydraulic and electric riveter. Temporary Joining
(Fasteners & their uses), General Idea about temporary fasteners & their uses
(C) Familiarity with the Use of Various Tools Used in Mechanical Engineering Workshop
(a)Marking & Measuring Tools (b) Holding Tools (c) Cutting Tools (d) Files (e) Thread
Cutting Tools (h) Miscellaneous Tools. They should be shown physically to each student for
familiarity.

UNIT 5
(A) Protection of Fabricated Structures From Weather:
(a) Painting: Its need, Introduction to methods of painting (classification only) operations
involved description steps only, surface preparation materials, tools and equipment used
(name, size specification for identification), Brushes-round and flat wire brush, scraper,
trowel, spray gun, compressor, Defects likely to occur in painting and their remedies
(b) Varnishing & Polishing: Its need, operation involved (description of steps only), surface
preparation method of old and new articles, application of polishing materials, materials
used for preparation of french and sprit polish, copal varnish, Defects likely to occur.
Safety of Personnel, Equipment & Tools to be observed
(B) Foundry Work:
Elementary idea of patterns, green sand moulds and moulding, tools and equipment used in
green sand moulding.

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Reference Books:
1. Workshop Technology, Vol. I: Hazra & Chaudhry
2. Workshop Technology, Vol. I: BS Raghuwanshi
3. Karyashala Takniki: JK Kapoor

(4.GV.03) IT Tools

I. Computer Organization & OS: User perspective.

• Understanding of Hardware.
• Basics of Operating System.

II. Networking and Internet.

• Network Safety concerns.
• Network Security tools and services.
• Cyber Security.
• Safe practices on Social networking.
III. Office automation tools:
• Spreadsheet.
• Word processing.
• Presentation.
IV. Multi Media Design: (Open Source Design Tools).
 Interface and Drawing Tools in GIMP.
 Applying Filters.
 Creating and handling multiple layers.
 Using Stamping and Smudging tools.
 Importing pictures.
V. Troubleshooting: Hardware, Software and Networking.
 Commonly encountered problems.
 (Monitor: No display, KB/Mouse not responding, monitor giving
beeps, printer not responding, check for virus, Delete temporary
files if system is slow, adjust mouse speed).
Work Integrated Learning IT – ISM
 Identification of Work Areas.
 Work Experience.

Reference Books:
1. IT Tools, R.K. Jain, Khanna Publishing House
2. Information Security & Cyber Laws, Sarika Gupta, Khanna Publishing House
3. Mastering PC Hardware & Networking, Ajit Mittal, Khanna Publishing House

(4.GE.05) Language - II

Module – 3: Listening and speaking skills

In this module the learners will be exposed to a variety of listening activities recorded on
audiotapes. These will be samples of good spoken English, which the learners can use as
models. Work sheets will accompany the listening material.
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This module will include the following:
1. Introducing yourself/friends in formal and informal situations.
2. Inviting people (over the phone and face to face) giving details of occasion, time
place and date. Acceptance and refusal of invitation – formal and informal.
3. Seeking and supplying information (example opening an account in a bank, applying
for loans etc.)
4. Talking and conveying messages (over the phone and face to face).
5. Giving directions / instruction.
6. Discussing contemporary issues related to environment, child labour, gender bias
etc.
7. Listening to excerpts from television and radio.
8. Listening to poems/plays (prescribed).
9. Listening to speeches / talks.
10. Listening to songs like “We shall overcome”

Module – 4 to 6 (English for specific purposes) (opt any one)

There modules are being offered. A learner has to opt for any one. The first is for academic
purposes and the next two are for vocational purposes. The focus is not on the teaching of
the subject matter like science and literature but on the way in which language is used in
the deferent subjects.

Module 4: English for Science

This course will introduce learners to some interesting pieces of popular science

1. Health and hygiene

2. Conservation of (nearly extinct) animals.
3. Plant life.
4. Bio gas / solar energy.
These pieces illustrate the use of English in scientific writing: giving information
factually, logically and objectively.

Module 5: English for Receptionist

This module will introduce the learners to a variety of exercises, tasks and meaningful
activities related to the receptionist’s use of English. The printed course materials will be
supported by tapes.
The following competencies be developed:
1. Receiving messages, making request etc.
2. Supplying information
3. Giving advice and making suggestions
4. Dealing with complaints
5. Making entries in an appointment book, register etc.

Module 6: English for Office Use

This course will help the learner to use English effectively and appropriately in the office
environment. The competencies will be developed.
1. Using the telephone taking and passing messages.
2. Receiving messages
3. Marking noting on files and circular.
4. Writing office notes, memos, notices, agendas for meetings.
5. Telegrams and fax messages.
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6. Writing business letters, application enquires, complaints.
7. Filling in forms, cheques, pay in slips etc.

Reference Books:
1. Effective Communication Skills, Kulbhushan Kumar, Khanna Publishing House
2. Business Communications, Varinder Bhatia, Khanna Publishing House

(4.VP.01) Workshop Practice - I

1. CARPENTRY SHOP WORK:

(EX-1) Planing and sawing practice
(EX-2) Making of lap joint
(EX-3) Making of mortise and tanon joint
2. PAINTING AND POLISHING:
(EX-1) To prepare a wooden surface for painting apply primer on one side and to paint the
same side. To prepare french polish for wooden surface and Polish the other side.
(EX-2) To prepare metal surface for painting, apply primer and paint the same.
(EX-3) To prepare a metal surface for spray painting, first spray primer and paint the same
by spray painting gun and compressor system.
The sequence of polishing will be as below- (i) Abrasive cutting by leather wheel. (ii)
Polishing with hard cotton wheel and with polishing material. (iii) Buffing with cotton wheel
or buff wheel.
3. SHEET METAL WORKING AND SOLDERING:
(EX-1) Cutting, shearing and bending of sheet.
(EX-2) To prepare a soap case by the metal sheet
(EX-3) To make a funnel with thin sheet and to solder the seam of the same
(EX-4) To make a cylinder and to solder the same
4. FITTING SHOP WORK:
(EX-1) Hack sawing and chipping of M.S. flat
(EX-2) Filing and squaring of chipped M.S. job
(EX-3) Filing on square of rectangular M.S. Plate
5. PLUMBING SHOP WORK:
(EX-1) Cutting and threading practice for using socket, elbow and tee etc and to fit it on
wooden practice board.
6. SMITHY SHOP WORK:
(EX-1) To prepare square angular piece by M.S. rod
(EX-2) To Braze M.S. flat/Tipped tool on M.S. shank
(EX-3) To make a screw driver with metallic handle
7. WELDING SHOP WORK:
(EX-1) Welding practice gas & electric
(EX-2) Welding for lap joint after preparing the edge
(EX-3) Welding Butt joint after preparing the edge

Reference Books:
1. Workshop Technology, Vol. I: Hazra & Chaudhry

(4.VP.02) IT Tools Lab.

