Foundrymanc
Foundrymanc
Foundrymanc
of
TRADE THEORY-I
&
TRADE PRACTICAL-I
Under
Trade: Foundryman
Re-Designed in
– 2014 -
By
Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
1
CONTENTS
A Rationale 3
2
A. RATIONALE
Success & Sustainability of any Training System depends upon, given other things,
availability of good quality instructors. An Instructor should possess good trade skills to
impart skill training.
Ability to understand and interpret the course content is imperative to ensure proper
delivery. It is the domain Skills and Knowledge which enable comprehending the
prescribed contents and subsequent lesson/demonstration planning for effective delivery.
Thus it is imperative for any trade instructor to have adequate domain skills so that same
can be transferred.
To deliver effectively, both knowledge and skills, in depth know how are very much
needed. At the same time the main objective of Instructor training programme is enabling
instructors to demonstrate higher productivity and higher accuracy in performing a task/job.
Recognizing this importance more emphasis has been given to the Trade Practical & Trade
Theory in all Engineering Trades in Craft Instructors Training Scheme (CITS) under
NCVT.
3
B. GENERAL INFORMATION
1. Name of the Course : Craft Instructor Training
2. Duration of Instructor Training : 1Year (Two semesters each of six months duration).
4
C. SEMESTER WISE ALLOTMENT OF TIME & MARKS AMONG THE SUBJECTS FOR CITS
SUBJECTS Hrs. / % of Marks Sessional Full Pass Marks
Week time Marks
allotted Exam. Sessional Total
Trade Practical – 1 20 50 200 30 230 120 18 138
Trade Theory - 1 6 15 100 20 120 60 12 72
Workshop Cal. & Sc. 6 15 50 - 50 30 - 30
First
semester Engineering Drawing 6 15 100 - 100 60 - 60
Library 2 5 - -
TOTAL for Sem. - I 40 450 50 500 270 30 300
Trade Practical – 2 16 40 200 30 230 120 18 138
Trade Theory - 2 4 10 100 20 120 60 12 72
Second
Training 12 30 200 30 230 120 18 138
semester
Methodology -
Practical
Training 6+2 20 100 20 120 60 12 72
Methodology -
Theory + IT
TOTAL 40 600 100 700 360 60 420
GRAND TOTAL 80 1050 150 1200 630 90 720
Hourly Distribution TOTAL: 1200 marks for 2 semesters Pass marks: 720
Subject Time in % Marks in %
Trade Practical 45 38
Trade Theory 12.5 20
Total for Trade 57.5 58
Training Methodology 15 19
(Practical)
Training Methodology 12.5 10
(Theory) + IT
Total for Training 27.5 29
Methodology & IT
Engineering Drawing 7.5 12
Workshop Cal. & Sc. 7.5 4
Library 2.5 -
5
D. TOPIC WISE DISTRIBUTION OF TIME & MARKS
TRADE: FOUNDRYMAN
CRAFT INSTRUCTOR TRAINING SCHEME
SEMESTER-I
Note: During the discussion of any machine tools, related precautions and safety measures should be discussed.
Note: During the discussion of any machine tools, related precautions and safety measures should be discussed.
8
15-16 Preparation of mold with Cover core & Ram up Core, Setting the
Introduction of heat treatment. Different type of heat treatment.
Heat Treatment in different metals and its alloy. Difference type of core into a molds with suitable Gating system
heat chamber
17-20 Preparation of Mold with Chill or Denseners, setting the core into
Different type of coolant. Iron-carbon diagram, TTT, CCT
diagram. a mold, along with suitable gating system.(use chill, denseners,
Furnace. Exo- thermic materials).
Brief Information about the Construction, operation, Maintenance
& Turbule Shooting of Melting Furnace.
( solid-Liquid-Gas-Electrical Fuel) Prepare induction furnace for charging, Prepare charges for
I. Cast Iron Melting- Cupola, Rotary Furnace, charging, operate and melt aluminium/ magnesium and pour
Electrical Arc Furnace.
II. Steel Melting- aluminium/ magnesium into the mould and identify defects.
Electric Arc & Induction Furnace – Types, construction, operation,
and maintenance, Converter.
II. Non-ferrous metal melting. Crucible Furnace, Pot furnace,
Reverberatory furnace, Rotary furnace,
Induction furnace
Charging the Metals & Chemical
analysis. Measure Molten Metal
Temperature by Using Of
Pyrometers: Introduction, Necessity, Thermocouple, Pyrometer,
Optical Pyrometer, Radiation Pyrometer, Infrared Thermograph
21-22 Reeling of Furnace. Relining and Patching of Tilting / Pit furnace,
Furnace:
Modern developments of Cupola. (Coke less cupola, Hot blast Preparation of Ladle lining by Fire clay mixture and C02 sand
cupola, Dived blast cupola.)
