SRI RAMAKRISHNA INSTITUTE OF TECHNOLOGY, COIMBATORE-10



|SRI RAMAKRISHNA INSTITUTE OF TECHNOLOGY, COIMBATORE-10 |

|(Approved by AICTE, New Delhi – Affiliated to Anna University, Chennai) |

|Department of Mechanical Engineering |

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|Course Title: Design of Jigs, Fixtures, Press Tools and Moulds | Number of Credits: 4 |

|Department : Mechanical Engineering | Programme: B.E |

|Semester : Seven | Academic Year: 2013-2014 |

|Course Instructor : Dr B.Chokkalingam | | | |

|Associate Professor | | | |

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|Prerequisite Courses : 1. Engineering Materials and Metallurgy |

|2.Manufacturing Technology I |

|3.Manufacturing Technology II |

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|References : |

|Text Books |

|T1. Joshi, P.H. “Jigs and Fixtures”, Second Edition, Tata McGraw Hill Publishing Co., Ltd., New |

|Delhi, 2004 |

|T2. Donaldson, Lecain and Goold “Tool Design”, III rd Edition Tata McGraw Hill, 2000 |

|Reference Books |

|R1. K. Venkataraman, “Design of Jigs Fixtures & Press Tools”, Tata McGraw Hill, New Delhi, 2005. |

|R2. Kempster, “Jigs and Fixture Design”, Hoddes and Stoughton – Third Edition 1974. |

|R3. R.G.W.Pye, Injection Mould Design, SPE Publication, 2000 |

|R4. Hoffman “Jigs and Fixture Design” – Thomson Delmar Learning, Singapore, 2004 |

|R5. ASTME Fundamentals of Tool Design Prentice Hall of India |

|e-Learning Resources: |

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|Instructor Mail : bchokkalingam@ |

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|Objectives: |

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|1. To implement the tool design process when designing tooling for the manufacturing of a product. |

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|2. Design and develop work holders, jigs and fixtures to manufacture products. |

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|3. To design the various elements of dies for press working operations. |

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|4. Design, develop and evaluate tooling for press working operations such as bending, forming and drawing. |

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|5.To study the mould and injection die design concepts. |

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|Course Plan: |

|S.No |

|Topic(s) |

|Unit Objectives |

|Hours Planned |

|T/R Book |

|Page(s) |

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|Unit I Locating and Clamping Principles |

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|1 |

|Objectives of tool design, Function and advantages of Jigs and fixtures |

|To list the objectives of tool design. |

|To identify the types of locators and supports used for jigs and fixtures |

|To select locating and supporting and clamping devices best suited for the components. |

|To select the correct clamping. |

|To identify various drill bushings |

|To select tolerances and materials for jigs and fixtures |

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|1 |

|T1 |

|R3 |

|2 |

|1 |

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|2 |

|Basic elements, |

|principles of location |

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|2 |

|T1 |

|9-13 |

|1,35 |

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|3 |

|Locating methods and devices, Redundant Location |

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|2 |

|T1 |

|R2 |

|13-35 |

|15 |

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|4 |

|Principles of clamping |

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|1 |

|T1 |

|39-42 |

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|5 |

|Mechanical actuation, pneumatic and hydraulic actuation |

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|1 |

|T1 |

|62-67 |

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|6 |

|Standard parts, Drill bushes and Jig buttons, Tolerances and materials used. |

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|1 |

|T1 |

|T1 |

|T1 |

|R4 |

|85-91 |

|223-231 |

|2-7 |

|67-71 |

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|Unit II Jigs and Fixtures |

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|7 |

|Design and development of jigs and fixtures for given component |

|To identify the types of jigs and fixtures |

|Design a suitable jig/fixture after analyzing the part data. |

|To choose a right type of jig and fixture for the selected operations on parts |

|To design a suitable assembly, inspection and welding fixtures for the parts. |

|To know the primary purpose and process of building a modular fixture |

|2 |

|R4 |

|139-146 |

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|8 |

|Types of Jigs, Post, Turnover, Channel, latch, box, pot, |

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|1 |

|T1 |

|T2 |

|R2 |

|91-109 |

|540-554 |

|38-47 |

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|9 |

|angular post jigs, Indexing jigs |

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|1 |

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|10 |

|General principles of |

|milling, Lathe, fixtures |

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|2 |

|T1 |

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|115-132 |

|135-157 |

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|11 |

|boring, broaching and grinding fixtures |

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|1 |

|T1 |

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|163-167 |

|158-162 |

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|12 |

|Assembly, Inspection and Welding Fixtures |

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|2 |

|T1 |

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|168-176 |

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|13 |

|Modular fixturing systems, Quick change fixtures |

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|1 |

|T1 |

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|190-194 |

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|Unit III Press Working Terminologies & Elements of Cutting Dies |