 Spreadsheets, Word, Presentation

 Multimedia Design
 Troubleshooting
 Project / Practical File
 Viva Voce

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Level 4 (Semester II)

(4.GV.04) General Foundation Course – II

A. Business Management and Entrepreneurship

Management of Business, Elementary treatment/exposure to basic conceptual frame work
of the topic listed below:
(a) Basic Function (b) Marketing Management(c) Financial Management (d) Production
Management (e) Personnel Management
B. Computational Skills
1. (a) Solution of linear equations and their application to problem of commercial
mathematics.
(b) System of linear equations and in equation in two variables. Applications in formation
of simple linear programming problems
2. Statistics: Raw data, bar charts and Histogram; Frequency Tables; Frequency Polygon;
Ogive; Menu, Median and Mode of ungrouped and grouped data; Standard Deviation;
Introduction to Mortality tables; Price Index etc. Introduction to Computers
C. Environmental Education & Rural Development
Environmental Education:
a. Modernization of agriculture and environment, irrigation, water logging, use of fertilizers,
pesticides, soil erosion, land degradation (desertification and deforestation), silting and
drying of water resources.
b. Rational utilization, conservation and regeneration of environmental resources (soil, air,
water, plant, energy, minerals).
2. Rural Development
Principles and goals of rural development, major problems/constraints in rural
development in India

Reference Books:
1. Environmental Studies, M.P. Poonia & S.C. Sharma, Khanna Publishing House
2. A Textbook of Environmental Sciences, Rimpi Mehani Ne’ Chopra, Khanna Publishing House
3. Elements of Mathematical Analysis, R. Agor, Khanna Publishing House

(4.GV.05) Material Science & Materials

UNIT 1
GENERAL: Brief introduction to the subject metallurgy and its scope in engineering field,
classification of materials of industrial importance. Their chemical thermal, electrical,
magnetic, mechanical and technological properties and their selection criteria for use in
industry
STRUCTURE OF METALS AND THEIR DEFORMATION:
Structure of metals and its relation to their physical, mechanical and technological
properties, Elementary idea of arrangement of atoms in metals, molecular structures,
crystal structures and crystal imperfections, Deformation of metals, effects of cold and hot
working operations over them. Recovery re-crystallisation and grain growth, solid
solutions, alloys and inter metallic compounds, effect of grain size on properties of metals.
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PROPERTIES AND USAGE OF: (1) Metals: (a) Ferrous Metals (b) Non Ferrous Metals (2)
Non-metallic Materials.

UNIT 2: METALS-FERROUS METALS

(a) Classification of iron and steel. (b) Cast iron types as per I.S. - White, malleable, Grey (c)
Steels: Classification of steels according to carbon content and according to use as per I.S.
Mechanical properties of various steels and their uses. Availability of steel in market, Its
forms and specifications (d) Alloy Steel: Effect of alloying various elements, viz Cr, Hi, Co,
V,W, Mo, Si, and Mn, on mechanical properties of steel, Common alloy steels, viz, Ni-steel,
Ni-Cr-steel, Tungsten steel, Cobalt steel, Stainless Steel, Tool steel - High Carbon Steel, High
Speed steel, Tungsten Carbide, Silicon manganese steel, Spring Steel, Heat Resisting alloy
Steels etc.

UNIT 3: NON-METALIC MATERIALS

(a) Plastic and Other Synthetic Materials: Plastics- Important sources-Natural and
Synthetic, Classification, thermo-set and thermoplastic, Various trade names, Important
Properties and engineering use of plastics. Market forms of Plastics
(b) Paints, Enamels, Varnishes and Lacquers: Paints and Enamels-types, its purpose,
essential ingredients and their role, characteristics of a good paints and enamel, trade
names of some important types of products. Varnishes-types purpose of varnish, essential
ingredients and their role, characteristics, preparation, trade names storage of varnish,
Lacquer- characteristics, preparation and uses

UNIT 4: NON-METALIC MATERIALS

(c) Heat Insulating Materials: Classification of Heat Insulating material, properties and uses
of China clay, Cork, Slag wool, Glass Wool, Thermocole, Puff, Properties and uses of asbestos
as filler material.
(d) Hardware: General specification, uses and methods of storage of G.I. and C.I. steel,
Copper, A.C. pressure conduits, R.C.C. spun, P.V.C. Pipes and their uses. General sheets
specification (I.S.) and uses, Method of storage of G.I. sheets, M.S. sheets, General
specification of pipe fitting

UNIT 5
IDENTIFICATION AND TESTING OF METAL ALLOYS: Selection, specification forms and
availability of materials.
HEAT TREATMENT OF METALS: Elementary concept, purpose, Iron-carbon equilibrium
diagram. T.T.T. and `S' curve in steels and its significance, Hardening, Tempering,
Annealing, Normalising and case hardening.

Reference Books:
1. MATERIAL SCIENCE: RS Khurmi & RS Shedha

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(4.GV.06) Manufacturing Technology – II

UNIT 1
GENERAL PROCESS: Classification and elementary idea of metal forming processes on the
basis of the properties of deformability (Plasticity), fusibility and divisibility viz., Rolling,
Forging, Drawing, Extruding, Spinning, Pressing, Punching, Blanking, Welding, Soldering,
Brazing, Metal cutting processes-turning, Drilling, Boring, Shaping, Grinding, Elementary
idea of machines used for the above processes.
WELDING: (a) Weld edge preparation, Introduction to various welding processes with
procedure equipment and applications such as (i) Electric arc welding. (ii) Resistance
welding. (iii) Thermit welding (iv) Carbon arc gauging. (v) Metal-Inert-Gas welding (MIG)
(vi)Tungsten Inert Gas welding (TIG) (vii) Atomic Hydrogen arc welding. (viii) Stud
welding. (ix) Laser Beam, Electron Beam welding, Explosion welding (b) Welding Arcs:
Definition, arc initiation, arc structures, types of arc, metal transfer characteristics and
influencing parameters, weld bead geometry, various types of electrodes used in various
processes.

UNIT 2
WELDING OF SPECIAL MATERIALS: (a) Welding of plastics, equipment, filler rods,
weldability, procedures and precautions. (b) Welding of Grey Cast Iron, shielded metal arc
gas welding procedures. (c) Welding of Aluminium, Argon arc and gas welding procedures.
(d) Welding of copper, Brass and Bronze, Gas shielded metallic arc welding, TIG, Oxy-acetylene
method.
TESTING OF WELDS & RELEVENT WELDING CODES: (a) Destructive methods (b)
Non- destructive methods-visual, X-ray, Y-ray, Magnetic particles, fluorescent, penetrant
and ultrasonic testing.

UNIT 3 & UNIT 4: FOUNDRY PRACTICE

PATTERN & MOULDING: The pattern materials used, Types of pattern allowances and
pattern layout, Colour scheme patterns defects, Types of cores and their utility.
Moulding and Pouring: Classification of mould materials according to characteristics, Types
of sands and their importance test, parting powders and liquids, Sand mixing preparation,
Moulding defects
MELTING AND POURING: Brief idea of refractory material and fluxes, Fuels and metallic
materials used in foundry. Melting furnaces used in foundry such as pit furnace, Tilting and
cupola furnaces, their construction and operation, metals and alloys. Additions to molten
metal, Closing and pouring of the moulds, Coring-up, venting and closing, use of ladles, spur
and risers, Defects due to closing and spurring, Basic idea of fettling operations. Surface
treatment, Salvaging of castings, Factors determining soundness of casting.

UNIT 5
FOUNDRY PRACTICE: Elementary idea of special casting processes-Shell mould casting, die
casing, investment mould casting, centrifugal and continuous casting full mould casting.
Elementary idea of mechanisation of foundries
POWDER METALLURGY: Introduction, principle, scope and names of processes. Production
of metal powders, compaction, sintering and sizing, Self-lubricated bearings. Advantages of
the process and its limitations (Elementary concept only)

Reference Books:
1. Workshop Technology, Vol. I: BS Raghuvanshi
2 . Production Technology, Vol. I: Hazra & Chaudhry
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(4.GV.07) General Mechanical Engineering - I

UNIT 1: Strength of Materials & Power Transmission

Stress, strain, elastic constraints, stress in circular shaft subjected to pure torsion only,
Riveted and bolted joints.

