Tool & Die Maker (Press Tools, Jigs & Fixtures)

ITI Tool & Die Maker (Press Tools, Jigs & Fixtures) Syllabus (English)

Course Overview

• Trade Name: Tool & Die Maker (Press Tools, Jigs & Fixtures)
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Mathematics and Science
• Objective: To train candidates in designing, manufacturing, and maintaining press tools, jigs, and fixtures, equipping them for roles such as tool and die makers, press tool setters, or jig/fixture fabricators in manufacturing industries, or for self-employment in tool-making workshops.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Tool & Die Making: Role of press tools, jigs, and fixtures in manufacturing; industry applications (automotive, aerospace).
• Engineering Materials: Properties of steel, cast iron, non-ferrous metals; heat treatment processes (annealing, hardening).
• Measuring Instruments: Vernier calipers, micrometers, dial indicators, gauge blocks; calibration techniques.
• Hand Tools: Files, hacksaws, chisels, hammers; proper usage and maintenance.
• Safety Practices: Workshop hazards, PPE (gloves, goggles), machine guarding, fire safety.
• Basic Machining: Principles of turning, drilling, grinding; lathe and drilling machine components.
• Workshop Organization: Tool storage, 5S methodology, workflow planning.

Trade Practical

• Measurement Practice: Using vernier calipers, micrometers, and height gauges for precise measurements.
• Hand Tool Skills: Filing, sawing, chipping, scraping; achieving flat surfaces.
• Bench Work: Marking, punching, and layout preparation on metal workpieces.
• Lathe Operations: Plain turning, step turning, facing, drilling; setting workpieces.
• Safety Drills: Practicing PPE usage, machine isolation, emergency response.
• Grinding: Sharpening tools using pedestal grinders; checking angles.
• Project Work: Fabricating a simple component (e.g., washer) using lathe and hand tools.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Lathe Operations: Taper turning, thread cutting (metric, Whitworth), knurling; calculations for gear trains.
• Milling Machines: Types (horizontal, vertical), cutters, indexing methods, dividing heads.
• Press Tools Basics: Types (blanking, piercing, bending), components (punch, die, stripper).
• Jigs and Fixtures: Definitions, types (drill jigs, milling fixtures), design principles.
• Fasteners and Fits: Bolts, nuts, screws; types of fits (clearance, interference).
• Metrology: Surface finish, tolerances, limit gauges, inspection techniques.
• Heat Treatment: Tempering, quenching, case hardening; effects on tool life.

Trade Practical

• Advanced Lathe Work: Taper turning (internal/external), thread cutting, eccentric turning.
• Milling Operations: Slab milling, slot cutting, keyway milling; using dividing head.
• Press Tool Components: Filing and grinding punch and die blanks to size.
• Jig Assembly: Assembling a simple drill jig; aligning bushings.
• Inspection: Measuring tolerances with plug gauges, slip gauges; surface plate work.
• Heat Treatment: Hardening and tempering small tool steel components.
• Project Work: Manufacturing a simple blanking die with punch and die set.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Press Tools: Progressive and compound dies, clearance calculations, strip layout.
• Jigs and Fixtures Design: Locating, clamping, guiding elements; modular fixturing.
• CNC Machining: Basics of CNC lathe and milling, G-code, M-code, tool offsets.
• EDM and Wire EDM: Principles, applications in die making, electrode materials.
• Hydraulics and Pneumatics: Basic circuits, actuators, valves in tool automation.
• Tool Maintenance: Wear analysis, regrinding punches, die sharpening.
• Quality Control: Statistical process control, defect analysis, ISO standards.

Trade Practical

• CNC Operations: Setting and programming CNC lathe/milling for tool components.
• EDM Practice: Machining die cavities using spark erosion; preparing copper electrodes.
• Progressive Die: Manufacturing components for a progressive die (e.g., stripper plate).
• Jig/Fixture Fabrication: Building a milling fixture with clamps and locators.
• Hydraulic/Pneumatic Circuits: Assembling basic circuits for press tool automation.
• Inspection: Checking die alignment, punch clearance using gauges.
• Project Work: Constructing and testing a progressive die for a simple component.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Complex Tooling: Draw dies, forming dies, combination tools; material selection.
• Automation in Tooling: Role of sensors, PLCs, and robotics in press tool systems.
• Tool Repair: Overhauling dies, welding cracks, reconditioning jigs/fixtures.
• Production Management: Tool tryouts, cycle time optimization, lean manufacturing.
• Entrepreneurship: Starting a tool-making workshop, costing, market analysis.
• Industry Trends: Industry 4.0, additive manufacturing in tooling, smart factories.
• Environmental Safety: Waste disposal, coolant recycling, emission norms.

Trade Practical

• Complex Die Making: Fabricating a forming die or draw die; testing for accuracy.
• Tool Repair: Welding and regrinding worn punches, dies; restoring fixtures.
• Automation Skills: Integrating sensors into a press tool setup; basic PLC programming.
• Industrial Exposure: Hands-on training in tool rooms or manufacturing units (4-6 weeks).
• Production Trials: Conducting tool tryouts, adjusting clearances, optimizing output.
• Quality Assurance: Inspecting finished tools for defects, dimensional accuracy.
• Project Work: Designing and building a compound die or milling fixture, with full testing.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Gear ratios, cutting speeds, die clearances, strip layout optimization.
  • Science: Mechanics (stress, strain), metallurgy, fluid dynamics in hydraulics.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Reading and creating blueprints for press tools, jigs, fixtures; sectional views, tolerances.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication, teamwork, time management, resume writing, interview preparation.
  • IT literacy: Using CAD software, ERP tools for tool design documentation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive).
  • Practical: Tasks like die fabrication, jig assembly, CNC programming.
• Evaluation Criteria: Tool accuracy, machining precision, safety adherence, project quality.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters.

Career Opportunities

• Employment: Tool and die maker, press tool setter, jig/fixture fabricator in automotive, aerospace, or manufacturing industries.
• Self-Employment: Tool-making workshops, contract manufacturing of dies and jigs.
• Further Studies: Diploma in Mechanical Engineering, CITS in Tool & Die Making, CAD/CAM certifications.