Machinist (Grinder)

ITI Machinist (Grinder) Syllabus (English)

Course Overview

• Trade Name: Machinist (Grinder)
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in operating grinding machines (surface, cylindrical, tool, and cutter) to produce precision components with fine tolerances, equipping them for roles as grinder operators, tool room machinists, or precision technicians in manufacturing, automotive, or aerospace industries, or for self-employment in grinding services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Grinding: Role of grinding, types of grinding machines (surface, cylindrical, centerless), applications.
• Safety Practices: Machine safety, PPE (goggles, gloves, face shields), dust hazards, first aid, workshop ergonomics.
• Workshop Tools: Vernier calipers, micrometers, dial gauges, sine bars; usage and maintenance.
• Grinding Machine Basics: Parts (bed, wheel head, table), types of grinding wheels, abrasives (aluminum oxide, silicon carbide).
• Material Properties: Ferrous (steel, cast iron) and non-ferrous (aluminum, brass) metals; hardness and grindability.
• Wheel Selection: Grain size, bond types (vitrified, resinoid), wheel marking systems, balancing wheels.
• Engineering Drawing: Reading blueprints, tolerances, surface finish symbols, grinding job sketches.

Trade Practical

• Safety Drills: Using PPE, handling abrasive dust, practicing machine shutdown, emergency procedures.
• Tool Handling: Measuring with vernier calipers/micrometers, setting sine bars for angles.
• Grinding Machine Setup: Mounting grinding wheels, checking wheel balance, aligning workpieces.
• Basic Surface Grinding: Grinding flat surfaces on mild steel, achieving parallelism (±0.02mm).
• Measurement Practice: Checking surface finish with comparators, verifying tolerances.
• Drawing Interpretation: Reading grinding job drawings, marking workpieces for precision.
• Project Work: Grinding a mild steel plate to specified flatness and surface finish.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Cylindrical Grinding: External and internal grinding, machine types, work-holding devices (chucks, centers).
• Grinding Wheel Dressing: Truing, dressing tools (diamond, star dresser), techniques for wheel preparation.
• Coolants and Lubricants: Types (water-based, oil-based), functions, effects on grinding efficiency.
• Grinding Parameters: Wheel speed, feed rate, depth of cut; impact on finish and heat generation.
• Heat Treatment Effects: Hardening, tempering, annealing; influence on grinding processes.
• Quality Control: Surface roughness standards (Ra, Rz), inspection methods, ISO tolerances.
• Workshop Calculation: Wheel speed (RPM), surface area calculations, grinding time estimation.

Trade Practical

• Cylindrical Grinding: Grinding external surfaces of steel shafts, maintaining roundness (±0.01mm).
• Wheel Dressing: Truing wheels with diamond dressers, shaping wheels for specific profiles.
• Coolant Application: Using coolants during cylindrical grinding, maintaining flow and filtration.
• Internal Grinding: Grinding bores in steel components, ensuring cylindricity.
• Inspection Tasks: Measuring ground surfaces with dial gauges, checking roughness with profilometers.
• Precision Setup: Using magnetic chucks, centers for accurate workpiece alignment.
• Project Work: Grinding a cylindrical steel component (e.g., shaft) with external and internal finishes.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Tool and Cutter Grinding: Grinding drills, milling cutters, reamers; machine setup and geometry.
• Centerless Grinding: Principles, regulating wheels, through-feed vs. in-feed grinding, applications.
• CNC Grinding Basics: CNC grinding machines, G-codes, M-codes, programming for precision grinding.
• Advanced Wheel Technology: CBN and diamond wheels, super-abrasives, applications for hard materials.
• Metrology: Slip gauges, CMM, optical comparators; precision measurement techniques.
• Machine Maintenance: Lubricating grinding machines, checking spindle alignment, wheel balancing.
• Production Planning: Job scheduling, wheel life estimation, optimizing grinding cycles.

Trade Practical

• Tool Grinding: Sharpening drills, milling cutters on tool-and-cutter grinders, verifying angles.
• Centerless Grinding: Setting up for through-feed grinding, achieving consistent diameters.
• CNC Grinding Practice: Programming CNC grinders for simple profiles, running test jobs.
• Advanced Wheel Use: Grinding hard materials (e.g., tool steel) with CBN wheels, optimizing finish.
• Precision Measurement: Using CMM for complex profiles, slip gauges for calibration.
• Maintenance Tasks: Lubricating machine ways, aligning grinding spindles, replacing worn belts.
• Project Work: Grinding a tool (e.g., milling cutter) and a centerless-ground component to specifications.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Advanced CNC Grinding: Multi-axis CNC grinding, profile grinding, CAD/CAM integration.
• Special Grinding Techniques: Creep-feed grinding, high-speed grinding, grinding exotic alloys (titanium, Inconel).
• Troubleshooting: Diagnosing grinding faults (burn marks, chatter), wheel glazing, spindle issues.
• Automation Trends: Industry 4.0, IoT in grinding, smart grinding machines.
• Entrepreneurship: Starting a grinding workshop, costing, market trends in precision components.
• Environmental Practices: Recycling abrasive dust, reducing coolant waste, energy-efficient grinding.
• Quality Standards: ISO 9001, Six Sigma, ensuring defect-free grinding output.

Trade Practical

• CNC Profile Grinding: Programming complex contours, grinding precision dies with CAD/CAM files.
• Special Grinding: Performing creep-feed grinding on tool steel, optimizing depth of cut.
• Troubleshooting Tasks: Correcting burn marks, re-dressing glazed wheels, recalibrating spindles.
• Automation Practice: Testing IoT-enabled grinder features (e.g., real-time monitoring).
• Field Exposure: Hands-on training in tool rooms or manufacturing units (4-6 weeks).
• Quality Inspection: Using optical comparators for profile checks, documenting tolerances.
• Project Work: Producing a precision-ground component (e.g., punch die) using CNC and manual grinding.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Grinding wheel speed, feed rate, stock removal, cycle time estimation.
  • Science: Mechanics of abrasive cutting, heat generation, surface integrity principles.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Grinding machine layouts, tool geometries, tolerance and surface finish annotations.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork.
  • IT Literacy: Using CAD/CAM for grinding, CNC programming software, online metrology resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like surface grinding, tool sharpening, CNC grinding, quality inspections.
• Evaluation Criteria: Grinding accuracy, surface finish quality, safety adherence, troubleshooting skills.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Grinder operator, tool room machinist, precision technician in manufacturing, automotive, or aerospace industries.
• Self-Employment: Precision grinding workshop, tool sharpening services, contract grinding jobs.
• Further Studies: Diploma in Mechanical Engineering, certifications in CNC grinding or precision metrology.