UNIT 2: Shear Force & Bending Moment

Elementary idea of Shear force and bending moment for concentrated, uniformly
distributed loads on simply supported beam cantilever and overhanging beam, Simple
Shear force and bending moment diagrams, Relationship between shear force and bending
moment

Unit 3: Power Transmission: Pulleys, Gears & Shaft

Classification of Pulleys, Types of Belts, Simple calculation of pulley diameter, Classification
of Gears, Simple calculation of number of teeth and speed, Power transmission by solid and
hollow shaft

UNIT 4: Hydraulics & Hydraulic Machines

Properties of fluids, pressure of fluid and its measurement. Flow of fluids, velocity and
discharge, Bernoulli’s theorem and its application in venturimeter, flow through pipe, head
loss due to friction

Unit 5: Water Turbines & Pumps

Capacity & Working of Turbines- Pelton and Reaction, reciprocating and centrifugal pump

Reference Books:
1. Basic Mechanical Engineering, M.P. Poonia & S.C. Sharma, Khanna Publishing House
2. Strength of Materials, D.S. Bedi, Khanna Publishing House

(4.VP.03) Material Science Lab.

1. (a) Study of various crystals structures through models BCC, FCC, HCP, tetrahedral and
octahedral voids.
(b) Material identification of, say, 50 common items kept in a box.
2. Specimen preparation for metallographic examination /micro structural examination-
cutting, grinding, polishing, etching.
3. Comparative study of microstructures of different given specimens (mild steel, gray C.I.,
brass, copper etc.)
4. Heat treatment experiments such as annealing, normalizing, quenching, case hardening
and comparison of hardness before and after.
5. Study of Microstructure and hardness of steel at different rates of cooling, Microstructure
examination of white cast iron.

(4.VP.04) Workshop Practice - II

1. WELDING SHOP WORK

Exp-1: Welding practice-gas and electric
Exp-2: Welding for lap joint after preparing the edge
Exp-3: Welding for Butt joint after preparation of the edge
Exp-4: `T' joint welding after preparation of edge.
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2. CARPENTRY
(i) Bridle joint (ii) Dovetail joint (iii) Utility article like picture frame, larger peg, Name
plate etc.
3. FITTING
(i) Drill a hole in MS Block & tapping the same (ii) Making a Bolt & Nut by Tap & Die set.
(iii) Utility article-screw driver, Paper weight.
4. SMITHY
(i) To make square or hexagonal head bolt (ii) To make ring with hook (iii) Utility
article-to prepare a fan hook.
5. TIN SMITHY, SOLDERING, BRAZING
(i) To prepare different types of joint such as lap joint single seam, double seam & cap
joint-hem & wired edge. (ii) Utility article-waste paper basket or paper tray (iii) Study &
sketch stakes/ anvils.

Reference Books:
1. Elements of Workshop Technology Vol. I: BS Raghuwanshi

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Level 5 (Semester I)

(5.GV.01) Machine Tool Technology

UNIT 1: CENTRE LATHE

The centre lathe and its principle of working, Types of lathes, Lathe specification and size,
Features of lathe bed, Head stock and tail stock, Feed mechanism and change-gears.
carriage saddle, Cross slide, Compound rest, Tool post, Apron mechanism, lathe accessories,
Chucks, Face plate, Angle plate, Driving plate, Lathe doges, mandrils, Steady rest, Lathe
attachments, Lathe operations-plane and step turning, Taper turning, Screw cutting,
Drilling, Boring, reaming, Knurling, Parting off, Under cutting, Relieving, Types of lathe tools
and their uses, Brief description of semi-automatic lathes such as capstan and turret lathes,
their advantages and disadvantages over centre lathe, types of job done on them. General
and periodic maintenance of a centre lathe

UNIT 2: SHAPING, PLANING & SLOTTING MACHINES

Working principles of planer, shaper and Slotter, Differences and similarities among them,
quick return mechanism applied to the machines. types of work done on them, types of
tools used, their geometry, General and periodic maintenance of a shaper.
DRILLING & BORING MACHINES: Types of tools used in drilling and boring. Classification of
drilling and boring machines, principle of working and constructional details of simple and
radial drilling M/C and general and periodic maintenance. Operations like facing, counter
boring, tapering.

UNIT 3: MILLING MACHINES

Types of milling machines, constructional features of horizontal milling M/C. general
maintenance of the machine, types of milling cutters, milling operations like plane milling,
space milling, angular milling form milling, straddle milling, gang milling, Negative rake
milling, cutting speed and speed for different tools in up and down milling. Simple,
compound and differential indexing, milling of spur gears and racks

UNIT 4: GRINDING MACHINES

Common abrasives, grinding wheel materials, Bonds, Grain and grit of abrasive, Grain
structure and shapes of common wheels, various speeds and feeds, Use of coolants,
Methods of grinding, Types of grinding machines, precision finishing operations like
honing.
BROACHING MACHINES: Types of work done on broaching machine. Simple types of
broaches and their uses, Types of broaching machines

UNIT 5: JIGS AND FIXTURES

Object of Jigs and Fixture, Difference between jigs and fixtures, Principle of location,
Principle of clamping, Locating and clamping devices. Types of jigs -Simple open and closed
(or box) jigs. Drill jigs- bushes (Fixed, Liner, Renewal, Slip). Template, Plate jigs. Channel
jigs, Leaf jigs, Simple example of milling, turning, grinding, horizontal boring fixtures and
broaching fixtures. Welding fixtures
COOLING PROCESS: Cooling and cutting fluids, difference between coolant and cutting fluid,
function and action of cutting fluids, Requirement of good cutting fluids, their selection for
different materials and operations
AUTOMATION OF MACHINE TOOLS: Introduction to CNC lathe (Computer Numerical
Control Lathe) and FMS (Flexible Manufacturing System) Introduction only.

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Reference Books:
1. Production Technology: Jain & Gupta
2 . Machine Tool Technology (Hindi): JK Kumar
3. Workshop Technology Vol. II: Hazra & Choudhary

(5.GV.02) General Mechanical Engineering - II

UNIT 1: Basics of Thermodynamics

Basic definition of heat, work, Thermodynamic process, parameters of working body and
their units, Equation of state, Universal gas constant, Relation between heat capacity and
temperature. Determination of quantity of heat

Unit 2: Laws of Thermodynamics

Elementary concept of laws of thermodynamics, first law and second law, Graphical
representation of process, The work of expansion and compression of a gas, Change in the
state of ideal gas-Isochoric, Isothermal and Adiabatic process, Carnot-cycle

UNIT 3: IC ENGINES
External & internal combustion engines, working of diesel and petrol engine, horse power
of IC engines,

Unit 4: Steam Generators & Condensers

Construction and working of Babcock & Wilcox boiler, Cochran boiler, Steam condenser &
its types

Unit 5: Steam & Gas Turbines

Steam turbine, classification and principle of operation, gas turbine

Reference Books:
1. Basic Mechanical Engineering, M.P. Poonia & S.C. Sharma, Khanna Publishing House
2. Strength of Materials, D.S. Bedi, Khanna Publishing House
3. GENERAL MECHANICAL ENGINEERING: JK Kapoor
4. MECHANICAL ENGINEERING: Khurmi & Gupta

(5.GV.03) Production Technology

UNIT 1
PRODUCTION MACHINE TOOLS: Machine tools used for quantity production, semi
automatic multi tools centre lathe. Auto-lathes, sliding head types, Single spindle
automatics, Multi-spindle automatics, Mechanical copying systems, Hydraulic servo copying
systems for lathe, Electric copying systems.
TRANSFER MACHINES: Types of productions. Types of layout, Economic justification of
transfer machines, Inline transfer, drum type transfer machines. Automatic loading &
Transferring methods, Machining heads, Automatic inspections, Tool servicing, Transfer
press linked lines.

