DPT Syllabus II IV Sem

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DPT SYLLABUS STRUCTURE

SEMESTER II

THEORY

CODE SUBJECT CH TH EHMARKS

INT EXT TOTAL

GE 201 Communication English-II 72 08 3 40 60 100GE 202 Applied Mathematics 72 08 3 40 60 100

GE 203Fundamentals of Electrical andElectronics Engineering

52 08 3 40 60 100

GE 204 Engineering Drawing-II 40 60 3 40 60 100PT 201 Fundamentals of Polymer Science 72 08 3 40 60 100PT 202 Plastics Materials - I 72 08 3 40 60 100

Total (20 weeks - 24 hours per week) 480 18 240 360 600

PRACTICAL

Code Name of Laboratory Exc. Hrs EHMarks

INT EXT TotalGEL 205

Electrical and ElectronicsEngineering Lab

40 4 50 50 100

PTL 203 Utilities & Service Equipments Lab 80 4 50 50 100PTL 204 Workshop Practices - II 160 8 100 100 200

*ISAP / Library 40 - - - -Total (20 weeks - 16 hours per week) 320 16 200 200 400

CH- Contact Hours TH-Tutorial Hours EH- Examination Hours

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SEMESTER II

GE 201 COMMUNICATION ENGLISH II (80 Hours)

Unit I (20 Hours)

Grammar - Changing a sentence into negative without changing the meaning; Changing words fromone form to another; Degrees of Comparison; Simple, Compound & Complex sentences; Rewriting asentence with 'It' / 'There' in the initial position; Answering the verbal questions in affirmative andnegative; Synonyms and Antonyms; forming meaningful sentences for the words given; phrases /structures indicating use and purpose; concord; Modal Verbs; Definitions; Spelling and Punctuations,sequencing of Jumbled sentences.

Unit II (40 Hours)

Composition - Conversion of Graphics (pie-chart, bar-chart, table ) ; Letter writing - Business andOfficial letters (Letter of Quotation, Letter of Clarification, Letter of Complaint, Letter Placing orders,Letter for Seeking Permission for Industrial visit , Letter to editor, Letter of request for Leave / Bonafide

Certificate / Testimonials, Letter of Application for a job with Bio-data / Curriculum vitae);

Unit III (20 Hours)

Technical Report writing (Analytical Report, Accident Report, Project report, Inspection Report,Production Report, Investigation Report, Field Report); Check list.

Text / References Books

1. A.S. Homby . 'The Advanced Learners Dictionary of Current English' Oxford University Press: 1973.

2. Wren & Martin, 'High School English Grammar and Composition. S.Chand & Co., Ltd.3. Glennis Pye, 'Vocabulary in Practice - Part 1 to 4', Cambridge University Press, 2004.

4. Shiv.K.Kumar & Hemalatha Nagarajan, 'Learn Correct English', Pearson Longman.

5. Raymond Murphy, 'Essential English Grammar', Cambridge University Press, 1990.

6. M.Thomas, 'Common Errors in English', Lotus Press, New Delhi, 2006.

7. Michael Swanm 'Basic English Usage,' E,BS/OUP, 1989.

GE 202 - APPLIED MATHEMATICS (80 Hours)

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Unit I (15 Hours)

Vector Algebra

1.1 Introduction

Definitions - Types - Addition and Subtraction of Vectors - Properties - Position Vector, Resolutionof Vector in two and three dimensions, Direction Cosines and Direction Ratios of Vectors, Simpleproblems.

1.2 Product of VectorsScalar and Vector product of two vectors - Geometrical meaning - Angle between two vectors -Unit vector perpendicular to two vectors.

1.3 Applications of VectorsWork done - Moment - Scalar and vector triple product - Geometrical interpretation of scalar tripleproduct - Coplanar Vectors, Scalar and Vector product of four vectors, Simple problems.

Unit II (15 Hours)

Integral Calculus

2.1 IntegrationDefinition - Integral values using reverse process of differentiation - Integration usingdecomposition method - Integration by substitution - Integrals of the form [f(x)]n f'(x) dx, n # - 1. f'(x)/f(x) dx, [f(x)] f'(x) dx

2.2 Standard IntegralsIntegral of the form dx/ (a2 x2), dx/x2 - a2, dx/ a2 - x2, dx /(x+a) (x+b),

(Ax+ B) dx / ax2 + bx +c - simple problems.

2.3 Integration by partsIntegration by parts and Bernoull's form to evaluate x sin nx dx, x cos nx dx, x2dax, xn log x dx, log x dx.