23 Industrial visit & Submission of Report
24 - 26 Revision & Trade Test
9
F. List of Tools & Equipment
Trade – FOUNDRYMAN
Under CITS
For a batch of 20 Trainees
Semester-I
SL. No. Name of the tools and equipment Qty per unit
10
TOOLS, MEASURING INSTRUMENTS AND SHOP OUTFIT
11
SL. NO ITEMS QTY
41. Stand for Fire buckets 1
42. Face shield clear 10 pair
43. Helmet (engineers) 10 pair
44. Gauntlets leather Fettling 10 pair
45. Gauntlets leather or asbestos for Furnace 10 pair
46. Footwear asbestos over shoes l0 pair
47. First aid Box based on burn Treatment 1 set
48. Dividers Firm joint 20 cm 5
49. Moulding Boxes 30 x 40 x 15 cm RSDL 20 pair
50 Moulding Boxes 75 x75 x 25cm RSDL l0 pair
51. Snap Flask 40 x 35 x 12 cm RSDL 2 Pair
52. Snap Flask 30 x30 x 10 cm RSDL 2pair
53. Sprit level 5nos
54. Wheel barrows 2nos
55. Plane grooving 6mm cutter 2nos
56. Cutting Pliers 2nos
57 Set of Spanners , and Alegen keys 2 set each
58. Venire calipers 1no.
59. Set of Tongs For Melting & Charging. 2sets
60. Equipment for conducting BLS (Basic Life Saving) training. 1 set
12
LIST OF EQUIPMENTS AND GENERAL MACHINERY
13
Syllabus for the subject
Of
TRADE THEORY-II
&
TRADE PRACTICAL-II
Under
Trade: Foundryman
Re-Designed in
– 2014 -
By
Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
14
G. GENERAL INFORMATION
1. Name of the Course : Craft Instructor Training
2. Duration of Instructor Training : 1 Year (Two semesters each of six months duration).
15
H. TOPIC WISE DISTRIBUTION OF MARKS & TIME
TRADE: FOUNDRYMAN
CRAFT INSTRUCTOR TRAINING SCHEME
SEMESTER-II
Note: During the discussion of any machine tools, related precautions and safety measures should be discussed.
17
Quality And Finish,
9-10 Sound Test, Preparation of mold and core flask less system, No-bake system
Pressure Testing \ Leak Testing,
Testing Of Mechanical Properties:
Tensile Testing
Hardness Testing
The brinell Test or The Rockwell Test, Fracture Test, Impact
Test, Creep Testing.
11-12 Heat-Treated all Types of Metal Casting and Salvaging of Preparation of mould & core by Co2 Process.
Metallurgical Problems
13-14 NON- DESTRUCTIVE TEST: Introduction, Radiography, Preparation of mold & core by Shell molding Process
(X-ray & y- ray) Magnetic Particle Inspection, Fluorescent -
Penetrate Inspection. Ultrasonic Inspection.
15-16 SOME ADVANCEMENTS IN INSPECTION AND Preparation of mold with Special molding Process like
TESTING Instrumented Impact Testing, Thermal Inspection, INVESTMENT CASTING process.
X-Ray Diffraction Analysis, Materials Characterization
Automation of Surface Defect Detection, Image Analysis,
Industrial Computed Tomography, Computerized Testing
17-18 THE USE OF STATISTICAL METHODS IN QUALITY Preparation of a solid casting & Hollow Casting by using of Gravity
CONTROL OF CASTING. Die casting Machine
(a)Sampling Inspection,
(b)Control Charts.
Design of new casting Software package for the design and
production of casting. Program Structure the knowledge-base-
Parting line analysis Feeder head design Gating design-
Pattern plate layout concluding.
19-20 Energy Conservation and Preparation of a Solid Casting & Hollow casting by using of Pressure Die
Environment Control. Energy conservation in Melting, & Casting Machine.
Casting, Heat-Treatment. Energy saving, Environmental pollution
in foundries and its control. Cost and Estimation of Casting.
Casting weight calculation
21-22 QUALITY CONTRAL IN FOUNDRIES: Introduction, Preparation of Casting by Centrifugal casting Machine
18
Quality Control In Pattern And Mold Making, QUALITY Control
In Melting,
Quality Control in Heat-treatment, Quality Control in Fettling and
Cleaning, Quality Control in Final Inspection, Dust control in
foundries.