UNIT 2
GENERATION OF FORMS: Forming `V' generating. Thread chasing. Die heads. Thread
rolling. Thread milling. Thread grinding. Gear planning, Gear shaping, Gear hobbing,
Straight Bevel Gear Manufacture. Spiral bevel Gear Manufacture.

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UNIT 3
SURFACE TREATMENT & FINISHING: Meaning of the terms surface treatment and its
purpose, Elements of surface treatment cleaning protecting, Colouring, Altering surface
properties.

Surface Treatment Processes- Wire brushing, Belt sanding, Alkaline cleaning, Vapour
degreasing, Pickling, Latest trends in Surface preparation, Ultrasonic cleaning, Solvent
cleaning, Painting application by dipping, Hand spraying, Automatic spraying, Electrostatic
spray finishing. Electro-coating, Hot dip coating, phosphate coating- Packerising and
bonderasing, Buffing, Blackening, Anodising. Electro Nickle Plating, Nickle carbide plating,
Sputtering, Automation in Painting,
AUTO CONTROL OF SIZE: Auto sizing, Mechanical calliper for turning operation, Pneumatic
sizing of external cylindrical ground work, Pneumatic slide position measuring device,
Digital slide position measuring device, Auto sizing device for centre-less grinding
operation. Friction rollers, Optical measurement

UNIT 4
CUTTING TOOLS FOR MACHINING: Elements of machining process, Single point tools -
Basic angles, Chip formation, Effect of manipulating factors such as velocity, size of cut,
effect of tool geometry, Tool material, Cutting fluids and contamination in them, Work piece
material, Tool life model, Machining economics, Specific power consumption
Basic principles of multipoint tools, Linear travel tools, Broaches, Gear shaper cutters, Axial
feed rotary tools-Twist drill, Reamers, Core drills, Counter bores and counter sinks,
Multiple diameter tools, Hobs,
Characteristics of tools materials,. Tool materials, Tool steels, High speed steel, Cast cobalt
alloys. Carbides or cintered carbide, Ceramics, Carbide tools
Surface treatment of cutting tools- Its advantage, Tin coated high speed steel diamonds.
Cubic boron nitrides, Specialised knowledge of steel cutting

UNIT 5
PRESS TOOLS: Factors affecting press tool design, Shearing, Bending, Drawing,
combination tools, Progression tools, Rubber die formatting, high energy forming,
Explosive forming
SPECIFICATION OF QUALITY & RELIABILITY: Quality, Specification Designing for
production Standardisation, Preferred numbers, Limits and fits, Tolerance build up,
Geometric tolerances. Limit gauging

Reference Books:
1. Production Engineering: PC Sharma
2 . Production Technology: CK Singh

(5.GV.04) Metrology and Measuring Instruments

UNIT 1
INTRODUCTION: Meaning and scope of metrology in field of engineering, Standards and
types of measurements (Line and Wave, length, Primary, Secondary and Tertiary
measurement concept only). Limits, Fits and Tolerances, Interchangeability, precision and
accuracy, Sources of error
PRINCIPLES AND CLASSIFICATIONS OF MEASURING INSTRUMENTS:
(a) Principle of Mechanical Measuring Instruments: Lever method, Vernier method, screw
and screw nut method, compound gearing and helical spring methods.
(b) Principles of Optical Instruments: Reflection, Refraction, Interference, Polarisation,
Optical prisms, Lenses and Optical projectors.
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(c) Principles of Electrical measuring Instruments.
(d) Principles of Hydraulic and Pneumatic Instruments.

UNIT 2: COMPARATORS
General principles of constructions, balancing and graduation of measuring instruments,
characteristics comparators, use of comparators, difference between comparators, limit
gauges and measuring instruments. Classification of comparators, construction and
working of dial indicator, mechanical comparator, mechanical-optical, zeiss optotest,
electro limit, electromechanical electronics, pneumatic comparators, gauges, tool makers
microscope.

UNIT 3: SURFACE FINISH

Geometrical characteristics of surface roughness- Wavyness, layflaws, Effect of surface
quality on its functional properties. Factor affecting the surface finish, Drafting symbols for
surface roughness, Evaluation of surface finish RMS and CLS values, Methods of measuring
surface roughness qualitative and quantitative methods, Comparison of surface produce by
common production methods.

UNIT 4
VARIOUS TYPES OF INSTRUMENTS USED FOR:
(i) (a) Physical Measurements such as-Length, distance, height, Thickness, Gaps, Curvature,
Angle, Taper, Area, Undulations, Surface finish, Thread and Gear measurement (b) Liquid
Level & Viscosity-Liquid level measuring methods and devices, Viscometer - Plate and cone
Viscometer, Two float viscometer, Rheo viscometer
(ii) Mechanical Quantities: (a) Displacement. velocity, acceleration, space troque-Use of
transducers and electronic count stroboscope, vibrating reeds and technometers (b)
Pressure and Vacuum - Idea of atmosphere pressure, Gauge pressure and vacuum - Use of
instruments such as manometers and those use elastic elements such as diaphragm,
capsule Bellows, Bourdon tube and various transducers thermo couple, vacuum gauges (c)
Strain - Use of Strain gauge and load cells (d) Mechanical Power - Dynomometers -
absorption and transmission type both. (Reference Only)
TEMPERATURE MEASUREMENT: Various types of thermometers, thermocouples,
pyrometers (Radiation and optical type both)

UNIT 5
INSPECTION OF GEOMETRICAL ERRORS: Construction and working of auto collimeter,
checking of straightness, flatness, squareness and parallelism, circularity (By dial gauge and
telerod).
MAINTENANCE OF MEASURING INSTRUMENTS: Defects likely to occur in measuring
instruments and their remedies. General maintenance of measuring instruments

Reference Books:
1. Metrology: RK Jain
2. Mechanical Measurement: RK Jain

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(5.VP.01) Metrology and Measuring Instruments lab.

1. Measurement of angle with the help of sine bar/ Vernier Bevel protractor.
2. Study and sketch of various types of optical projectors.
3. Study and sketch of various types of comparators and use them for comparing length of
given piece.
4. To measure the diameter of a hole with the help of precision balls.
5. To measure external and internal taper with the help of taper gauges, precision rollers.
6. To test the squareness of a component with auto-collimeter.