Unit III (15 Hours)

Applications of Differentiation

3.1 Velocity and Acceleration, Tangents and Normals - Simple problems.3.2 Maxima and Minima of Single variable - Simple Problems.

3.3 Partial differentiation of two variables upto second order - Euler's Theorem - Simple problems.

Unit IV (15 Hours)

Applications of Integration

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4.1 Definite Integral, Area and volume - Area of circle, Volume of Sphere and Cone - Simpleproblems.

4.2 Solution of Differential Equations - Variable Seperable - Linear type Differential Equations -Simple problems.

4.3 Second order differential equation with constant coefficients ad2y/dx2 + bdy/dx + cy = e ax wheref (a) # 0.

Unit V (20 Hours)

Probability & Statistics

5.1 Definitions - Axioms - Addition Formula, Mutually exclusive event, Addition Theorem onProbability, conditional probability - Multiplication Theorem

5.2 Random Variable

Types of random variable- Definition of Discrete Random Variable, probability mass function,continuous random variable and probability density function - simple problems. Mathematicalexpectation of discrete random variable, simple problems.

5.3 Discrete Distributions

(a) Binomial Distributions

p(X = x) = nCxpxqn - x x = 0,1,2...........n0 otherwise

Expression for mean, variance and standard deviation - simple problems

(b) Poisson Distribution

Definition of Poisson distributionp(X = x) = e- x / x! x = 0,1,2........

0 otherwise

Expression for mean, variance and standard deviation - Simple problems

5.4 Continuous Distribution

Normal distribution: Definition of normal and standard normal distribution - Constants of normal

distribution - Properties of normal distribution - Simple problems using the table for standardnormal distribution.

Text / Reference Books

1. Applied Mathematics for Polytechnic Colleges (Second Semester) - P.Krishnamurthy, N.Thangasamy.

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2. Higher Secondary - First Year - Tamil Nadu Text Book Cooperation.

3. Engineering Mathematics - Dr.M.K.Venkatraman, Natinal Publishing Co, Chennai.

4. Engineering Mathematics - Dr.P. Kandasamy & Others, Schand & Co Ltd., New Delhi.

GE 203 - FUNDAMENTALS OF ELECTRICAL ANDELECTRONICS ENGINEERING (60 Hours)

Unit I (12 Hours)

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DC & AC Circuits and BatteriesDefinitions Electric current, Voltage and Resistance Ohms Law and Kirchoffs Laws Resistance inseries, parallel and series parallel Simple problems Electromagnetism, Magnetic flux, Flux density,Magnetic field Intensity, MMF, Permeability, Reluctance, Faradays Laws of Electromagnetic Induction.Fundamentals of AC voltage and current Peak, average, RMS value of sine wave, Frequency, timeperiod, amplitude, power, power factor, Ac circuits RLC in series star, Delta Connections - relationship

between phase and line voltages, current in star and Delta connections.Batteries classification of cells construction of ni iron and cadmium cell concept of recharging cells

lead acid cell construction - indication of full charged cells defects, and remedies, applications.

Unit II (12 Hours)

DC Generator, DC Motor, Transformer and AlternatorDC Generator Construction Principles of Operation, Types and Applications, DC Motor construction Principles of Operation, Types and Applications, Necessity for starter three point, four point starter,Transformer Principle of Operation and Construction EMF Equation Losses in a Transformer Efficiency Autotransformer Three Phase Transformer Applications, Alternator Construction Principle of Operation Types and Applications.

Unit III (12 Hours)

AC Motors and Electrical SafetyPrinciple of Operation of single phase capacitor start induction motor applications three phaseinduction motors squirrel cage and slip ring IM (construction and working principle) applications speed control of three phase induction motor necessity of starter DOL and star delta starter.

Special Motor: PMDC, Stepper motor Construction, Working Principle and Application.Electrical Safety Importance of Earthing Electric shock First aid for electric shock Precautionsagainst shock Cause of Accidents and their preventive measures Energy conservation.

Unit IV (12 Hours)

Basic Electronics and Logic GatesSemiconductor materials N type and P type PN Junction forward and reverse bias, characteristicsof PN junction diode Half wave rectifier, full wave rectifier, bridge rectifier, zener diode and avalanchebreak down, characteristics of zener diode application of zener diode.Transistor construction of NPN and PNP types basic bias requirements (common emitterconfiguration), Thyristors principle and working of SCR characteristics applications, Introduction ofintegrated circuits classification and packages applications, Logic Gates positive and negativelogic, definition, symbol, truth table, Boolean expression for OR, AND, NOT, NOR, NAND, EXOR andEXNOR gates.

