[PDF] Syllabus Workshop Instructor Tool And Die|242/2023 Syllabus Kerala PSC

Syllabus Workshop Instructor Tool and Die: DETAILED SYLLABUS FOR THE POST WORKSHOP INSTRUCTOR /
INSTRUCTOR GRADE II / DEMONSTRATOR / DRAFTSMAN GRADE II IN
TOOL AND DIE ENGINEERING (TECHNICAL EDUCATION
DEPARTMENT), Cat No: 242/2023
(Total Marks- 100)

Contents

242/2023 syllabus Kerala PSC

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Module 1: Production Engineering (10 Marks)

Elementary ideas about various basic workshop practices of foundry, welding, smithy and Fitting
and various tools using in each sections. Powder metallurgy.
Machine tools like lathe, shaper, planer, milling, drilling and slotting machines and its
operations, Cutting tools, Tool materials, cutting speed, feed, depth of cut, tool nomenclature,
tool life.

Module 2: Engineering Graphics & Tool Engineering Drawing (10 Marks)

First angle projection method and its symbol, projection of points and line in four quadrants,
construction of various conic sections like ellipse, parabola and hyperbola, Development of
surfaces, section of solids, Isometric and oblique projections.
Screw thread nomenclature, forms of thread, types of bolts and nuts, riveted joints, limit, fit and
tolerances, surface texture and geometric tolerances in drawing.

Module 3: Strength of Materials & Material Science (10 Marks)

Simple stresses and strains, Hook’s law, elastic constants, Factor of safety, linear stress strain,
lateral stress and strain, Poisson’s ratio, Thermal stress and strains, composite bar, Shear force
and bending moments, torsion of shafts, thin and thick cylinders, Columns and struts.
Mechanical properties, crystal structures, ferrous metals and its alloys, iron and carbon steels,
alloy steels, destructive and non-destructive testing, heat treatment processes, non-ferrous metals
and its alloys.

Module 4: Fluid Mechanics (5 Marks)

Definition of fluid, properties of Fluid, Pascal’s Law, Measurement of pressure, Total
pressure, center of pressure, Buoyancy, Meta centre, Metacentric height, types of fluid flow,
discharge, continuity equation, Euler’s equation, Bernoulli’s equation and applications, flow
through Orifices, notches and weirs, water hammer, vapour pressure. Basic circuits in
hydraulic and pneumatic systems.

Module 5: Moulds & Dies Technology (15 Marks)

Plastic materials and their properties, thermo and thermo setting plastics, injection moulding
and injection moulding machine, terminology used in moulds, feed system, ejection
techniques, cooling system, classification of moulds, compression moulding, transfer
moulding, extrusion moulding, blow moulding, rotational moulding, calendaring, vacuum
forming, multi colour moulding. Die casting process, die casting machines, die casting alloys.

Module 6: Press Tool Technology (15 Marks)

Press machine parts, specification, classification and working. Press tool parts, terminology
and operations like blanking, piercing, shearing, cropping, notching, lancing, coining,
embossing, stamping, curling, drawing, bending and forming, types of dies and construction
of various dies, pilots, strippers, knock outs, stoppers, gauges, fasteners and dowels in press
tools, theory of bending, types of bending, fine blanking.

Module 7: Tool Design (10 Marks)

Die set types, Strip layout, cutting clearance, cutting force, strip layout percentage utilization,
blanking force, bending stress, bending pressure, bending radius, bend allowance, blank
development calculation in bending, calculation of drawing force, flat blank diameter, number
of draws required, blank holding force calculation in drawing(basics only).
Runner diameter, gate size, shrinkage, temperature control in moulding, types of compression
moulding, types of transfer moulding.

Module 8: Engineering Metrology (10 Marks)

Methods of measurements: direct & indirect, Terms applicable to measuring instruments:
precision and accuracy, sensitivity and repeatability, range, threshold, hysteresis, calibration;
errors in Measurements.
Measuring gauges including limit gauges, comparators, linear and angular measurements,
vernier caliper, vernier height gauge and depth gauge, micrometer, vernier micrometer,bevel
protractor, vernier bevel protractor, slip gauges, sine bar, clinometer, spirit level, auto
collimator.

Module 9: Jigs & Fixtures (5 Marks)

Fool proofing, degrees of freedom, 3-2-1principle of location, types of locators, principles of
clamping, types of clamping, jig bushings, drill jigs, types of fixtures like turning fixtures,
milling fixtures, grinding fixtures etc.

Module 10: Modern Production Process (10 Marks)

Non-conventional Machining Processes like ultra-sonic machining, electric discharge
machining, wire cut EDM, abrasive water jet machining, laser beam machining, electro
chemical machining, NC and CNC machines, programming in CNC machines, part
programming, computer integrated manufacturing, flexible manufacturing system.