iti 15 April 2025
Operator Advanced Machine Tools

ITI Operator Advanced Machine Tools Trade Syllabus

The ITI Operator Advanced Machine Tools trade is a two-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This engineering trade trains individuals to operate, set up, and maintain advanced machine tools, including CNC (Computer Numerical Control) lathes, milling machines, grinders, and other precision equipment, to manufacture metal components for industries like automotive, aerospace, and manufacturing. The syllabus combines theoretical knowledge, practical machining skills, and employability skills to prepare students for roles such as CNC operators, machinists, or tool room technicians in industrial settings, or as self-employed professionals running workshops.

Course Overview

  • Duration: 2 years (4 semesters, each 6 months)
  • NSQF Level: Level 5
  • Eligibility: Minimum 10th grade pass with science and mathematics (or equivalent)
  • Objective: To equip trainees with skills to operate advanced machine tools, program CNC machines, and produce precision components meeting industrial standards.

Detailed Syllabus Breakdown 

1. Trade Theory (Theoretical Knowledge)

Covers machine tool operations, CNC programming, and quality control principles.

  • Semester 1
    • Introduction to Machine Tools
      • Overview: role of operators, scope in manufacturing, safety practices.
      • Machines: lathes, drilling machines, grinders, their components, and functions.
      • Safety: handling tools, machine guards, personal protective equipment (PPE).
    • Engineering Materials
      • Types: metals (steel, aluminum), alloys, their properties, heat treatment.
      • Selection: choosing materials for machining based on strength, durability.
      • Testing: hardness, tensile strength, material defects.
    • Measuring Instruments
      • Tools: vernier calipers, micrometers, dial gauges, their calibration.
      • Techniques: precision measurement, tolerance, surface finish checks.
      • Standards: BIS, ISO for quality control in machining.
    • Cutting Tools and Operations
      • Tools: single-point, multi-point, tool geometry, tool life.
      • Operations: turning, facing, drilling, boring, knurling, parting-off.
      • Parameters: cutting speed, feed rate, depth of cut, their calculations.
    • Lathe Operations
      • Types: center lathe, turret lathe, their setups, and applications.
      • Processes: thread cutting, taper turning, eccentric turning.
      • Accessories: chucks (3-jaw, 4-jaw), faceplates, steadies, mandrels.
    • Basic Workshop Practices
      • Skills: marking, filing, hacksawing, chipping, scraping.
      • Equipment: bench vices, hand tools, surface plates, their maintenance.
      • Drawings: reading blueprints, interpreting GD&T (Geometric Dimensioning and Tolerancing).
  • Semester 2
    • Milling Machines
      • Types: vertical, horizontal, universal milling machines, their parts.
      • Operations: face milling, slot milling, profile milling, gear cutting.
      • Accessories: dividing heads, rotary tables, indexing mechanisms.
    • Grinding Machines
      • Types: surface, cylindrical, centerless grinders, their setups.
      • Processes: grinding wheels, dressing, truing, balancing, surface finish.
      • Parameters: wheel speed, work speed, depth of grind, coolant use.
    • Drilling and Boring
      • Machines: radial, pillar, gang drilling machines, boring mills.
      • Operations: drilling, reaming, counterboring, countersinking, spot facing.
      • Tools: twist drills, reamers, boring bars, their selection, and sharpening.
    • Jigs and Fixtures