23 Industrial visit & Submission of Report
24 - 26 Revision & Trade Test
19
J. List of Tools & Equipment
For a batch of 20 Trainees for the trade of – FOUNDRYMAN
Under Craft Instructors Training Scheme
Semester-II
SL. No. Name of the tools and equipment Qty per unit
20
TOOLS, MEASURING INSTRUMENTS AND SHOP OUTFIT
21
SL. NO ITEMS QTY
41. Stand for Fire buckets 1
42. Face shield clear 10 pair
43. Helmet (engineers) 10 pair
44. Gauntlets leather Fettling 10 pair
45. Gauntlets leather or asbestos for Furnace 10 pair
46. Footwear asbestos over shoes l0 pair
47. First aid Box based on burn Treatment 1 set
48. Dividers Firm joint 20 cm 5
49. Moulding Boxes 30 x 40 x 15 cm RSDL 20 pair
50 Moulding Boxes 75 x75 x 25cm RSDL l0 pair
51. Snap Flask 40 x 35 x 12 cm RSDL 2 Pair
52. Snap Flask 30 x30 x 10 cm RSDL 2pair
53. Sprit level 5nos
54. Wheel barrows 2nos
55. Plane grooving 6mm cutter 2nos
56. Cutting Pliers 2nos
57 Set of Spanners , and Alegen keys 2 set each
58. Venire calipers
59. Set of Tongs For Melting & Charging.
22
LIST OF EQUIPMENTS IN GENERAL INSTALLATION
SL. NO: NAME OF EQUIPMENT QUANTIT Y
1 Air Compressor with maximum working pressure of 17.5kg/sq.cm 2.nos
2 Pneumatic Rammer with Rubber head 2.nos
3 Pneumatic Chisel (with suitable Chisel) l. no
4 Molding Sand Mix, Each one unit
Molding Sand Muller 50kg capacity per minute
5 Mould Green Hardness tester - dial type -Risdale dials standard 1 no
6 Core hardness tester 1 no
7 Co2 Cylinder with Co2 probe and rubber hoses with nozzle 12mm 1 no
wheel valve.
8 L.P.G Cylinder With heating torch (Industrial Purpose) 1 no
9 Cylinder trolley Suitable to Co2 Cylinder and Indane/similar Gas 2 no
Cylinder
10 Heating and Plumbing Unit to suit to oil Fired Tilting type Crucible l. unit
Furnace with Heating Pressure Gauge etc. Oil tank Motorized Rotary
pump-Pre heater.
11 Sand testing Equipments - Permeability meter, Universal Strength tester, Each One Set
Sieve Shaker, standard Sand Rammer, Shutter Index Tester, Clay
Content Tester, Speedy Moisture teller. Electric Hot Air oven.
12 Molding Machine Hand squeeze With Stripping device pin lift type. One unit
( latest version ) With Suitable Compressor & Lifting Device.
13 Sand Aerator. One unit
14 Testing Of Mechanical Properties: Each one unit
Tensile Tester,
Hardness Tester,
The brinell Tester,
The Rockwell Tester,
Fracture Tester,
Impact Tester,
Creep tester.
Specification:
Equipments suitable for Training Purposes.
15 NON- DESTRUCTIVE TEST: Radiography, Each one unit
(X-ray 8L y- ray) Magnetic Particle Detector,
Dye Fluorescent -Dye Penetrants Detector,
Ultrasonic Flaw Detector,
Specification:
Equipments suitable for Training Purposes.
16 Metal Chemical Composition Analyzers / Spectrometer Each one unit
17 Heat -Treated Furnace ( Electrical Furnace) One Unit
23
K. FURNITURE, ACCESSORIES AND AUDIO VISUAL AIDS FOR
THE SEMESTER-I & II (COMMON FOR ALL ENGG. TRADES)
24
L. LIST OF TRADE COMMITTEE MEMBERS
25
Members of Core Group
22. N. Nath. (ADT) CSTARI, Kolkata Co-ordinator
23. H.Charles (TO) NIMI, Chennai. Member
24. Sukhdev Singh (JDT) ATI Kanpur Team Leader
25. Ravi Pandey (V.I) ATI Kanpur Member
26. A.K. Nasakar (T.O) ATI Kolkata Member
27. Samir Sarkar (T.O) ATI Kolkata Member
28. J. Ram Eswara Rao (T.O) RDAT Hyderabad Member
29. T.G. Kadam (T.O) ATI Mumbai Member
30. K. Mahendar (DDT) ATI Chennai Member
31. Shrikant S Sonnavane (T.O) ATI Mumbai Member
32. K. Nagasrinivas ATI Hyderabad Member
(DDT)
33. G.N. Eswarappa (DDT) FTI Bangalore Member
34. G. Govindan, Sr. ATI Chennai Member
Draughtsman
35. M.N.Renukaradhya, Govt. ITI, Tumkur Road, Member
Dy.Director/Principal Grade I., Banglore, Karnataka
36. B.V.Venkatesh Reddy. JTO Govt. ITI, Tumkur Road, Member
Banglore, Karnataka
37. N.M.Kajale, Principal, Govt. ITI Velhe, Distt: Pune, Member
Maharashtra
38. Subrata Polley, Instructor ITI Howrah Homes, West Bengal Member
39. VINOD KUMAR.R Govt.ITI Dhanuvachapuram Member
Sr.Instructor Trivendrum, Dist., Kerala
40. M. Anbalagan, B.E., Assistant Govt. ITI Coimbatore, Tamil Member
Training Officer Nadu
41. K. Lakshmi Narayanan, T.O. DET, Tamil Nadu Member
Other industry representatives
42. Venugopal Parvatikar Skill Sonics, Bangalore Member
43. Venkata Dasari Skill Sonics, Bangalore Member
44. Srihari, D CADEM Tech. Pvt. Ltd., Member
Bengaluru
45. Dasarathi.G.V. CADEM Tech. Pvt. Ltd., Member
Bengaluru
46. L.R.S.Mani Ohm Shakti Industries, Bengaluru Member
26