Unit V (12 Hours)

Programmable Logic ControllerPLC Features and Benefits of PLC Systems and its elements Input and Output elements PLCMemory System PLC circuit verses hardwired circuits Sensors Types of Sensors Limit Switch,Reed Switch, Photo Electric Sensor, Inductive Proximity Sensor Types of contacts normally open(NO) contact, normally closed (NC) contact ladder logic symbol AND logic OR logic , truth table

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steps involved in application circuits using a PLC PLC scan input Programme and output scan design ladder diagram for operation of motor using AND and OR logic.Design ladder logic diagram for ON delay control of a motor and OFF delay control of a motor.


1. B.L. Theraja, Fundamentals of Electrical and Electronics Engineering, S.Chand & Co.

2. T. Thiyagarajan, Fundamentals of Electrical and Electronics Engineering, Scitech Publicatiuons(India) Pvt.ltd.

3. Mikell P. Groover, Automation, Production System and Computer Integrated Manufacturing, Edn. 2Published by Pearson Education (Singapore) Pte. Ltd., Indian Branch, 2842 F.I.E., Patparganj,Delhi 110 002, India.

4. KB Raina & S.K.Battachariya, Electrical Design Estimating and Costing, Edn. 6, Tata McGraw HillPublishing Co., 7, West Patel Nagar, New Delhi 110 008.

5. Gary Dummy, Introduction to Programmable logic controls, Thomson Debnar learning secondedition second reprint 2003.

6. B.L.Theraja & A.K. Theraja, Electrical Technology Vol. I & II, Edn. 23, published by S.Chand & Co.Ltd., Ram Nagar, New Delhi 110 055.

GE 204 ENGINEERING DRAWING II (100 Hours)

Unit I (25 Hours)

1.1 Sectional views of objectsNeed for sectional drawing of an engineering object- Sectioning of solids in simple verticalposition by cutting planes inclined to one reference plane and perpendicular to the other,obtaining true shape of section.

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1.2 Auxiliary viewsNeed of auxiliary views auxiliary views given engineering drawings.

1.3 Development of surfacesDevelopment of Lateral Surfaces of Simple and Truncated Solids- Prisms, Pyramids, Cylindersand Cones- Development of Lateral Surfaces of Solids with Cylindrical Cutouts, Perpendicular to

the axis.

Unit II (30 Hours)

2.1 Pictorial drawingsPrinciples of Isometric Projection, Construction of Isometric Scales- Isometric Projections ofSimple Solids, Truncated Prisms, Pyramids, Cylinders and Cones -Isometric Projection of SimpleEngineering.

2.2 Perspective drawingPrinciple of Perspective Projection Type of Perspective Projection Perspective Projection ofPrisms, Pyramids and Cylinders by Visual Ray Method.

Unit III (15 Hours)

Fastening DevicesBasic Fastening Devices - Temporary and Permanent Fastenings Areas of Applications Bolts andNuts Different types of bolted joints for different applications purpose of locking nuts Types of locknuts. Exercises in drawing bolted connection using standard proportion. Exercises in the selection ofappropriate fastening devices to meet the given working conditions.

Unit IV (30 Hours)

Assembly and Detail Drawings of Machine Part

Need and functions of assembly and detailed drawings selection of sheet sizes preparation of titleblock bill of materials and parts list Steps in preparing assembly and detailed drawings.Exercises in assembly and detailed drawings of sleeve & cotter joint, socket & spigot joint , knuckle

joint, muff coupling, half lap muff coupling , protected flanged coupling, Plummer block, Tail stock andScrew jack.


1. Engineering Graphics, Julyes Jaisingh.2. Engineering Drawing by N. D Bhutt.3. Engineering Graphics by P. I. Varghese.4. Machine Drawing by P.I. Varghese & K.C. John.5. Machine Drawing by N.D. Bhatt.6. A test book of Machine Drawing by V. Lakshmi Narayan.7. Machine Drawing by K.R. Gopalakrishna.

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PT 201 FUNDAMENTALS OF POLYMER SCIENCE (80 Hours)

Unit I (16 Hours)

Introduction to Polymer ScienceThe science of large molecules Definitions Monomers & its requirement- Broad Classifications ofPolymers - Types based on Structure Processing and Application - Molecular Force and ChemicalBonding in Polymers Polymer structure Homo Polymers and Copolymers Geometric Isomerism Tacticity Nomenclature Molecular Weight and Distribution and its effect on Properties andProcessing of Polymers- Thermal Transition Tg & Tm.