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|14 |

|Press Working Terminologies |

|To know the press working terminologies and operations. |

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|To design the strip layout and various elements of dies |

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|To design and prepare four standard views of simple blanking, piercing compound and progressive dies. |

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|1 |

|R5 |

|319-322 |

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|15 |

|Press Working Operations |

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|1 |

|T2 |

|632-636 |

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|16 |

|Types of presses, press accessories |

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|1 |

|T2 |

|636-643 |

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|17 |

|Computation of press capacity, Strip layout, Material Utilization |

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|1 |

|T2 |

|711-715 |

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|18 |

|Shearing action ,Clearances , Press Work Materials |

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|1 |

|T2 |

|T2 |

|650-657 |

|711 |

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|19 |

|Center of pressure, Design of various elements of dies |

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|1 |

|R5 |

|326-328 |

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|20 |

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|Die Block, Punch holder, Die set, guide plates |

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|1 |

|T2 |

|660-666 |

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|21 |

|Stops, Strippers, Pilots, Selection of Standard parts |

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|1 |

|T2 |

|690-711 |

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|22 |

|Design and preparation of four standard views of simple blanking, piercing |

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|T2 |

|676-711 |

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|23 |

|compound and progressive dies. |

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|1 |

|T2 |

|666-671 |

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|Unit IV Bending Forming and Drawing Dies |

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|24 |

|Difference between bending, forming and drawing |

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|To know the difference between bending, forming and drawing operations. |

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|To design the blank development for bending, forming and drawing operations |

|To understand the functions of direct and indirect pressure pads and ejectors. |

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|To design and development of bending, forming drawing reverse re-drawing and combination dies |

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|To design blank development for axi- symmetric, rectangular and |

|elliptic parts |

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|1 |

|T2 |

|730-731 |

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|25 |

|Blank development for above operations, Types of Bending dies |

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|1 |

|T2 |

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|731-734 |

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|26 |

|Press capacity, Spring back, knockouts |

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|1 |

|T2 |

|735 |

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|27 |

|direct and indirect, pressure pads, Ejectors |

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|T2 |

|745 |

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|28 |

|Variables affecting Metal flow in drawing operations, draw die |

|Inserts |

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|1 |

|T2 |

|761-773 |

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|29 |

|draw beads, ironing |

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|1 |

|T2 |

|736 |

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|30 |

|Design and development of bending, forming |

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|1 |

|T2 |

|737-761 |

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|31 |

|drawing reverse re-drawing and combination dies |

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|1 |

|T2 |

|T2 |

|670-671 |

|757-759 |

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|32 |

|Blank development for axi- symmetric, rectangular and |

|elliptic parts |

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|1 |

|T2 |

|773-778 |

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|33 |

|Single and double action dies |

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|1 |

|T2 |

|778-781 |

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|Unit V Design of Moulds |

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|34 |

|Types of moulds and dies for various processing methods |

|To understand the types of moulds and dies for various processing methods |

|To know the Injection Mould design and basics of mould construction |

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|To design of feed system, ejection system, venting and cooling system. |

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|To know the mould alignment concepts and De-moulding Techniques |

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|To design Moulds with a slide core and split cavity moulds |

|1 |

|R3 |

|3-30 |

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|35 |

|Mould and Die Design Concept and Materials |

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|1 |

|R3 |

|31-73 |

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|36 |

|Injection Mould Design, Basics of mould construction |

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|1 |

|R3 |

|513-531 |

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|37 |

|Methodical Mould Design, Design of Feed System, Ejection System |

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|2 |

|R3 |

|74-134 |

|135-167 |

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|38 |

|Venting, Design of Cooling system |

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|1 |

|R3 |

|179-180 |

|224 |

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|39 |

|Mould alignment concepts and De-moulding Techniques. |

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|2 |

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|R3 |

|257-300 |

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|40 |

|Moulds with a slide core, Split cavity moulds |

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|1 |

|R3 |

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|Total : 45 Periods |

| Total duration required : 45periods + 3 periods for Tests = 48 Periods |

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|Additional Contents over and above the curriculum: |