      • Concepts: design, purpose, types (locating, clamping).
      • Applications: improving accuracy, repeatability in mass production.
      • Maintenance: cleaning, inspecting jigs/fixtures for wear.
    • Lubrication and Coolants
      • Types: oils, emulsions, synthetic coolants, their properties.
      • Systems: splash, flood, mist lubrication, coolant circulation.
      • Importance: reducing friction, heat, tool wear in machining.
    • Quality Control Basics
      • Standards: tolerance, fits, surface roughness, inspection methods.
      • Tools: comparators, profilometers, CMM (Coordinate Measuring Machine).
      • Processes: statistical process control (SPC), defect analysis.
  • Semester 3
    • Introduction to CNC Machines
      • Concepts: CNC lathe, milling, their components, control panels.
      • Programming: G-codes, M-codes, coordinate systems, tool paths.
      • Operations: setting workpieces, tools, zero points, dry runs.
    • CNC Programming Basics
      • Languages: ISO, FANUC, Siemens control systems.
      • Programs: linear, circular interpolation, canned cycles (drilling, tapping).
      • Tools: CAD/CAM software basics, program simulation, editing.
    • CNC Machine Operations
      • Setup: work holding, tool selection, offset settings.
      • Execution: running programs, monitoring machining, adjusting parameters.
      • Maintenance: cleaning, lubricating CNC machines, checking alignments.
    • Hydraulics and Pneumatics
      • Systems: pumps, valves, actuators, their roles in machine tools.
      • Circuits: hydraulic/pneumatic controls in CNC, clamping systems.
      • Troubleshooting: leaks, pressure issues, system failures.
    • Advanced Cutting Tools
      • Materials: carbide, ceramic, CBN (Cubic Boron Nitride), coatings.
      • Types: inserts, end mills, drills, their geometries, applications.
      • Selection: optimizing tools for materials, speeds, and feeds.
    • Production Planning
      • Concepts: batch production, job scheduling, time estimation.
      • Tools: process sheets, work orders, production charts.
      • Efficiency: minimizing downtime, optimizing machine utilization.
  • Semester 4
    • Advanced CNC Programming
      • Techniques: multi-axis machining, subprograms, macros.
      • Cycles: deep hole drilling, threading, milling complex profiles.
      • Optimization: reducing cycle time, improving tool life, accuracy.
    • CNC Machine Maintenance
      • Tasks: preventive maintenance, spindle alignment, backlash adjustment.
      • Diagnostics: error codes, sensor calibration, servo motor checks.
      • Records: maintenance logs, spare parts inventory management.
    • Automation and Robotics
      • Concepts: automated loading, robotic arms, Industry 4.0 basics.
      • Integration: CNC with PLC (Programmable Logic Controllers), IoT.
      • Applications: lights-out manufacturing, smart factories.
    • Tool Room Practices
      • Operations: die making, mold making, precision grinding.
      • Equipment: EDM (Electrical Discharge Machining), wire-cut machines.
      • Skills: reverse engineering, tool modification, repair.
    • Metrology and Inspection
      • Advanced Tools: laser scanners, optical comparators, 3D scanners.
      • Techniques: in-process inspection, final quality checks, reporting.
      • Standards: ISO 9001, AS9100 for aerospace, automotive industries.
    • Entrepreneurship and Industry Trends
      • Business: starting a machining workshop, cost estimation, client relations.
      • Trends: additive manufacturing, green machining, AI in CNC.
      • Certifications: NIMS (National Institute for Metalworking Skills), ASME.