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Unit II (24 Hours)

PolymerisationChain growth Polymerization Addition Polymerisation Reaction Mechanism - Free Radical Reaction

Ionic Reaction Coordination Polymerization Ring Opening Polymerization - CondensationPolymerization Extend of Reaction and Degree of Polymerisation Polymerization Techniques

Bulk, Solution, Suspension & Emulsion Polymerization Techniques and Co-polymerization.

Unit III (20 Hours)

Polymer Structure and PropertiesStructure Property Relationship Molecular Weight and Poly Dispersity Index (PDI) - Effect ofPolymerization on PDI Polymer solutions and solubility General Rules for Polymer solubility solubility Parameters, Properties of Dilute solutions - Solid state properties State of Polymer Crystalline, Amorphous, Semi-crystalline, Liquid crystalline Requirement of Crystallinity factorsaffecting crystallinity. Deformations in Polymer Mechanical properties - Stress Strain behavior Polymer Fracture and Toughness Cracking & Crazing Thermal & Electrical properties.

Unit IV (20 Hours)

Degradation & Stabilization of Polymer

Polymer CharacterizationIdentification and Characterization of Polymers Simple Spectroscopic Methods Molecular WeightDetermination Measuring Dilute Solution Viscosity Gas Chromatography Gel PermeationChromatography Melt Flow Characteristics - Thermal Analysis DSC and TGA Dynamic Mechanical

Analysis.


1. Polymer Science Gowariker V.R. & others.2. Text book of Polymer Science Billmeyer F.W.

PT 202 PLASTICS MATERIALS I (80 Hours)

Unit I (08 Hours)

Natural PolymerNomenclature of Polymers Sources of Raw Materials Methods of Manufacture GeneralCharacters & Properties, processing behaviour and applications of natural polymers such as ShellacResin Natural Rubber Casein.

Unit II (24 Hours)

Commodity Plastics

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Olefinic & Styrenic Plastics: Sources of Raw Materials Method of Manufacture GeneralCharacters & Properties Processing Behaviour and end use applications ofLDPE Low Density PolyethyleneLLDPE Linear Low Density PolyethyleneHDPE High Density Polyethylene

HMHDPE High Molecular weight High Density PolyethylenePP Polypropylene (Homo & Copolymer)PS PolystyreneHIPS High Impact Polystyrene

ABS - Acrylonitrile Butadiene StyreneSAN Styrene AcrylonitrileEPS Expanded Polystyrene

Unit III (24 Hours)

Commodity Plastics

Vinyl & Cellulosic Plastics: Sources of Raw Materials Method of Manufacture General characters& Properties Processing Behaviour and end use applications ofPVC - Polyvinyl chloride & Chlorinated PVC.PVDC Polyvinylidene Chloride.PVAc - Polyvinyl Acetate.PVA Polyvinyl Alcohol.CN Cellulose Nitrate.CA Cellulose Acetate.CAB Cellulose Acetate Butyrate.Regenerated Cellulose.

Acrylic Plastics (Polymethyl Methacrylate, Polyacrylonitrile).

Thermoplastic Elastomers.

Unit IV (24 Hours)

Thermoset PlasticsSource of Raw Materials Methods of Manufacture General Characters & Properties ProcessingBehaviour and Applications of Phenol Formaldehyde Urea Formaldehyde Melamine Formaldehyde

Unsaturated Polyesters Alkyd Resins Epoxy Resin Polyurethane Silicones.


1. Plastic Materials J.A. Brydson.2. Plastic Materials Hand Book A.S. Athalye.

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GEL 205 - ELECTRICAL AND ELECTRONICS ENGINEERING LAB (40 Hours)

1. Electrical Engineering Lab (20 Hours)

1. Study of Measuring Instruments Ammeter Volt meter Watt meter etc.

2. Determination of unknown resistance by Ohms Law.

3. Energy Measurement in a single phase circuit using Lamp Load.

4. Power Measurement in a Single Phase Circuit.

5. Load test on a Single Phase Transformer.

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6. Load test on a Single Phase Induction Motor.