7. To measure the pitch, angle and form of thread of a screw.

8. To measure the geometry of a gear having involute profile.
9. To measure the straightness of the edge of a component with the help of auto-
collimeter.
10. To measure the length, breadth, thickness, depth, height with micrometer.
11. To measure the length, breadth, thickness, depth, height, with height gauge and Vernier
calipers.
12. Calibration of Vernier calipers/micrometers.
13. Calibration of height gauge/depth gauge.
14. Study of a tool maker's microscope.
15. Checking of accuracy of snap gauge with slop gauge.
16. Checking of accuracy of a plug gauge with micrometer.
17. Measurement of areas by polar planimeter.
18. Use of feeler, wire, radius and fillet gauges measurement of standard parameters.

(5.VP.02) Machine Tool Technology Lab.

(A) MACHINE SHOP

1. (a) Square thread cutting (internal and external) - 2 jobs
(b) Multi-start thread cutting - 1 job
(c) Eccentric Turning - 1 job
2. Making utility job - Planner, Shaper, Slotter - 1 job
3. Group work on milling machine involving up & down milling in:
(a) Gang milling - 1 job
(b) Spur gear cutting - 1 job
(c) Helical gear cutting - 1 job

(B) FITTING SHOP

1. To make a cut and cup tool - 1 job
2. To make blank and pierce tool - 1 job
3. To make a male and female fitting jobs - 1 job
4. To grind a lathe/shaper/planer tool - 1 job
5. To make different types of keys - 3 jobs
6. To make complete gauge - 2 jobs

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Level 5 (Semester II)

(5.GV.05) Industrial Management

1. Introduction
Growth of industry, The management of men, materials and machines, the art of
management, Sources of capital- industrial individual enterprise, private partnership and
private Ltd. Co., Joint Stock Co. shares, debentures, financial agencies and their role in
promoting industries. Break even analysis.

2. Private sector and public sector:

Public sector enterprise, merits and demerits of public sector industry and private sector
industry, Line, staff and functional organizations, reasons for the choice of various types of
organization, functions of different departments, viz. stores, purchase and sales
departments relationship between individual departments.

3. Wages & incentives:

Definition of wages, real wage and nominal wage, systems of wage payment, incentives,
financial and non - financial incentives, Essentials of a good wage plan, essentials of a good
incentive scheme. Introduction to elements of cost & indirect expenses, Material cost,
labour cost, fixed and variable overheads, components of cost, selling price, Factory
expenses, administrative expenses, selling & distribution expenses, depreciation,
obsolescence, interest on capital, Idleness, Repair and maintenance.

4. Labour, industrial & tax laws:

Evolution of industrial law, factory act, workmen compensation act, payment of wages act,
employee’s state insurance act, Industrial dispute act. Role of technician in industry:
Position of technician in various engineering departments, Role of a supervisor in industry,
Foremanship, duties and qualities of a good foreman.

5. Material management:
Introduction, Scope of Material Management selective control techniques-ABC analysis,
Material handling, inventory control, Essential steps in inventory control, quality standards.

Reference Books:
1. Industrial Engineering and Management, S.C. Sharma, Khanna Publishing House
2. Industrial Safety, S.C. Sharma, Khanna Publishing House
3. Industrial Engineering & Management: Banga, Sharma & Agrawal
4 . Industrial Engineering Safety & Pollution (Hindi): Hemendra Dutt

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(5.GV.06) Total Quality Management

1. Introduction, Basic concepts of total quality management

Introduction to Quality, Dimensions of Quality, Quality Planning, Concept and definition
of quality cost, Determinants of Quality, Optimum cost of performance, Principles of TQM,
Pillars of TQM, Introduction to leadership and Leadership roles, Quality council and
Quality statement, Strategic Planning Process, Deming philosophy

2. Continuous process improvement

Input /output process Model, Juran trilogy, PDCA Cycle, 5 –‘S’ Housekeeping principle,
Kaizen Seven tools of Quality (Q-7 tools), Check Sheet, Histogram, Cause and effect
diagram, Pereto diagram, Stratification analysis, Scatter diagram, Control charts, Control
chart for variables & process capability, Control chart for attributes

3. Management planning tools & Bench marking

Affinity diagram, Relationship diagram, Tree diagram, Matrix diagram, Matrix data
analysis, Arrow Diagram, Process decision programme chart (PDPC), Concept of bench
marking, Reason to bench marking, Bench marking process, Types of bench marking,
Benefits of bench marking

4. Just in time (JIT)

JIT philosophy, Three elements of JIT, Principles of JIT Manufacturing, JIT
Manufacturing building blocks, JIT benefits, Kanban & 2 Bin Systems

5. Total productive maintenance (TPM)

Concept of Total Productive Maintenance, Types of maintenance, OEE (Overall
Equipment Efficiency), Stages in TPM implementation, Pillars of TPM, Difficulties faced in
TPM implementation.

Reference Books:
1. Total Quality Management, S.C. Sharma, M.P. Poonia, Khanna Publishing House

(5.GV.07) Entrepreneurship

1. Entrepreneurship and entrepreneur:

Need of Employment and Opportunities, Essential Characteristics of a good Entrepreneur,
Industrial Policy, Classification of industries- Micro, small scale, Medium scale, Large
scale, Type of industries- Production, Job based & Service

2. Entrepreneurial Development:
Product identification/ selection, Site selection, Plant layout, Institutional support
needed, Pre-market survey.

3. Entrepreneurship Support System and Start-ups:

Introduction to start-up’s, Role of District Industries Centre in setting up industry, Function of
NSIC, SISI, NISIET, NRDC, SSIC, SIDO, NMTC, KVIC, RSMML, Role of state finance corporation, state
electricity corporations, pollution control board, BIS, I.S.O. etc.

4. Introduction to Tax System, Insurance and Acts:

Idea of income tax, sales tax, excise duty and custom duty, Industrial and fire insurance,
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procedure for industrial insurance, Introduction to Industrial acts, factory act, Workmen's
compensation act 1923, Apprentices act 1961, Environmental protection act 1986

5. Project Report Preparation:

Procedure of preparing a project report, Format of project report, Preparation of project report,
Introduction to ISO: 9000 Series of Quality System

(5.VP.03) Project

On the basis of learning in the vocational diploma, a project to be taken up by the student
strengthening his/ her vocational skills

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Level 6 (Semester I)

(6.GV.01) Metal Casting Technology

1. Introduction
Design advantages of casting, Advantages of casting process, Metallurgical advantage.
Technology of pattern making requirement, Pattern material, wood &wood product,
plaster, Plastics and rubbers, Polyesters resins waxes, Machines and tools for pattern
making machine for wood pattern making, Machines for metal pattern making, Allowance
and other Technological considerations – contraction allowance, Machining allowance,
Draft or taper allowance, Rapping and shake allowance, Distortion allowance, Core Prints,
Core boxes, Use of loose pieces

2. Technology of moulding and core making

Moulding sands, Principal ingredients of moulding sands, Specification and testing of
moulding sands, Classification of Moulding sands, Additives to moulding and Core making
sands, Mould Dressings. Sand Conditioning, Sand Preparation equipment.

3. Moulding processes
Types of sand moulding, Tools for hand moulding, Characteristics of cores and core sands,
Types of cores, Use of chaplets, Machine moulding, Core making machines, Processes based
on organic binders.

4. Technology of metal casting processes

Permanent mould casting, Types of die casting machines, Centrifugal casting, continues
casting, Electro slag casting, Gating system, Riser of casting, Economic considerations,
Melting equipments for foundries, Defects in castings.

5. Modernization & Mechanization of foundries

Need, Area for mechanization, Material handling, Pollution control in foundries, Pollutants
in a foundry, Plant layout for foundries, steps in planning a foundry layout.

