Diploma in Plastic Mould Technology 5th Semester Syllabus

                                 DIPLOMA IN PLASTIC MOULD TECHNOLOGY (DPMT)

SEMESTER-V

CNC Machining Techniques 

(Understanding on manufacturing molds using CNC machines)

32.1 Understanding Basic components NC machine and its evolution 

32.2 CNC machine tools – Principles, open loop and closed control system, 

32.3 Structural configuration of CNC machines 

32.4 Knowledge on DNC and its components 

32.5 Knowledge on CNC machines – Programming – Controls -G & M Codes, CAM programming, manufacturing of mold elements with CAD.CAM – CNC controls 

32.6 Study of CNC machining Centres –classificationparts and operations 

32.7 Concept of 3, 4 and 5 axis machines 

32.8 Study of CNC milling operation –simple programming, cutting tools, work holding devices, work piece alignment and datum setting. Applications in mold making 

32.9 Study of CNC turning Centre classification-parts and operations- concept of 2-axis- simple programmingcutting tools, work holding devices, work piece alignment and datum setting, Applications in mold making 

32.10 Knowledge of CNC EDM Die Sinking EDMPrincipal parts and their function , Advantages , disadvantages and applications - Axis designations - Simple programming for CNC EDM operation for making mould elements. 

32.11 CNC Wire EDM- Principal parts and their function , Advantages , disadvantages and applications - Axis designations Simple programming for CNC EDM operation for making mould elements

Mold Manufacturing Technology

(Knowledge on mold steel and different techniques used for cavity machining, Inspection and assembly of molds and polishing / Texturing the mold surfaces)

 33.1 Material selection for different molds – mold steels and non-ferrous materials 

33.2 Knowledge of Conventional Techniques -Procedure for manufacturing of moulds –Significance of traditional machines like Shaper, Lathe , Milling and Drilling machines for machining of Mould parts 33.3 Understanding signification of Pantograph Engraving machine in mould making - Finishing of core & cavity using CNC machines. 

33.4 Introduction to Electrical Discharge Machining (EDM): principle- Process - Types of EDMConstruction, Principal parts, Advantages and applications of Die Sinking EDM & Wire EDM in mold making 

33.5 Understanding Technological Parameters of EDMSpark gap calculations - Electrodes – Materials and Design

33.6 Study of Die electric fluids – Purpose, Types and properties and Applications 

33.7 Study of Electroforming : Process, Design, Materials and Machining for electroformed blanks and mould cavities 

33.8 Preparing Check list for mould assembly- Fitting and assembly of various mould elements - core insert, cavity insert, sprue bush- ejection system assemblyBlue matching and die spotting-venting -Final inspection-Fitting of locating ring and carrier barMould trial. 

33.9 Understanding Concept and symbols of Surface Roughness, terminology – 

33.10 Knowledge of Surface finish of various mould elements- Surface Texturing of Moulds – Process of Etching. 

33.11 Understanding Polishing Technology in Mould Making: Basics of polishing technology - Effect of mould materials on polishability- Types of polishing tools 

33.12 Knowledge of Methods of polishing -Basic information on ultra sonic polishing – Principles of Electro deposition in damaged moulding surfaces/ Protective Coating.

 Process Planning and Cost Estimation
(Knowledge on process planning, estimation and budgeting)

34.1 Introduction to concept of Process Planning Information required to do process planning - factors process planning procedure - Make (or) Buy decision using Break Even Analysis - simple problems. 34.2 Manual process planning - Automated process planning and generator process planning - Advantage of computer aided process planning 

34.3 Understanding of Value Engineering – Definition - cost control Vs cost reduction - value analysis, selection of product. 

34.4 Knowledge of Process - technological, specific component, Process flow requirements. Factors affecting process selection - machine capacity – analysis of machine capacity - process and equipment selection procedure 

34.5 Determination of man, machine and material requirements - simple problems - selection of material – jigs - fixtures –elements – types – applications- principles of location & clamping-jig bushes 34.6 Study of Factors influencing choice of machinery - simple problems - preparation of operation planning sheet for simple mould components. 

34.7 Knowledge of work study Concept, Techniques to reduce work content - method study – Procedure – Recording techniques used in method study - Micro motion study - Principles of motion economy - Therbligs - Simo chart - cycle graph - Chrono cycle graph - work measurement – 

34.8 Basic Procedures for the conduct of time study - calculation of standard time - simple problems – Ergonomics – definition – objectives – applications - working environment - work place layout - other areas. 

34.9 Basic understanding of Cost estimation - components of cost – direct cost - indirect cost - overhead expenses - estimation of cost elements - set up time and economic lot size - tool change time - Inspection time - performance factor – 

34.10 Elements of metal machining - cutting speed - feed - depth of cut - procedure for assigning cutting variables - basic formulae for calculation of machining times for the machining operation, use of standard tables for feeds and cutting speeds – exercises in calculating the machine times for the above mentioned operations – simple problems based on DFM (Design For Machine) & DFA (Design For Assembly)

Industrial Management and Entrepreneurship

(Study the requirement of management & implementation of ISO and safety norms)

35.1 Describe principles of management 

35.2 Describe functions of management 

35.3 Understanding organization structure and human resource management 

35.4 Understanding Quality Planning and Control 

35.5 Quality Assurance concept, introduction of ISO 9000 

35.6 Understanding the Concept of TQM and Organizational Excellence, Techniques of TQMPDCA, TEI, POKA-YOKE- Failure proofing, JIT manufacturing 

35.7 Knowledge on steps to start small scale industries 

35.8 Knowledge on Taxes. 

Mould Manufacturing Practice

(Development of Automatic injection, compression, transfer and blow moulds)

36.1 Familiarization of cylindrical grinding operation to maintain functional dimensions of hardened guide pillar, guide bush, core and cavity and other elements of mould. 

36.2 Rough machining using shaping machine (Bolster/Mould plates). 

36.3 Surface grinding of mould plates and mould elements. 

36.4 Drilling, reaming and tapping of mould plates and mould element. 

36.5 Precision machining of guide pillar & guide bush holes in mould plates using Jig boring machine and CNC milling machine. 

36.6 Rough machining of Core and Cavity of moulds using Lathe/milling machine. 

36.7 Precision machining of Core and Cavity of moulds using CNC machine tools. 

36.8 Machining of intricate shapes of Core and Cavity (soft/hardened) using CNC EDM & CNC Wire EDM. 

36.9 Polishing of core, cavity, sprue bush, runner, gate etc to mirror finish. 

36.10 Engraving and embossing of script & monograms. 

36.11 Mould assembly practice. 

36.12 Inspection of various systems of mould (Aligning system / core / cavity / cooling system / ejector system / feeding system / venting system / clamping system / moulding surface polishing etc.).

                                                                    practical

CAM & CNC Lab

(Knowledge on programming and operation of CNC machines)

37.1 Familiarization of NC & CNC machine tools. 

37.2 Familiarization of cutting tools and cutting fluids. 

37.3 Programming and operating of CNC lathe machine. 

37.4 Programming and operating of CNC milling machine. 

37.5 Programming and operating of CNC EDM. 

37.6 Programming and operating of CNC Wire-EDM.

CAD Lab II 

(Hands on experience on using AutoCAD software to draw product and mold design)

38.1 Production drawing development for various mould elements and mould base design in CAD 

38.2 Provide dimension on the geometry by using AUTOCAD Software. 

38.3 Prepare the solid model by using the commands in auto-CAD and do the editing whenever it is necessary to modify. 

38.4 Knowledge on 3D part design-core and cavity design, electrode design 

38.5 Plot the drawing with the help of AUTOCAD software