7. Verification of Series and Parallel Circuit.

8. Study of DC & AC Machine Starters.

2. Electronics Engineering Lab (20 Hours)

1. Charactertics of PN Junction Diode.

2. Charactertics of Transistor.

3. Construction of Bridge Rectifier.

4. Verification of Logic Gates.

5. Charactertics of Photo Diode and Thermister.

6. Measurement using CRO and Megger.

7. Study of Microprocessor.

PTL 203 UTILITIES & SERVICE EQUIPMENTS LAB (80 Hours)(20 Weeks 4 hours a week)

1. Study of Air Compressor Elements, Safety Features, Drive Mechanism, Lubrication.

2. Study on Hydraulic Pumps , Motors Accumulators, Safety Features, Control Valves & SimpleHydraulic Circuits for Lifting Tackle, Manual Pump, Hydraulic Press, Hydraulic Valves Different

Types, Hydraulic Accumulators, Hydraulic Pressure Control and Flow Control, Hydraulic Pipingand Coupling, Safety and Trouble Shooting.

3. Working of 4/2, 2/2 & 4/3 directional control valve in Single Acting & Double Acting Cylinder.

4. Study of FRL unit and Air Dryer in the Pneumatic System & Hopper Drier.

5. Study of heat exchanger in Moulding Machine.

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6. Study of Mould Heating using Hot Oil Circulator.

7. Study of Chilling Plant/Cooling Tower.

8. Study of Electrical safety Measures & Demonstration about use of protective devices.

9. Study and Usage of Various Electrical Tools & Instruments like Voltmeter, Ammeter, Multimeter(Analogue 7 Digital), Wattmeter & Energy Meter & Megger

10. Study of Single Phase and Three Phase power supply. Identification of phase, Neutral and Earthpits.

11. Importance of three phase wiring and its effectiveness, laying out three-phase wiring for an ElectricMotor or any other three phase machine.

12. Study, Demonstration and Identification of common Electrical materials such as Wires, Cables,Switches, Fuses, Plugs, Connectors, Sockets etc.

13. Calculation of power and energy consumption.

14. Various types of protective devices such as: Wire Fuse, Cartridge fuse, slow acting/fast actingfuse, HRC fuse, thermal fuse, single/multiple miniature circuit breakers, over and under currentrelays, contractors, and Different types of switches, MCCB.

15. Study of Fluorescent lamp and CFL.

16. Study of Servo Voltage Stabilizer.

17. Study of Half wave / Full wave rectifier.

18. Study of different types of heater used in plastics processing Machinery using Voltmeter &Ammeter find out the unknown wattage of heater.

PTL 204 - WORKSHOP PRACTICES II (160 Hours)

Workshop Safety

General shop safety, safety on fitting bench and safety on machines.

1. Pedestal Grinding (20 Hours)

Sharpening of Cutting Tools - Single point and Knife tools, Form Tools, Parting and Grooving Tools,

Thread Cutting Tools.

2. Practice on Drilling Machine (20 Hours)

2.1 Familiarization with Drilling Machine - Principal parts, work holding device, Cutting Tools &Tool holding device.

2.2 Marking and Punching the layout.2.3 Drilling and Tapping.

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2.4 Drilling and Reaming.2.5 Counter boring and Counter sinking.

3. Practice on Lathe (40 Hours)

3.1 Familiarization with lathes- principal parts, work holding device, Cutting tools & tool holdingdevice.3.2 Plain turning and Step turning.3.3 Taper turning.3.4 Drilling and Reaming.3.5 Boring and counter boring.3.6 Thread cutting and knurling.

4. Practice on Milling Machine (30 Hours)

4.1 Familiarization with Milling Machine - Principal parts, work holding device, Cutting Tools & Toolholding device.

4.2 Plain surface Milling.4.3 Slot Milling.4.4 Pocket Milling.

5. Practice on Surface Grinding Machine (30 Hours)

5.1 Familiarization with Grinding Machine - Principal parts, work holding device, grinding wheels.5.2 Plain Surface Grinding.5.3 Slot Grinding.5.4 Angular Surface Grinding.

