Detailed Syllabus For Kerala PSC LECTURER IN TOOL AND DIE ENGINEERING (POLYTECHNIC COLLEGES)

Materials: Brick; varieties and strength, characteristics of the good brick. Cement:

varieties and grade of cement and its uses. Steel: types of steel for reinforcement bars,

steel structural sections. Aggregates: types & requirements of good aggregates. Concrete:

grades of concrete as per IS code, water-cement ratio. Workability, mixing, batching,

compaction and curing.

Construction: Parts of building – foundation – types of foundations – spread footing,

isolated footing, combined footing, Raft, pile and well foundations. Masonry – types rubble

masonry, brick masonry, English bond and Flemish bond. (One brick wall).

Surveying: Chain surveying – principles, instruments, ranging, and chaining survey

lines, fieldwork and field book, selection of survey stations, units of land area.

Levelling: Levelling instruments, different types, benchmark, reduced level of points,

booking of field notes, reduction of levels by the height of collimation method (simple

problem). Modern survey – instruments – Total station, Electronics theodolite, Diplomat.

The importance of IC Engines: Definition, classification – two-stroke engines, four stroke engines, working of two-stroke engines and four-stroke engines with the help of line sketches, comparison between two-stroke and four-stroke engines, comparison between petrol and diesel engines, the function of the flywheel, clutch, gearbox, propeller shaft and the differential in power transmission, explain with sketch the working of differential, briefly explain power transmission of 4 wheel vehicle with line diagram.

The importance of Power Plants: Introduction, classification of power plants – working of hydroelectric power plant with schematic sketches – working of thermal (Steam and Diesel) power plant with schematic sketches – working of nuclear power plant with schematic sketches.

Review with a discussion of electric current, potential difference, power, EMF, resistance and its laws, Ohms law and series-parallel circuit, electromagnetism, generation of AC and DC supply.

The idea of a Basic electrical circuit: Electrical supply and load and its functioning, division of voltage and current in a parallel and series circuit – simple problems, units of power and energy, solution of DC circuit with the calculation of energy consumption in an installation.

Circuit parameters: Resistance, Capacitance and inductance. AC circuit with R, L, C.

A simple solution of typical AC circuit with resistance, impedance, power and power factor.

The electrical circuit of an installation: Earthing, lightning protection.

Active and passive devices – review only. LED – working, applications, comparison of

LED lighting and CFL lighting. Full-wave rectifier – diagram and explanation, 5 V power

supply – with a bridge rectifier and 7805. SMPS – block diagram and advantages. Integrated

circuits. SMDs – advantages. Static electricity – precautions in handling electronic circuits.

Switches: ON / OFF, push to ON, push to OFF, push to ON / OFF, SPST, SPDT, DPDT. Working and application of limit switches, proximity switches, relays.

Microcontrollers: Simple block diagram of 8-bit microcontrollers – application.

Mobile technology: CDMA and GSM. Compare – 2G and 3G technologies.

Inverter & UPS: Block diagram. Compare – inverter and UPS. Online and offline UPS – differentiate. Battery selection for UPS and inverter.

E-waste: Health hazards of e-waste.

Press Tool Operations: Piercing, Blanking, Lancing, extrusion, embossing, coining, bending, drawing, swaging, shaving, deep drawing etc.

Press Tools: Guide Plate Tool, Progressive Tool, Compound tool and Combination Tool Strip layout - % utilization.

Punches: Cutting and non-cutting punches, hybrid punches – Load on punches – size determination – clearance, punch, die size, die block – solid, split.

Strippers: types, box, fixed, travellers, stripping force for blanking and piercing – fool

proofing – pilots – purpose – direct and indirect pilots – size – methods of piloting.

Side Cutters: Functions, advantages.

Ejectors and Shedders: Functions and Types.

Knockouts: Functions.

Fasteners and dowel: Screws, function, types – socket head, countersunk, cheese head, Rivets, Cotter pin. Positing of screws.

Die sets: Types, precision and commercial/standard and non-standard, top plate, bottom plate, guide pillar material, Shut height.

Press:  parts, capacity, power – mechanical, hydraulic, pneumatic, press selection.

Blank development for cylindrical shell – Algebraic method, graphical method, Layout the method, CG method.

Fine Blanking: Calculation of Punch and die, materials suitable for fine blanking – work hardening – steel, copper and copper alloys.

