Mould & Die Manufacturing

Mould Making Introduction of mould parts, Mechanism of metal cutting, types of tools, influence of tool angles, Cutting fluids, Tool materials used including coated tools. Mould material, Material selection for mould making, Properties of steels for moulds. Nonferrous metals for moulds ‐ Zinc base alloys and aluminium alloys, Beryllium Copper, Polyesters, Epoxies, Silicones. Review of various machining operations.

Jig boring, Pantograph, Profile grinding, Electrical discharge machining Characteristics, physical processes, special technological features, types of EDM, design consideration & functions and technological planning. Applications of wire cut EDM in mould making. Electroforming for mould manufacturing ‐ discussion of the process, materials for electroforming, machining for electroformed blanks

Heat Treatment Processes, Various Types of Furnaces. Hobbing for mould making – Discussion of the hobbing process & its advantages, elements of hobbing like hobbing punch, shape of the hob, materials used for cavity, lubrication, and depth of hobbing, Hobbing presses, Hobbing operations & its economy with examples.

Polishing technology in mould making Definition of surface roughness, basis of polishing technology, Effect of mould materials on polishability, Types of polishing tools, Methods of polishing. Basic information on electrosonic polishing. Principles of electro‐deposition in damaged moulding surfaces. Surface Texturing of moulds ‐ Process description, types of moulds, types of patterns and mould shapes, metals that can be etched, mould preparation, limitations of chemical texturing.

• Computer aided Manufacturing and Measurement. Introduction to CAM; Automated Manufacturing system; Need of automation, Basic elements of automation, Levels of automation, Automation Strategies, Advantages &disadvantages of automation, classification of NC machine tools, NC Part Programming.
• Manual (word address format) programming‐ SIMPLE Examples: Canned cycles, Subroutine, and Macro. APT programming. Geometry, Motion and Additional statements, Macro‐ statement Open and closed loops. Control of point to point systems‐Incremental open loop control, Incremental close loop, Absolute close loop; Control loop in contouring systems; Adaptive control.