6. Plumbing (20 Hours)

6.1 Pipe cutting and Thread cutting practice.6.2 Coupling joint.6.3 Elbow joint.6.4 Tee joint.

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SEMESTER IV

THEORY

Code Subject CH TH EHMarks

INT EXT Total

PT 401 Fundamentals of Plastics Product & MouldDesign

72 08 03 40 60 100

PT 402 Plastics Processing Techniques - II 72 08 03 40 60 100PT 403 Plastics Testing Techniques - II 52 08 03 40 60 100PT 404 Polymer Composites and Applications 52 08 03 40 60 100Total Theory Hours (20 weeks - 14 hours a week) 280 12 160 240 400

PRACTICAL

Code Name of Laboratory Exc. Hrs EHMarks

INT EXT Total

PTL 405 Plastics Processing Lab II(20 weeks 12 hours a week)

240 08 100 100 200

PTL 406 Plastics Testing Lab -II(20 weeks 8 hours a week)

160 08 100 100 200

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PTL 407 Design Practical by Auto CAD Lab(20 weeks - 4 hours a week)

80 - - - -

Library ( 20 weeks 2 hours a week) 40 - - - -Total Hours 520 16 200 200 400

CH- Contact Hours TH-Tutorial Hours EH- Examination Hours

SEMESTER IV

PT 401 FUNDAMENTALS OF PLASTICS PRODUCT AND MOULD DESIGN (80 Hours)

Unit I (20 Hours)

Product Design

Product Design Concepts size, shape, function, aesthetics, life, tooling aspects on product design process variables Vs product design - product design thumb rules for plastics - cost reduction throughproduct design concepts - design of external, internal undercuts - side openings - hinges - fits of boxand lid - assembly through resilience properties - case studies.

Unit II (26 Hours)

Injection Mould Design

Mould design concepts - Introduction - concept of design - design principles - parting line - mouldelements - types of moulds - construction of core and cavities - position of gate - gate balancing ejection - types of ejections - mould cooling - mould alignment - ancillary parts of the mould.

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Types of Injection Moulds - Two plate mould - Direct Sprue injection - Single Impression - MultiImpression - Side Gated Three Plate Moulds - Stack Moulds - Multi Day Light Moulds.

Split moulds - external undercut - internal undercut - delayed action - cam track actuation - hydrauliccore pulling devices - split cavities - split cores - threaded inserts - internal and external.

Methodical approach to mould design - determination of economical number of cavities mould

standards bolsters - standard mould parts - mould design check list.

Unit III (20 Hours)

Compression Mould Design

Types of compression mould, open flash, semi-positive type, positive, displacement moulds, types ofloading chambers, bulk factor, flash thickness, pot design, projected area, compression pressure,clamping force, no. of impression by technological method, heating system, types of heaters, heat loss,heat requirement & heater capacity.

Transfer Mould Design - Types of transfer moulds, integral pot transfer mould, auxiliary ram transfer

mould, transfer pot design, projected area, transfer pressure, clamping force, pressure pad design,design of sprue runner and gate, advantages and disadvantages of transfer mould - design relatedcalculations.

Unit IV (14 Hours)

Blow Mould DesignTypes of Blow Moulds - Extrusion - Injection and Stretch Blow Moulds - Blow Ratio - Parison Design -pinch off design - Parting Line - Clamping Force - Mould venting, Mould Cooling - Mould Alignment.

Extrusion Die Design -Principles of Extrusion - Die geometry - die swell - Die Land Design - Sizing diedesign - Construction of extrusion dies - blown film - pipe - profile - flat film - sheet - Wire Coating and

Co-Extrusion Dies.

Design of other Moulds-Thermoforming-vacumm forming-rotational mould


1. Technical Manual on Plastics Mould Design CIPET2. Injection Mould Design for Thermoplastics Pye, R. G. W.3. Plastics Product Design Engineering Dubois H.

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PT 402 PLASTICS PROCESSING TECHNIQUES - II (80 Hours)

Unit I (12 Hours)

Rotational Moulding

Basic principle - Material selection & Estimation through trial analysis - Type of machine - Processvariables - Charge size - wall thickness control - Heating and Cooling system Process requirement forthe moulding of water tank - Dust Bin, etc. Application of Rotational Moulding - Ejection & Finishing Fault - Causes & Remedies - Merits & Demerits of Rotational Moulding Process.

Unit II (24 Hours)

Thermoforming

Basic principles Advantages - Material Selection - Thermoforming machine Single Stage - Multi

Stage - Sheet fed m/c - Packaging Machine - Mould Material - Thickness Control - Types of Forming Vacuum Forming Free Forming - Plug-assist-forming - Drape forming - Matched die forming - Drapeforming - Snap back forming - Dual sheet forming - Skin & Blister pack forming - Types of heating -process variables - Forming of Disposal Cups & tumbler - Refrigerator Panel & Automobile Body Faults - Causes & Remedies.

Unit III (12 Hours)

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Calendering

Process Description - Materials used - Advantages over extrusion - Types of Calender Rolls - HeatingSystem - Roll Bending - Complete Description of Calendering line with their function Heating &Cooling System - Winding Type & Method - Finishing Trouble Shooting.