Moulds and Dies Technology: Plastics in the mould Industry, properties,

applications processing Techniques – Injection moulding, principle, applications, Injection

Moulding machines – Shot weight calculations, Plasticizing capacity, Clamping force –

Number of cavity calculation – Testing of plastics – visual Test, Smoke Test, Carbon Black

Test – Terminology, mould materials, feed system – Runner, types of runner, runner dia

the calculation, gate – Types of Gates, Ejection Techniques, Ejection force calculation.

Venting, shrinkage, parting surface. Factors governing shrinkage, cooling – mould cooling

calculation. Side core and side cavity – two, three plate moulds, runner fewer moulds, multi

daylight moulds – mould maintenance – compression moulding – applications, basic types

– Flash, positive, landed positive, semi-positive.

Transfer moulds – application – advantages and limitations. Types – pot and plunger.

Extrusion moulds – application – blow moulding, rotational moulding, casting and

moulding – advantages and applications.

Calendaring – vacuum forming – preform moulding, mat and fabric moulding, premix

moulding, filament winding, multicolour moulding.

Die casting – advantages of die casting – principle – limitations of pressure die casting

process. Die casting Terminology – die casting alloys – Al, Zinc, Mg, Cu etc.

Composition – properties of different die cast alloys – Die casting machines Hot Chamber

and cold chamber – die casting dies.

Material Technology: Mechanical properties of materials – Tensile strength,

Compressive strength, Ductility, Malleability, Hardness, Brittleness, Impact strength,

Fatigue and Creep resistance.

Structure of material – unit cell, space Lattice, BCC, FCC, HCP. Effect of grain size on

mechanical properties.

Elastic deformation and plastic deformation, slip mechanism, work hardness, recrystallisation.

Ferrous metals and alloys – production and properties of pig iron, wrought iron and cast

iron.

Classification of Cast Iron – white, moulted, Grey cast iron alloy cast iron

Production and properties of Steel – Bessemer, LD, open-hearth, Electric Furnace.

Effect of alloying elements on properties of steel – Nickel, Chromium, Manganese,

Molybdenum, Silicon, Vanadium, Tungsten.

Properties and uses of alloy steel – nickel steel, Tool and Die steel, HSS Tool steel,

Stainless steel, spring steel.

Nonferrous metals and alloys in Engineering application – Properties and uses of Al, Cu,

lead, Tin, Zinc, Magnesium, Nickel.

Nonferrous alloys – Cu base, Brass, Bronze, Aluminium Alloys.

Bearing or Antifriction alloys – Properties and uses of Phosphor Bronze, White metal,

Babbit metal.

Destructive and Non-destructive Tests – Tensile Test, hardness Test, Impact test, Fatigue

Test, Creep test.

X-ray, magnetic particle, Fluorescent penetrant Test, ultrasonic test, Crystallographic test,

X-ray diffraction test, electron microscopic Test.

Heat Treatment – objectives – Annealing, Normalizing, Hardening and Tempering.

Surface hardening – Case hardening, nitriding, cyaniding, flame hardening, induction

hardening.

Heat Treatment of Tool Steel – TTT diagram, Bainite Transformation, Martensite

Transformation, Austempering, Martempering – heat Treatment Furnaces – Defects in heat

treatment.

Polymers – polymerisation – Types of Thermosetting and Thermoplastics – examples –

properties and uses of polythene, PVC, PTFE, Acrylics, Bakelite, Phenolics, Epoxies,

Silicone, Polyesters

Metal Joining - Permanent and semi-permanent and Temporary

Welding – Fusion and non-fusion – Arc welding – principle, tools and equipment –

Electrode – Types and specifications.

Resistance Welding – spot, seam, projection, butt and percussion

Other welding methods – Thermit, TIG, MIG, Ultrasonic, Plasma Arc, Electron Beam and

Laser Beam.

Gas Welding – Gases, Different Flames, Welding Techniques, Gas cutting – Welding

symbols as per BIS.

Lathe – Types – specifications, accessories, functions, work holding and tool holding

devices, single point cutting Tool, nomenclature, mechanism of tool cutting, chip

the formation, Types of chips, Tool life, equation.

Cutting speed, feed and Depth of cut.

Lathe operations – Plain turning, Taper turning, Thread cutting and other operations.