2. Trade Practical (Hands-On Skills)

Focuses on operating machines, programming, and quality checks in workshop settings.

  • Semester 1
    • Safety and Workshop Practices
      • Practicing: wearing PPE, handling tools, emergency stops.
      • Performing: marking, filing, drilling on bench workpieces in labs.
      • Checking: tool conditions, workplace cleanliness in workshops.
    • Lathe Operations
      • Setting up: workpieces on 3-jaw/4-jaw chucks, aligning centers.
      • Performing: turning, facing, threading, taper turning in labs.
      • Measuring: dimensions, tolerances using verniers, micrometers.
    • Cutting Tool Preparation
      • Grinding: single-point tools, drills, checking angles in tool rooms.
      • Setting: tools in lathe tool posts, ensuring proper rake angles.
      • Testing: tool performance, surface finish on machined parts.
    • Precision Measurement
      • Using: vernier calipers, micrometers, height gauges in labs.
      • Checking: roundness, flatness, parallelism of workpieces.
      • Recording: measurements, deviations in inspection sheets.
    • Project Work
      • Task: machining a simple component (e.g., shaft, bush) in labs.
      • Output: achieving tolerances (±0.1 mm), documenting process.
      • Report: detailing setup, tools, challenges faced.
  • Semester 2
    • Milling Operations
      • Setting up: workpieces on milling tables, using vises, clamps.
      • Performing: face milling, slotting, keyway cutting in labs.
      • Using: dividing heads for gear cutting, indexing tasks.
    • Grinding Operations
      • Preparing: grinding wheels, dressing, mounting on grinders.
      • Performing: surface grinding, cylindrical grinding in labs.
      • Measuring: surface finish, tolerances using profilometers.
    • Drilling and Boring
      • Setting up: radial drilling machines, boring bars in labs.
      • Performing: drilling, reaming, boring to specified depths.
      • Checking: hole accuracy, alignment using dial gauges.
    • Jigs and Fixtures
      • Assembling: jigs for drilling, milling in mock setups.
      • Testing: repeatability, accuracy of machined parts in labs.
      • Maintaining: cleaning, storing jigs/fixtures properly.
    • Project Work
      • Task: machining a component with multiple operations (e.g., keyway, slot).
      • Output: achieving tolerances (±0.05 mm), verifying fits.
      • Portfolio: documenting setup, inspection, and outcomes.
  • Semester 3
    • CNC Machine Setup
      • Preparing: CNC lathe/milling, installing tools, workpieces.
      • Setting: tool offsets, work offsets, zero points in labs.
      • Testing: dry runs, verifying tool paths before machining.
    • CNC Programming
      • Writing: simple programs for turning, milling using G/M codes.
      • Simulating: programs on CNC simulators, checking errors.
      • Executing: programs on CNC machines, producing parts in labs.
    • CNC Operations
      • Operating: CNC lathe for turning, threading in mock setups.
      • Milling: slots, pockets, contours on CNC milling machines.
      • Monitoring: machining process, adjusting feeds/speeds.
    • Hydraulic/Pneumatic Systems
      • Assembling: simple circuits for clamping, tool movement in labs.
      • Testing: pressure, flow, detecting leaks in systems.
      • Troubleshooting: valve failures, actuator issues in setups.
    • Project Work
      • Task: programming and machining a CNC component (e.g., flange).
      • Output: achieving tolerances (±0.02 mm), verifying quality.
      • Report: including program code, setup photos, inspection data.
  • Semester 4
    • Advanced CNC Programming
      • Creating: multi-axis programs, subprograms for complex parts.
      • Optimizing: tool paths, cycle times using CAM software in labs.
      • Executing: programs for 3D contours, threading in CNC setups.
    • CNC Maintenance
      • Performing: lubrication, alignment checks, backlash adjustments.
      • Diagnosing: error codes, mechanical faults in CNC machines.
      • Documenting: maintenance schedules, spare parts usage in labs.
    • Automation Integration
      • Setting up: automated loading systems, robotic arms in mock setups.
      • Programming: basic PLC controls for CNC integration in labs.
      • Testing: automated cycles, ensuring repeatability, safety.
    • Tool Room Operations
      • Machining: dies, molds using EDM, wire-cut machines in labs.
      • Repairing: worn tools, modifying fixtures for production.
      • Inspecting: tool accuracy using CMM, laser scanners.
    • Project Work
      • Task: producing a precision component (e.g., gear, mold insert) in labs.
      • Output: meeting industry tolerances (±0.01 mm), full documentation.
      • Portfolio: compiling drawings, programs, inspection reports.

3. Workshop Calculation and Science

Supports machining with mathematical and scientific concepts.

  • Semester 1: Arithmetic (tolerances, ratios), physics (force, friction).
  • Semester 2: Geometry (angles, tapers), mechanics (torque, stress).
  • Semester 3: Trigonometry (tool angles, CNC coordinates), thermodynamics (heat in machining).
  • Semester 4: Algebra (programming equations), material science (alloys, coatings).

4. Engineering Drawing

Focuses on technical drafting for machining.

  • Semester 1: Orthographic projections, sectional views, machining symbols.
  • Semester 2: Assembly drawings, milling setups, GD&T basics.
  • Semester 3: CNC tool path sketches, jig/fixture designs.
  • Semester 4: 3D drawings, mold/die blueprints, CAM integration.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (reporting issues), basic IT (software tools).
  • Semester 2: Teamwork (workshop collaboration), time management.
  • Semester 3: Problem-solving (troubleshooting machines), leadership basics.
  • Semester 4: Entrepreneurship (workshop setup), industry awareness (trends).

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
  • Evaluation: Based on machining accuracy, CNC programming, quality control, and project work.

Career Opportunities

  • Employment: CNC operator, machinist, tool room technician in automotive, aerospace, or manufacturing industries.
  • Self-Employment: Starting a machining workshop, CNC service center, or tool repair unit.
  • Further Studies: Diploma in Mechanical Engineering (lateral entry), certifications like NIMS, or B.Tech.

Note

  • This syllabus aligns with NCVT guidelines but may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.
  • Source: Adapted from NCVT CTS framework and machining industry standards.

Trade Type

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