Unit IV (16 Hours)

Fibre Reinforced Plastics (FRP)

Introduction - FRP processing methods - contact moulding - hand lay up, spray up method - vacuumbag & pressure bag moulding, filament welding, centrifugal casting, pultrusion, matched die moulding.

Unit - V (16 Hours)

Secondary Processes

Powder coating, casting, machining & joining of plastics - Decoration of plastics - Metalizing - Printing &

Painting etc - Post moulding operations.


1. Compression Moulding Iyesaw, A.I.2. Technical Manual on Plastics Processing CIPET3. Plastics Engineering Hand Book Society of Plastics Industry Inc.4. Plastics Materials & Processing Strong A Brent.

PT 403 PLASTICS TESTING TECHNIQUES II (60 Hours)

Unit I (20 Hours)

Electrical & Optical PropertiesDielectric strength - Dielectric constant and Dissipation factor - Insulation resistance - Volume andSurface resistivity - Arc resistance - Antistatic tests.

Refractive index - Luminous transmittance - Clarity and Haze - Photo-elastic properties - Colourmeasurements and Specular Gloss.

Unit II (16 Hours)

Chemical Properties

Introduction Immersion test Stain Resistance of Plastics Environmental Stress Cracking

Resistance (ESCR).Flammability

Introduction Flammability Test Ignition Properties Oxygen Index Test Flammability of CellularPlastics Smoke Density Test UL90 Flammability Test.

Unit III (12 Hours)

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Weathering Properties

Introduction environmental factors affecting plastics Accelerated weathering tests outdoorweathering of plastics Resistance of plastics to biological systems.

Bio-degradability Testing

Test methods and standards for bio-degradable plastics - Criteria used in evaluation of bio-degradableplastics - Description of current test methods.

Unit IV (12 Hours)

Product Testing

Plastics Pipes Films Wovensacks Water Tanks Containers & Plastic Foams.

Failure Analysis

Introduction Types of failure Analyzing Failures Non Destructive Testing (NDT) Ultrasonicmethods & its application in plastics, Gamma & Beta Transmission Laser X-ray Fluorescence.


1. Text Book on Fundamentals of Plastics Testing - Prof. (Dr.) S.K. Nayak2. Plastics Testing Technology Hand Book Shah Vishu

PT 404 POLYMER COMPOSITES AND APPLICATIONS (60 Hours)

Unit I (16 Hours)

Introduction to Composites

Definition Advantages Raw Material Matrix Reinforcements Properties of Polymer Matrix -Thermoplastics Materials such as Polypropylene, Nylon-6, 66, 610, 11 & 12 PolybutyleneTerephthalate (PBT) Polycarbonate (PC) Polyoxymethylene (POM) Polyphenylene Sulphide(PPS) Vinyl Plastics & Thermoset Plastics such as PF, UF, MF Unsaturated Polyester Resin

Alkyd Resin Epoxy Resin Polyimide Resin Polyurethane & Silicon.

Unit II (16 Hours)

Reinforcement Materials & Other Ingredients

Fillers & Reinforcement for composites Natural & Synthetic Fibers Natural Fiber Cellulose, Jute,

Coir, Linen, Vegetable Fiber Synthetic Fiber Glass Fiber Types Properties & Applications Carbon Fiber Properties & Applications Aramide Fiber Properties & Applications PolymericFiber Properties, Applications & Metallic Fiber Properties & Applications Coupling Agent Curing

Agents Lubricants Plasticizer Nano Filler.

Unit III (20 Hours)

Composite Processing Methods

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Processing Fundamentals Requirement Dough Moulding Compound (DMC) / Bulk MouldingCompound (BMC) / Sheet Moulding Compound (SMC) Open Mould Process Hand Layup, Spray-up, Bag Moulding, Filament Winding Closed Mould Process Centrifugal Casting, Resin Injection,Continuous Process High Pressure laminate Pultrusion Process.

Unit IV (8 Hours)

Applications of Composites

Application of Composites in Aerospace Automobiles Building & Construction Wind PowerGeneration Electrical & Electronics Applications of Nano Composites.


1. FRP Manufacturing Process Philip Ball.2. Composite Polymeric Materials Sheldon.3. FRP Technology Weathehead.4. Advanced Polymer Composites Borz Jang.

5. Technical Manual on Plastic Processing CIPET.

PTL 405 PLASTICS PROCESSING LAB II (240 Hours)(20 weeks 12 Hours a week)

Sl.No.