Shaper, Slotter and Planer – Parts, Functions, mechanisms, work holding devices,

specifications, cutting speed, feed and depth of cut.

Drilling machines – types – specifications – speed, feed and depth of cut – parts and its

functions – Drill bit, types, nomenclature.

Grinding and Grinding machine – Abrasives, Types, Types of bonds, selection of Grinding

wheel, Specification of Grinding wheel, cylindrical grinder and surface grinder, special

purpose grinders – specifications – working – parts – functions. Work holding devices –

mounting of the wheel, truing and dressing of wheel, various speed, feed and depth of cut for

different materials – Balancing of the wheel.

Milling Machines – Types – specifications – parts – functions – milling cutters – Types –

nomenclature – Tool material – specification – cutter holding devices – work holding

devices – speed, feed, depth of cut – milling operations – conventional milling and climb

milling

Plain milling – Keyway milling, T-slot milling. Indexing Head, Calculation – direct

indexing, simple and differential indexing.

Cutting fluid – functions – properties – classification – effect on tool life - selection –

method of application.

Jig Boring Machine – Types – open front, cross rail, Jig grinding, internal - proper

selection of Jig grinding wheel – Method of holding work.

Surface finishing and Coating – Lapping, Honing and superfinishing, electroplating, Hot

dipping, tin coating, metal spraying.

Broaching – Purpose – tools – parts of the tools – Broaching machine

Die sinking and engraving – Necessity and use – cutter for die-sinking – Pantograph

machine – applications.

NC machines – use, principles of EDM, Electro discharge grinding, ECM, AJM, LBM,

wire cut EDM, Ultrasonic machining.

NC / CNC / DNC – Classification based on Control system – Point to point, straight,

contour system, classification based on feedback, open-loop, closed-loop, elements of CNC

– work holding devices.

CAD-CAM – Advantages, applications, CNC programmes G code & M code.

Robots – Classifications, features, necessity – components – various generation – power

drives used – Types of grippers – manipulators – degree of freedom – end effecters – types

– applications – advantages.

FMS – Basic components of FMS.

Engineering Metrology: Definitions – Range, sensitivity, True value, Indicated value,

error, corrections, Accuracy, Precision.

Linear measurements & Angular measurements – surface plate, angle plate, ‘V’ Block,

Straight edge, Combination set, universal surface Gauge, Feeler Gauge – Bevel protractor,

sine bar, Clinometer.

Precision Instruments – Vernier Caliper, height gauge, depth gauge, micrometre,

micrometre depth gauge, slip gauge. Measurement of tapered recess whose angle is very

small

Gauges – limit gauges, Go and No go gauges, Plug gauge, Snap gauge, Ring gauge –

advantages and limitations.

Dial Gauge – profile projector.

Comparator – Mechanical, electrical and electronic, optical comparator, pneumatic

comparator.

Surface finish – Evaluation of surface roughness – CLA and RMS value – method of

measuring surface finish – Interferometer – Michelson’s Interferometer – Tomlinson’s

surface meter – working of optical flat – classification, Type A, Type B, flatness test,

parallelism test.

Calibration – need – requirements – annual calibration programme – calibration of Vernier

calliper, Vernier height gauge, depth gauge, dial gauge, limit gauges, slip gauges, Surface

plate.

Measuring machines – Toolmaker’s microscope, Vernier optimeter, CMM, Computer-aided

metrology.

Direct Stresses and Strains: Types – tensile and compressive – longitudinal and

lateral strain – Poisson’s ratio – the behaviour of mild steel under tension – stress-strain

diagram – limit of proportionality – elastic limit – yield point – ultimate stress – working

stress – a factor of safety – comparison of stress-strain diagram of mild steel and a brittle

material – Hooks law and Young’s modulus – the principle of superposition – stresses in

varying, composite sections, Shear stress and shear strain – modulus of rigidity –

volumetric strain, bulk modulus, Thermal stress and strain, Nature and magnitude of

stresses due to change in temperature – total or partial prevention of expansion and

contraction – temperature stress on the composite bar.

Friction: Type – static, dynamic, sliding, rolling, pivot, limiting friction, angle of friction,

coefficient of friction, cone of friction – Laws of friction – static friction and kinetic friction

– sliding body resting on a horizontal plane – force acting along the plane and at an angle.