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|41 |

|Developments of Jigs and Fixtures |

|To understand the latest Developments of Jigs and Fixtures |

|To know the Inspection Devices |

|To understand the Shop Setups |

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|1 |

|T1 |

|177-190 |

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|42 |

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|Inspection Devices |

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|1 |

|T1 |

|195-206 |

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|43 |

|Shop Setups |

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|1 |

|T1 |

|R4 |

|207-215 |

|316-326 |

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| |Assignments/ Tutorials/ Case Study/ Innovative Work | | |

|Assignment: |

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|A1: Design and drawing of a drill jig and a milling fixture. The drawings should contain all the tolerances and materials. |

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|Submission Deadline for A1: August 20, 2013. |

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|A2: Design and drawing of one progressive die |

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|Submission Deadline for A2: October16,2013. |

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|Case Study/ Innovative Work: |

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|Assembly drawings of a simple drill jig or turning fixture using CAD software |

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|Course Assessment Plan: |

|Internal Assessment (20) |

|Internal Assessment Test 1 will be conducted for 50 Marks. (5*2=10 & 2*20=40) |

|Internal Assessment Test 2 will be conducted for 50 Marks. (5*2=10 & 2*20=40) |

|Internal Assessment Test 3 will be conducted for 50 Marks. (5*2=10 & 2*20=40) |

|Tests as per the schedule given by the university - Best two performance is considered for assessment out of 15. |

|Course Attendance |

|assessment out of 5 ( Attendance percentage 96-100 : 5; 91-95 : 4; 86-90 : 3; 81-85 : 2; 76-80 : 1) |

|External Assessment (80) |

|University will conduct end semester examination for 100 marks (10*2=20 & 5*16=80) |

|Performance will be considered for assessment out of 80. |

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|Course Outcome: |

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|CO1.Design a suitable jig and fixture for any component. |

|CO2.Select proper location and clamping of the components. |

|CO3.Decide a suitable jig/fixture among many types according to the design of the component. |

|CO4.Understand the press working operations, design the strip layout and various elements of dies, design the blank development for bending, forming and drawing |

|operations |

|CO5.Design the feed system, ejection system, venting and cooling system for plastic injection moulds. |

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|PEOs Mapping : |

|This Course is conducted to achieve the following Programme Educational Objectives (PEOs): |

|Be able to apply the principle of Mechanical engineering, Mathematics, Mechatronics, Automobile Engineering and related Engineering fields to solve real time |

|problems appropriate to the discipline and succeed in the career. |

|Be able to contribute and communicate effectively in multidisciplinary projects and perform services related to mechanical engineering to meet the customer |

|requirements satisfactory in both quality and quantity. |

|Function with ethics and responsibility and also professionally involve and contribute to the society. |

|Update the modern trends in engineering and technology through continuous learning and be the leaders in their professional society. |

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|The Outcome of this course facilitate to attain the following Program Outcomes (POs): |

|Out come (b) an ability to design and conduct experiments, as well as to analyze and interpret data, |

|Outcome (c) an ability to design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, |

|political, ethical, health and safety, manufacturability, and sustainability, |

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|CO/PO |

|PO1 |

|PO2 |

|PO3 |

|PO4 |

|PO5 |

|PO6 |

|PO7 |

|PO8 |

|PO9 |

|PO10 |

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|CO1 |

|2 |

|2 |

|2 |

|2 |

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|1 |

|1 |

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|CO2 |

|2 |

|2 |

|2 |

|1 |

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|1 |

|1 |

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|CO3 |

|2 |

|2 |

|2 |

|2 |

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|1 |

|1 |

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|CO4 |

|2 |

|1 |

|2 |

|1 |

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|1 |

|1 |

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|CO5 |

|2 |

|2 |

|2 |

|2 |

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|1 |

|1 |

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|Course Instructor HOD-Mech PRINCIPAL |

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