(6.GV.02) Production Automation & Computer Integrating Manufacturing

UNIT 1
GENERAL: Automation-Definition, Scope, its types and their merits, reasons for
automation, Its appreciation and criticism, Meaning of the term Computer Integrated
Manufacturing (CIM CAD/ CAM) Relationship between CIM and Automation
FUNDAMENTALS OF MANUFACTURING AND AUTOMATION: Types of Industries-
Manufacturing, Processing; Basic producers, Converter, Fabricators.
Types of Production-Job shop production, Batch production Mass production (Quantity
Production and Flow production). Manufacturing - Functions - Processing - Basic
processing, Secondary processing; Operations enhancing physical properties and finishing
operations, Assembly, Material handling and Storage; Inspection and test and control, their
meaning with automation point of view, Automation of welding
Manufacturing Process Inputs - Raw materials, Equipments (Machine Tools), Tooling and
fixtures, Energy and Labour, Outputs - Finished product and Scrape/Waste. Plant Layout -
Its meaning and concept of fixed position layout, Process Layout, Product layout and Group
technology layout, Organisation and Information Processing Business functions, Product
design, Manufacturing planning and Manufacturing control
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UNIT 2
PRODUCTION CONCEPT: Such as Manufacturing Lead Time (MLT), Production rate,
Components of Operation Time, Production Capacity (PC), Utilisation and availability, Work
in Process (WIP), Time in Plant (Tip), WIP Ratio, Tip ratio, their meaning and significance.
Simple numerical problems
Automation Strategies and Their Effect - Specification of operation, Combined operations,
Simultaneous operations, Integration operations, Increase flexibility, Improved material
handling and storage, on-line inspection, process control and optimization, Plant operation
control, computer integrated manufacturing.
PRODUCTION ECONOMICS: Methods evaluation investment alternatives, Constraints in
manufacturing, Break Even Analysis, Unit Cost of Production, Cost of manufacturing, lead
time and work in process.

UNIT 3
ASSEMBLY SYSTEM AND LINE BALANCING: The assembly process, Assembly system,
Manual assembly lines, Line balancing problems, Computerised line, balancing methods,
Other ways to improve the line balancing, flexible manual assembly line
AUTOMATED ASSEMBLY SYSTEMS: Design for automated assembly, Types of automated
assembly systems, Parts feeding devices, analysis of multi-station Assembly machines,
Analysis of single station assembly machines

UNIT 4: NUMERICAL CONTROL PRODUCTION SYSTEM

Numerical controlling, Coordinate system, and Machine motions, Types of N.C. systems,
Machine tool applications, Economics of NCS

UNIT 5
N.C. PART PROGRAMMING: Tape and Tape format, Methods of N.C. part programming,
Computer assisted part programming, The APT Language, Manual data inputs, N.C. part
programming using CAD/CAM and Computer automated part programming.
DNC, CNC & ADAPTIVE CONTROL: Direct Numerical Control (DNC), Computer Numerical
control (CNC), Adaptive Control Machining, Current trends in N.C., introductory idea of FMS
(Flexible Manufacturing System)

Reference Books:
1. Numerical Control Machines: NK Mehta
2. Production Automation & Computer Integrated Manufacturing: MP Groover

(6.GV.03) Fundamentals of Mechatronics

1. Introduction:
Introduction to Mechatronics, systems, measurement systems, control systems, the
Mechatronics approach.
Introduction to Transducers: Sensors and transducers, operating characteristics of
transducers, measurement of displacement, velocity, pressure, flow, and temperature.

2. Signal conditioning:
Signal conditioning- their features and various blocks, the operational amplifiers,
Protection, Filtering, Wheatstone bridge, Digital signals, Multiplexers, Data acquisition,
Digital signal processing.
Data Presentation Systems: Displays, Data presentation elements, Magnetic recording,
Displays, Data acquisition system, Telemetry- electrical, optical and pneumatic methods of
telemetry.
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3. Introduction to process control systems:

Importance of process control, analog and digital processing, Supervisory digital control,
direct digital control. Controller Characteristics: Process characteristics, control system
parameters, Discontinuous controller modes (two position, multiple position, floating
position), Continuous controller modes i.e. P, I, D, PI, PD, PID.

4. Introduction of Mechanical Actuation Systems:

Mechanical Actuation Systems for motion, Kinematics chains, Cams, Gear trains, Belt and
chain drives, Bearings.
Pneumatic and Hydraulic Systems: Actuation systems, Pneumatic and hydraulic systems,
Directional control valves, Pressure control valves, Cylinders, Process control valves, rotary
actuators.

5. Introduction of Electrical Actuation Systems:

Electrical systems, Mechanical Switches, Solid-state switches, Solenoids, DC motors, AC
motors, Stepper motors.

(6.GV.04) Machining and Machine Tools

1. Classification of Metal Removal Process and Machines Mechanics of Metal Cutting:

Geometry of single point cutting tool and tool angles, tool nomenclature in ASA, ORS, NRS
and interrelationship, introduction of mechanism of chip formation and types of chips, chip
breakers, orthogonal and oblique cutting, cutting forces and power required, theories of
metal cutting, thermal aspects of machining and measurement of chip tool interface,
temperature, friction in metal cutting.

2. Machinability:
Concept and evaluation of machinability, tool life, mechanisms of tool failure, tool life and
cutting parameters, machinability index, factors affecting machinability, Cutting fluids,
types, properties, selection and application methods, General Purpose Machine Tools:
tooling, attachments and operations performed, selection of cutting parameters, Simple
calculation of time for machining.

3. Special Purpose Machine Tools:

Automatic lathes, capstan and turret lathe machines, tracer attachment in machine tools,
mechanical-copying machines, Hydraulic tracing Devices, Electric tracing systems,
Automatic tracing, Abrasive Processes: Abrasives, natural and synthetic, manufacturing,
nomenclature, selection of grinding wheels, wheel mounting and dressing, characteristic
terms used in grinding, machines for surface and cylindrical grinding, their constructional
details and processes, surface finishing, honing, lapping, super finishing, polishing and
buffing processes.

4. Thread and Gear Manufacturing:

Casting, thread chasing, thread cutting on lathe, thread rolling, die threading and tapping,
thread milling, thread grinding, Gear Manufacturing Processes: Hot rolling, stamping,
powder metallurgy, extruding etc. gear generating processes, gear hobbling, gear shaping,
gear finishing processes, shaving, grinding, lapping, shot blasting, phosphate coating, gear
testing.
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5. High Velocity Forming Methods:
(High-energy rate forming processes) Definition, Hydraulic forming, explosive forming,
electro-hydraulic forming, magnetic pulse forming

Reference Books:
1. Machine Design, Sadhu Singh, Khanna Publishing House
2. Machine Design Data Book, Sadhu Singh, Khanna Publishing House

(6.VP.01) Metal Casting Technology Workshop

Minimum work in each section is indicated against that

PATTERN MAKING: (a) Making Patterns (At least two) (i) Solid one-piece pattern (ii) Split
tow piece pattern (iii)Split three-piece pattern (iv) Gated pattern (b) Making Core Boxes (At
least one) (i) Straight Core Box (ii) Bent Core Box.

MOULDING
SAND PREPARATION AND TESTING: (a) Sand Testing (At least one Experiments) (i)
Grading (Grain Size). (ii) Determination of Moisture content (iii) Determination of Clay
content. (iv) Determination of Permeability for gases (b) Preparation of: (i) Green Sand
Composition. (ii) Dry sand Composition. (iii)Loan Sand composition (iv) Oil Sand for Cores.