Centre of Gravity of Sections: Centroids – the centre of gravity – axis of symmetry and

the axis of reference – methods to find the centre of gravity – simple geometric sections – Triangle,

Circle, semi-circle – Combination of symmetrical Sections T- sections, I-sections, Channel

sections, Combination of unsymmetrical sections, L section, plane sections with cut out

holes.

Moment of Inertia: Radius of gyration, methods to find the moment of inertia, Moment of

the inertia of rectangular and circular sections – parallel axis theorem, perpendicular axis

theorem, Moment of inertia of T-section, I, L and channel Sections.

Riveted Joints: Types – lap joint – single riveted, double-riveted (Chain and zigzag) –

butt joint - single cover, double cover single riveted – failure of riveted joints – design of

riveted joints, failure of rivets – shearing and crushing – failure of plates – tearing across a

a row of rivets - tearing off the plate at an edge – the strength of rivet, plate and riveted joints –

the efficiency of a riveted joint – single cover and double cover single riveted butt joint,

caulking and fullering of riveted joints.

Welded Joints: Types of fillet and butt weld – welding terms – Leg of the weld, size of

the fillet weld, throat thickness – effective length of the weld, side fillet weld and end fillet

weld, strengths of welded joints, fillet and butt, transverse, single and double rows –

parallel welds, a combination of transverse and parallel – butt weld.

Thin Cylinders: Failures of the thin cylinder – stresses in the thin cylindrical shell – hoop stress – longitudinal stress, the pressure of thin cylinders.

Torsion of Circular Shafts: Assumptions for shear stresses in a circular shaft

subjected to torsion, torsion equation, strength equation for a solid and hollow shaft –

power equations, polar moment of inertia – strength and power of shafts.

Springs: Types of springs, leaf and Helical – closely coiled, open coiled, deflection,

stiffness, torque and energy stored.

Shear Force and Bending Moment: Types of beams – cantilever, simply supported, overhanging, built-in and continuous beam. Types of loading – point load, uniformly distributed load, uniformly varying load, Shear force diagram, Bending moment diagram – a combination of point load, UDC load – maximum bending moment.

Deflection of beams – simply supported beam with Point Load (central), SS with UDL on the entire span, cantilever with a point load at the free end. Cantilever with UDL over the entire span.

Columns and Struts: Column, strut, buckling load, equivalent length, slenderness ratio – types of columns – short, medium, long – Euler equation and its assumptions for crippling load – for different end conditions. Both ends hinged, one end fixed and another end free – one end fixed and other end hinged. Both ends fixed – Rankine’s formula for columns – equivalent length – Slenderness ratio equivalent length on different end conditions.

Properties of Fluid: Specific weight-specific volume-specific gravity – viscosity - kinematics viscosity – Newton’s law of viscosity – types of fluids – compressibility – surface tension – capillarity.

Fluid Pressure and Measurements: Pressure at a point – pressure head – Pascal’s law – absolute, gauge, atmospheric and vacuum pressures – a measurement of fluid pressure – Piezometer tube – simple manometer – differential manometer – inverted differential manometer – Bourdon’s tube pressure gauge – total pressure – total pressure on the immersed surface – horizontal – vertical - inclined.

Kinematics and Dynamics of Fluid Flow: Types of fluid flow – steady and unsteady – uniform and non-uniform flow – Laminar and turbulent – compressible and incompressible flow – Rotational and irrotational flow – one, two and three-dimensional flow - the rate of flow or discharge – equation of continuity of liquid flow – the energy of a liquid in motion – potential energy – kinetic energy – pressure energy – total energy – total head of liquid in motion – Bernoulli’s equation – assumptions - applications – venturi meter – Orifice meter – Pitot tube.

Flow-through Orifices, Notches, Pipes and Nozzles: Orifices – types – Vena Contract – coefficient of contraction – coefficient of velocity – coefficient of discharge – Notches – types of notches – rectangular – triangular - trapezoidal – discharge over notches – simple pipes – loss of head in pipes – major energy losses -minor energy losses – losses due to friction – Darcy’s formula, loss of head in pipes – Chezy’s formula, loss of head due to sudden enlargement - sudden contraction – water hammer.

Fluid Power: Basic law – Applications of fluid power – properties of fluid such as viscosity index, oxidation stability, demulsibility, lubricity, rust prevention, pour point, flash and fire point – neutralisation number.

