ITI Tool & Die Maker Syllabus (English)

Course Overview

• Trade Name: Tool & Die Maker

• Duration: 2 Years (4 Semesters)

• NSQF Level: Level 5

• Eligibility: 10th Grade Pass with Science and Mathematics

• Objective: To train candidates in designing, manufacturing, and maintaining precision tools, dies, jigs, and fixtures used in manufacturing industries, preparing them for roles as tool and die makers, CNC operators, or self-employment in precision engineering services.

• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Tool & Die Making: Role in manufacturing, types of tools (cutting, forming, gauging), dies (blanking, piercing).

• Safety Practices: PPE (safety goggles, gloves), machine guarding, workshop hazard management.

• Engineering Materials: Properties of steel, cast iron, non-ferrous metals; heat treatment basics.

• Hand Tools: Files, hacksaws, chisels, hammers; their uses and maintenance.

• Measurement Tools: Vernier calipers, micrometers, dial gauges; accuracy standards (±0.01 mm).

• Workshop Machines: Lathe, drilling, milling machines; basic operations and setups.

• Drawing Basics: Orthographic projections, sectional views, dimensioning standards.

Trade Practical

• Safety Drills: Using PPE, practicing fire evacuation, securing workstations.

• Filing Practice: Filing flat surfaces, achieving squareness (±0.05 mm).

• Measurement: Using vernier calipers, micrometers to measure components accurately.

• Marking: Marking lines/centers on metal using scribers, punches, and surface plates.

• Hand Tool Operations: Sawing, chipping, scraping mild steel workpieces.

• Drilling: Drilling holes on drill press, maintaining depth accuracy (±0.1 mm).

• Project Work: Fabricate a simple tool (e.g., punch) with filing and drilling, ensuring dimensional accuracy.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Precision Machining: Lathe operations (turning, threading), milling (slot cutting), grinding basics.

• Jigs and Fixtures: Types (drilling, milling jigs), design principles, applications.

• Cutting Tools: Geometry of single-point tools, drills, milling cutters; tool angles.

• Metrology: Surface plates, angle plates, gauge blocks; calibration techniques.

• Heat Treatment: Annealing, hardening, tempering; effects on tool life.

• Fasteners: Types of screws, bolts, nuts; thread standards (metric, BSW).

• CAD Basics: Introduction to AutoCAD, 2D drafting for tool design.

Trade Practical

• Lathe Operations: Turning cylindrical parts, cutting threads, achieving tolerances (±0.02 mm).

• Milling Practice: Milling slots, keyways on mild steel, ensuring flatness.

• Grinding: Surface grinding flat plates, maintaining parallelism (±0.01 mm).

• Jig Assembly: Assembling a drilling jig, aligning bushings accurately.

• Heat Treatment: Hardening and tempering small tools, checking hardness.

• CAD Drafting: Drawing simple tool components (e.g., punch-die set) in AutoCAD.

• Project Work: Manufacture a drilling jig for a 50x50 mm plate with precise hole placement.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Die Design: Blanking, piercing, forming dies; die components (punch, die block, stripper).

• CNC Machining: CNC lathe/milling basics, G-code, M-code programming.

• Tool Design Standards: Tolerances, fits (clearance, interference), IS/ISO standards.

• Hydraulics and Pneumatics: Principles in die automation, actuators, valves.

• Press Tools: Types of presses (mechanical, hydraulic), tonnage calculations.

• Quality Control: Inspection methods, CMM, hardness testing, defect analysis.

• CAD/CAM: 3D modeling basics, CAM toolpath generation for dies.

Trade Practical

• CNC Operations: Setting up CNC lathe, machining simple die components.

• Die Manufacturing: Fabricating a blanking die punch, ensuring alignment (±0.01 mm).

• Press Setup: Installing dies on a press, adjusting stroke and clearance.

• Tool Inspection: Measuring die components with CMM, verifying tolerances.

• Hydraulic Systems: Assembling simple hydraulic circuits for die automation.

• CAD/CAM Practice: Designing a die in CAD, generating toolpaths in CAM software.

• Project Work: Fabricate a blanking die for a 2 mm steel sheet, test for clean cuts.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Advanced Die Making: Progressive dies, compound dies, transfer dies; design challenges.

• Mold Making: Injection molds, compression molds; parting line, runner systems.

• CNC Programming: Multi-axis CNC machining, complex G-code programming.

• Tool Maintenance: Repairing worn dies, regrinding tools, preventive maintenance.

• Production Planning: Tool room workflow, cost estimation, lead time management.

• Entrepreneurship: Starting a tool-making workshop, market trends in precision engineering.

• Industry 4.0: IoT in tool rooms, smart manufacturing basics.

Trade Practical

• Progressive Die Work: Manufacturing a progressive die stage, ensuring strip feed accuracy.

• Mold Fabrication: Machining a simple injection mold core, polishing cavities.

• CNC Programming: Writing G-code for a complex die component, machining on CNC mill.

• Tool Repair: Refurbishing a worn punch, regrinding cutting edges.

• Quality Assurance: Conducting die trials, analyzing defects, documenting results.

• Automation Practice: Integrating sensors in dies for automated operation.

• Project Work: Design and fabricate a progressive die for a small component, conduct production trial.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science

  • Calculations: Tool geometry, die clearance, press tonnage, machining time.

  • Science: Stress/strain in dies, thermal expansion, friction in machining.

  • Hours: 80 hours/year

• Engineering Drawing

  • Drawings: Detailed tool/die drawings, assembly drawings, exploded views.

  • Hours: 80 hours/year

• Employability Skills

  • Communication: Technical reporting, client discussions, team coordination.

  • IT Literacy: CAD/CAM software, ERP systems, online tool catalogs.

  • Soft Skills: Problem-solving, time management, resume writing, interview prep.

  • Hours: 60 hours/year

Assessment and Certification

• Exams:

  • Theory: Written exams per semester (MCQs, descriptive questions).

  • Practical: Fabricating tools/dies, CNC programming, quality inspections.

• Evaluation Criteria: Precision in machining, die functionality, adherence to tolerances, safety practices.

• Certification: NCVT National Trade Certificate (NTC), globally recognized.

Career Opportunities

• Employment: Tool and die maker, CNC operator, quality inspector in automotive, aerospace, or manufacturing industries.

• Self-Employment: Precision tool workshop, die repair services, freelance CNC programming.

• Further Studies: Diploma in Tool Engineering, certifications in CAD/CAM or CNC programming.