MOULDING: (a) Making at least 3 sands moulds of different forms with different types of
pattern using. (i) Floor Moulding. (ii) Two Box Moulding. (iii)Three Box (or more)
Moulding. (b) At least one of the following: (i) Making and setting of cores of different types.
(ii)Making one shell mould apparatus

(C) MELTING AND POURING: (Each to be demonstrated at least once in the section). (a)
Demonstration of Melting of cast iron in (i) Pit Furnace. (ii) Cupola. (b) Demonstration of
Melting a non-Ferrous metal in (i) Pit furnace. (ii) Tilting Furnace.
(c) Pouring of metals in moulds (Ferrous and Non-Ferrous).

(D) CLEANING AND INSPECTION: (a) Shaking, cleaning and fettling of casting (At least 2
Casting) (b) (i) Inspection of cast component (visual) and preparing inspection report (At
least one report). (ii) Establishing cause of Defects seen (At least one cause).

(E) CASE STUDY OF: At least 2 sand castings produced from sand preparation pattern
layout to final finished casting.

(6.VP.02) Mechatronics Lab.

1. Displacement Measurement using Capacitive & inductive Pick –ups.

2. Study of Speed Measurement System: (a) Magnetic Pick-up (b)Stroboscope
3. Study of Load Measurement System Load Cell
4. Measurement of temperature using thermocouple, thermistor and RTD
5. Measurement of displacement using POT, LVDT & Capacitive transducer
6. Torque measurement using torque measuring devices
7. Strain Measurement using strain gauge
8. Frequency to Voltage Converter and vice versa

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9. Position and velocity measurement using encoders
10. Study on the application of data acquisition system for industrial purposes

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Level 6 (Semester II)

(6.GV.05) Mass Production Devices

1. Tool holders:
Tool holders for turning and milling carbide inserts-types, ISO-designation and
applications, Tool holding and tool mounting systems for conventional milling and drilling
machine tools.

2. Locating and clamping devices:

Concept, meaning and definitions of location and clamping, Use of locating and clamping
principles in day-to-day supervision on shop floor, Degree of freedom-concept and
importance, 3-2-1 principle of location, Locators-Types, Sketches with nomenclature,
Working, Applications, Fool proofing and ejecting

3. Clamping devices:
Types, Sketches with nomenclature, Working, Applications

4. Jigs and fixtures:

Concept, meaning, differences and benefits of jigs and fixtures, Types, sketches with
nomenclature, working and applications of jigs, Types, sketches with nomenclature,
working and applications of fixtures

5. Design of Jigs and Fixtures:

Steps in designing jigs and fixture for given simple component

(6.GV.06) Lean and Agile Manufacturing

1. Introduction-
Introduction to Just in time production, Toyota production system, Introduction to lean
manufacturing (LM), history of LM, advantages of LM over mass production

2. Waste Identification-
Types of wastes, lean manufacturing principles; Value, value stream, flow, pull and perfection

3. Value stream mapping-

Introduction to value stream mapping, types of value stream mapping, value added
activities, necessary non value added activities, non-value added activities

4. Lean manufacturing tools-

Introduction to 5S, Kanban, kaizen, work standardization, Statistical process control,
automation and other lean tools

5. Agile manufacturing-
Introduction to agile manufacturing, advantages of agile manufacturing, differences with
lean manufacturing.

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(6.GV.07) Metal Forming Processes

1. Rolling-
Introduction, Types of rolling, Hot rolling, Two high reversing mill, Three high mill,
Continuous mill, Roll bending

2. Forging-
Introduction, Advantages of Forging, Application of Forging, Limitations of Forging,
Upsetting, Hollow Forging, Impression die or closed, Methods of Forging, Drop Forging,
Press Forging, Hammer and press Forging, Hot bar Forging, Upset Forging

3. Extrusion-
Direct and forward, Sleeve method of direct, Indirect or backward, Impact Extrusion, Tube
Extrusion, Stepped Extrusion, Combined forging and Extrusion

4. Drawing-
Wire Drawing, Cupping and Bending, Tube Drawing, Spinning, Hot and cold Spinning
Advantages of Metal Spinning

5. Pipe and Tube Production-

Manufacturing of seamless pipe- Butt welded pipe- Lap welded pipe

(6.GV.08) Non-conventional Machining

Unit-I Introduction: Limitations of conventional manufacturing processes, need of

unconventional manufacturing processes and its classification.

Unit-II Un-Conventional Machining Processes: Principle and working and applications of

unconventional machining processes such as Electric Discharge machining (EDM), Electro-
Chemical machining (ECM), Ultrasonic Machining (USM), and Abrasive Jet machining (AJM)

Unit-III Un-Conventional Welding Processes: Principle and working and applications of

unconventional welding processes such as Laser Beam Welding, Electron Beam Welding,
Ultrasonic Welding, Plasma Arc Welding processes.

Unit-IV Explosive Welding: Cladding etc. Under water welding, Metalizing Theory, Process
and applications

Unit-V Un-conventional forming processes: Principle and working and applications of

high energy forming processes such as Explosive forming, Electromagnetic forming. Electro
discharge forming Water hammer forming, Explosive Compaction

Reference Books:
1. Modern Machining Process, P.C. Pandey
2. Un-conventional machining, V.K. Jain

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(6.VP.03) Tool & Die Making Lab

 Manufacture of Box Jig and Angle plate jig

 Manufacture of DzVdz Block angle grinding Fixtures and profile milling fixture
 Manufacture of simple Blanking & piercing Tool
 Manufacture of Progressive tool for producing a Cycle chain link
 Manufacture of Press tools like Combination tool & Compound tool
 Manufacture of Draw tool
 Trial out On Fly press and power press the Produced components such as V, U, Cycle
link, Cup , Washer and Cycle bell cup
 Manufacture of simple V and U bending tool
 Maintenance of Jig & fixture and press tool

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Level 7 (Semester I)

(7.GV.01) Reliability, Maintenance and Safety Engineering

1. Reliability-
Definition, reliability function, Mean failure rate, mean time to failure (MTTF), mean time
between failures (MTBF), hazard rate curve. Bathtub curve, Conditional Reliability

2. Constant Failure rate model-

Exponential Reliability function, Failure Modes, CFR model, memory lessness, System
reliability: Series, parallel, mixed & complex configuration; Reliability improvement.

3. Design for reliability-

Reliability specifications and system measurements, System Effectiveness, redundancy,
Classification of Redundancy, Introduction of failure mode and effect analysis (FMEA)

4. Maintainability-
Analysis of Downtime, repair time distribution, stochastic point processes.

5. Safety engineering-
Fundamentals of industrial safety, Safety policy and safety terminology, Different types of
safety systems and equipments, Safety targets, standards, objectives

Reference Books:
1. Reliability Engineering, S.C. Sharma, Khanna Publishing House

(7.GV.02) Plant Layout & Product Handling

Objective of Facility Design: Types of layout problems, the layout function, organization of
layout. Analysis and Design of Material Flow: Systems approach to flow cycle, process
charts, flow process charts, Quantitative analysis of material flow; optimal material flow
configuration. Space and Area Allocation for Production and Physical Plant Services;

Computerized handling of layout algorithms; Algorithms for computerized Layout Planning,

Construction and Development type of computerized Layout Planning Techniques i.e.
CRAFT, ALDEP, CORELAP etc.;

Product handling; Design of system configurations conforming to various kinds of product features
and layout characteristics; Design concepts of common handling and transfer equipment; Different
types of conveyors, elevators, fork lifters;

Design concept of warehouse facilities commensurate with adopted kind of handling and
transfer devices; Automated Handling of materials, Automated Transfer lines, AGVS, Use of
Robots in Product handling, automated packaging devices.