Hydraulic System: Basis of system – oil reservoir pump unit, the principle of working of positive displacement pump – classifications – gear pump, screw pump, Vane pumps, lobe pump, simple piston pumps, hydraulic actuators – classifications – rotary, semi-rotary – Linear motion type – hydraulic motors – hydraulic cylinder types – single acting, double acting.

Hydraulic Control Elements and Components: Control valves – functions – classifications – relief valves – poppet valves – direction control valves – types – sliding spool-type – check valves – 1, 2, 3, way directional control valves, solenoid control valves – flow control valves – types – gate, globe, butterfly valves – non-return valves, application circuits and control valves – intensifier – accumulators – purpose – types – weight loaded, spring-loaded, gas loaded.

Hydraulic Circuits: Automatic cylinder, reciprocating circuit, a circuit for a robotic arm.

Hydraulic Machines: Centrifugal and reciprocating pumps – parts working, priming, air vessel efficiency. Turbine – Pelton, Francis turbine, parts, working efficiency

Pneumatic System: Comparison of pneumatic & hydraulic system – basic pneumatic system – pneumatic symbols - air filter – pressure regulator – lubricator – mufflers.

Control Elements and Components: Control valves 2, 3, 4-way directional control valves, solenoid valves – Cam operated flow control valves – Air cylinders – types – light, medium, heavy, tandem, duplex, double end types.

Pneumatic Circuits: Basic pneumatic circuits, power-operated holding devices – power-operated chucks, mandrel, collet and clamping circuits.

Hydro Pneumatic System: Comparison of hydraulic, pneumatic & hydro-pneumatic system – advantages and application of the combinational system of air and oil working of air controlled hydraulic valves

Principles of Management: Meaning of management – Taylor’s scientific management, Functions of management – Different types of ownership – organizational structure.

Wage Payment System: Types of Wages – Nominal, real, living, fair and minimum wages – Incentives.

Quality Planning and its developments: Definitions of quality – TQM concept

Project Management Techniques: Network analysis – terms used in CPM, PERT – CPM operations, earliest finish time (EFT), latest finish time (LFT), critical path, event, slack or float, dummy activity, construction of network diagrams – Fulkerson’s rule – PERT - Comparison – Calculation of expected time – Event, activity, successor event, predecessor event, earliest expected time, latest allowable time, slack.

Quantitative techniques in Management: Methods – Linear programming – formulation of LPP – transportation problem – North West corner rule, Vogel’s approximation method – Game theory – two-person zero-sum game – Maxi-min and minimax principle – saddle point.

Materials and Sales Management: Inventory management – definition and classifications – purchase procedure – buying techniques – EOQ and ABC analysis. Stores management – storekeeping functions – duties of storekeeper – store layout – Centralized and decentralized store – store records – indent forms – bin card – store ledger - Sales – importance – functions of the sales department – sales forecasting.

Production Planning and Control: Concepts of industry – Production and productivity – types of production – Job production, batch production, mass production, continuous production – Planning and control – Definitions, benefits and functions. Pre-planning activities – Forecasting, plant location, product planning, design and development, material selection. Process planning, determination of men, machines, material and tool requirements – Process planning – Choice of the machine in process planning – Break-even analysis – Process sheet – Process planning procedure – Routing – Scheduling – Dispatching – value engineering – plant location and layout – plant layout – Plant maintenance – Types of maintenance.

Method Study: Work-study – Advantages, applications – Method study – Therbligs and their symbols – Process chart – preparation of operation process chart, flow process chart, man-machine chart, right hand and left-hand process chart, SIMO chart – Flow diagram –Principles of motion economy – Rules concerning the human body, workplace layout and material handling, tools and equipment – work measurement – stop watch time study – standard time calculation – Production study – work sampling.

Inspection and Quality Control: Quality and quality control – product control – Inspection- Types – Advantages and limitations.

Fundamental of Statistical Concepts: Variability in measurements – Terms - variable, attribute, frequency, frequency distribution and frequency plot – Normal distribution curve, Tally sheet, Mean, mode, median and standard deviation Control charts – X, R, P, 100P and C.

Project Analysis: Need and scope – Elements of project analysis – Production cost – Market survey – Selling price – Capital investment – Return on investment – Elements of costing – Classification of cost – Depreciation – Types.