Name of M/cEquipment/

Mould

Description of practical exercise to bedone*

ExerciseCode No.

No. ofHours

1 Injection

Moulding SemiAutomatic

(i) Study of semi automatic Injection moulding

machines of all types in IRO. Comparativestudy of Pneumatic type & Hydraulic type ofmachines operating principles of machines withnomenclature of parts, machines specifications.(ii) Operation of Pneumatic & Hydraulic type ofSemi automatic Injection moulding machines,to produce components in different moulds.Cycle-time analysis, observations of processparameters & Procedure to be recorded.

PP-09

PP-10

40

30

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2 ExtrusionProcesses

(i) Study of extruders in IRO, Free sketch ofmachines, their parts and parts-function, List ofproducts manufactured by Extrusion process.Study of different types of extrusion process.(ii) Procedure for setting up of process-parameters eg. Temperature on different zones,

screw speed, Nip-roller speed, Winder speed,Blow ratio, Control of cooling-Air on bubble,Methodology & Practice by trainees to fix theBlown film die on M/c. Familiarization of Die-parts & their function, technical specification ofmachines, defects, causes & remedies, Practiceof operating machine to produce different sizesof blown film. Study of the machine parts &function from screw drive to the caterpillar.Practice of Die setting on the machine,Procedure for setting up of parameters &operation practice in running the machine to

produce Pipe/tube/Film.

PP-11

PP-12

30

40

3 Compression &Transfermoulding-Semiauto &

Automatic

Parameter setting, operation-practice on differentCompression & Transfer Moulds, observation &procedure of startup & shut down of machine.Setting up procedure for operation of machine,Safety precautions, type of mould clampingarrangement available on Machine-Platen, Mouldclamping procedure on machine, Operation ofmachine by setting the optimum temperature,curing time, clamping force, ejector-stroke etc. oncontinuous basis, Analysis of product defects &

remedies, Analysis of cycle-time, Practice onoperation of compression & Transfer moulds withthermoset materials.

PP-13 40

4 Blow-MouldingSemi Auto &

Automatic

Technical specification of machine, Mouldclamping on machines. Familiarisation withcontrol-switches/valves on the machine, &procedure of operation of machine.Machine-setting Procedure, Parameter SettingProcedure, Method of mould fixing & Parison-die setting on the machine, Practice by traineesto remove & fix the Parison die to produce an

appropriate Parison for blowing, type of blowingsystems, operation-practice on differentmoulds, cycle-time analysis, process-faults &remedies.

PP-14 40

Two practical test on Plastic Processing LabVIVA-VOCE

8 Hours Per Test4 Hours

240

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* Practical Exercises on operation of machines shall be done as per the operating-manual instruction of therespective M/cs.

*One test may be conducted in the middle of the Semester and the other one at the end of the Semesterfollowed by Viva-Voce.

PTL 406 PLASTICS TESTING LAB II (160 Hours)

(20 weeks 8 Hours a week)

S. No. Name of Exercise No. of Hours

1. Specimen Preparation by Injection Moulding 102. Specimen Preparation by Compression Moulding 103. Specimen Preparation by Cutting

104. Specimen Preparation by Punching

5. Hot Roll Milling for Melt Mixing 106. Determination of Tensile Properties 107. Determination of Flexural Properties 108. Determination of Compressive Properties 109. Determination of Izod & Charpy Impact Strength 10

10. Determination of Dart Impact Resistance of Plastic Films & Sheets 10

11.Determination of Hardness (Shore A & D, Rockwell Hardness,Barcol Hardness)

10

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12. Determination of Melt Flow Index 1013. Determination of Heat Distortion Temperature

2014. Determination of Vicat Softening Temperature15. Determination of Rate of Burning

1016. Determination of Limiting Oxygen Index17. Determination of Volume Resistivity & Surface Resistivity

1018. Determination of Arc Resistance19. Determination of Dielectric Strength20. Determination of Clarity &Haze 10

PTL 407 DESIGN PRACTICAL BY AUTO CAD LAB (80 Hours)

S. No. Name of the Exercise No. of Hours

1. Hand Injection Mould Design 04

2. Design of Mould Elements / Standard Mould Base 08

3. Single Impression Two Plate Mould 08

4. Multi-impression Two Plate Mould 08

5. Three Plate Mould (Multi-impression) 16

6. Split Mould Design 16

7. Mould Design for Internal Undercuts 16

8. Mid Term Test 04

Total 80

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Documents

DPT Syllabus II IV Sem