Application of pneumatic and hydraulic system in transportation and handling of products,

Design of integrated plant layout for product handling systems

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(7.GV.03) Product Design for Manufacturing

1. Importance of New Product-

Importance of new product for growth of enterprise, Definition of product and new
product, Classification of products from new product development point of view- Need
based/Market pull products, Tech. push, Platform based, Process based and customized
products

2. New product development process and organization-

Generic product development process for Market Pull and Market Push Products, Need
Identification and Analysis, Problem Formulation, establishing economic existence of need,
Engineering Statement of Problem, Establishing Target Specification

3. Generation of Alternatives and Concept Selection-

Introduction to Concept generation, Tools of creativity like brain storming, Analogy,
Inversion, introduction to Concept feasibility and Concept Selection, Establishing
Engineering Specification of Products

4. Preliminary and Detailed Design-

Preliminary design, Identification of subsystems, Subsystem specifications, detailed design
of subsystems, component design

5. Assembly drawing and review-

Preparation of assembly drawings, Review of product design from point of view of
Manufacturing, Ergonomics and aesthetics

(7.GV.04) CAD & CAM

1. Introduction CIM and CAD & Analysis:

CIM: Introduction of CIM– concept of CIM - evolution of CIM – CIM wheel –Benefits –
integrated CAD/CAM. CAD: Introduction– CAD definition – Shigley’s design process –
CAD activities – benefits of CAD. Types of CAD systems, CAD software packages, 2D & 3D
transformations, Geometric modeling: Techniques: Wire frame modeling – surface
modeling – solid modeling

2. Computer aided Manufacturing

CAM: Definition, functions, benefits. Group technology – Part families - Parts
classification and coding - coding structure – Optiz system, MICLASS system and CODE
System - process planning – CAPP – Types of CAPP: Variant type, Generative type –
advantages of CAPP – production planning and control – computer integrated production
management system – Master Production Schedule (MPS) – Capacity planning –
Materials Requirement Planning (MRP) –Manufacturing Resources Planning (MRP-II)

3. CNC Machine and Components:

CNC Machines: Numerical control – definition – components of NC systems –
development of NC – DNC – Adaptive control systems – working principle of a CNC
system – Features of CNC machines - advantage of CNC machines – difference between
NC and CNC – Construction and working principle of turning centre – Construction and
working principle of machining centers – machine axes conventions turning centre and
machining centre – design considerations of NC machine tools.

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4. Part Programming
NC part programming – methods – manual programming – conversational programming
– APT programming - Format: sequential and word address formats - sequence number –
coordinate system – types of motion control: point-to-point, paraxial and contouring –
Datum points: machine zero, work zero, tool zero NC dimensioning – reference points –
tool material – tool inserts - tool offsets and compensation - NC dimensioning –
preparatory functions and G codes, miscellaneous functions and M codes – interpolation:
linear interpolation and circular interpolation.

5. FMS, Integrated Material Handling and Robot:

Types of manufacturing - introduction to FMS – FMS components – FMS layouts – Types
of FMS: flexible manufacturing cell – flexible turning cell – flexible transfer line – flexible
machining systems – benefits of FMS - introduction to intelligent manufacturing system –
virtual machining. Computer Integrated material handling – AGV: working principle –
types, benefits – Automatic Storage and Retrieval Systems (ASRS). ROBOT – definition –
robot configurations – basic robot motion – robot programming method – robotic
sensors - industrial applications: characteristics, material transfer, machine loading,
welding, spray coating, assembly and inspection.

Reference Books:
1. Engineering AutoCAD, Pradeep Jain & A.P. Gautam, Khanna Publishing House
2. Engineering Graphics and Design, Pradeep Jain & A.P. Gautam, Khanna Publishing House

(7.VP.01) CAD & CAM Lab

 Introduction and different features of the CAD Software.

 2-D Drafting.
 3-D Modeling.
 3-D Advanced Modeling.
 Assembly modeling.
 Feature Modification and Manipulation
 Detailing.
 Sheet Metal Operations.
 Surface Modeling
 To prepare part programming for plain turning operation.
 To prepare part programming for turning operation in absolute mode.
 To prepare part program in inch mode for plain turning operation.

 To prepare part program for taper turning operation.

 To prepare part program for turning operations using turning cycle.
 To prepare part program for threading operation.
 To prepare part program for slot milling operation.
 To prepare part program for gear cutting operation.
 To prepare part program for gear cutting using mill cycle.
 To prepare part program for drilling operation.
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Level 7 (Semester II)

(7.GV.05) Rapid Prototyping and Reverse Engineering

1. Introduction:

Introduction to Prototyping, Traditional Prototyping Vs. Rapid Prototyping (RP), Need for
time compression in product development, Usage of RP parts, Generic RP process,
Distinction between RP and CNC, other related technologies, Classification of RP.

2. CAD Modelling and Data Processing for RP:

CAD model preparation, Data Requirements, different types of Data formats, Data
interfacing, Part orientation and support generation, Support structure design, Model
Slicing and contour data organization, direct and adaptive slicing, Tool path generation.
3. RP Systems:

Photo-polymerization process, Powder Bed Fusion process, Applications of Powder Bed

Fusion Processes. Extrusion - Based RP Systems, 3D Printing process modelling,
Applications of Printing Processes. Sheet Lamination process /Laminated Object
Manufacturing (LOM), Beam Deposition: Laser Engineered Net Shaping (LENS), Direct
Metal Deposition (DMD), Processing - structure- properties, relationships, Benefits and
drawbacks.

4. Rapid Tooling:

Conventional Tooling Vs. Rapid Tooling, Classification of Rapid Tooling, Direct and Indirect
Tooling Methods, Soft and Hard Tooling methods.

5. RP Applications:

Design, Engineering Analysis and planning applications, Rapid Tooling, Reverse

Engineering, Medical Applications of RP

(7.GV.06) Process Planning and Control

1. Demand Forecasting-
Introduction, components of forecasting demand, Approaches to forecasting: forecasts
based on judgment and opinion, Selection of forecasting technique.

2. Capacity Planning-
Defining and measuring capacity, determinants of effective capacity, capacity strategy,
steps in capacity planning process, determining capacity requirements, Capacity
alternatives, Evaluation of alternatives; Cost-Volume analysis.

3. Facility Location-
Need for location decisions, factors affecting location, qualitative and quantitative
techniques of location. Facilities layout: Product, Process, fixed position, combination and
cellular layouts; Designing product and process layout, line balancing.

4. Production Control-
Capacity control and priority control, production control functions; Routing, scheduling,

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dispatching, expediting and follow up, Techniques of production control in job shop
production, batch production and mass production systems

5. Sequencing-
Priority rules, sequencing methods, sequencing jobs through two work centers, scheduling
services, application of CPM and PERT techniques.

(7.VP.03) Project

On the basis of learning in the B.Voc. Programme, i.e. Level 5 to Level 7, a project to be
taken up by the student strengthening his/ her vocational skills.

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