Undergraduate Course: Manufacture 3 (MECE09032)
|School||School of Engineering
||College||College of Science and Engineering
|Credit level (Normal year taken)||SCQF Level 9 (Year 3 Undergraduate)
||Availability||Available to all students
|Summary||Manufacture is the creation, through one or several processing operations, of components or products from basic raw materials. The effectiveness of process selection will be based on the inter-related criterion of design parameters, material selection and process economies. Additionally the course aims to develop an understanding of the techniques used in Computer Aided Design and Manufacture. This is undertaken through both industry-
based CAD/CAM exercises and an introduction to the technologies involved in the research and development of CAD/CAM systems.
The course will consist of 30 x 1-hour lectures plus 10 x 2-hour computer lab sessions ( 20 hours) and 10 x 1-hour example classes.
1. Introduction. Processing overview. Materials-process matrix.
2. Microstructure and properties, Mechanical properties, length scales, examples
3. Materials Selection, Ashby approach using materials selection maps, Processes
4. Casting, Liquid to solid transition; phase diagrams. The importance of oxide films and residual stresses. Microstructure of castings; porosity; removal of porosity. Defects in castings, Sand casting, Die casting, Centrifugal casting, Slush casting. Investment casting aerospace turbine blade. Design for castings. Trends in casting
5. Thermomechanical processing (forging, extrusion and rolling) , the importance of grain size; Hall - Petch relationship , Forging , General deformation characteristics, Hot working, Cold working, Open die forging, Closed die forging,
Impression die forging. Rolling, Rolling dynamics, Rolling forces, Rolling design. Extrusion, Direct and indirect extrusion processes. The role of friction in extrusion.
6. Heat treatment, Steel heat treatment; precipitation hardening. Problems with heat treatment processes.
7. Machining processes, Single-point cutting, Multiple - point cutting, Tool geometry, Chip formation, Chip types. Cutting dynamics: Chip formation, Chip types, Cutting forces, Shear angle vs. shear stress, tool materials, tool life, cutting tool materials, Non-traditional machining processes Electrochemical machining, Electrodischarge machining, Ultrasonic machining, Electron - beam and laser machining. Polymers, composites, ceramics and glasses
8. Manufacture with plastics and composites, Plastic forming processes, compression moulding, blow moulding, extrusion, vacuum forming.
9. Ceramic and glass processing
10. Finishing and Surface treatments: Chemical cleaning, Ultrasonic cleaning, electropolishing, electroplating, and vapour deposition.
11. Joining, Fastening, Welding, MIG, TIG, laser, EBM, Bonding
12. Process Selection, How to select a process.
Wk2 Introduction and Parametric Modelling
Wk3 Assembly Modelling
Wk4 Finite Element Analysis
Wk8 Direct Modelling
Wk9 Standard Parts
Wk11 Revision Exercise
One large course work exercise [50%].
Students will be asked to produce using Solid Edge an assembly of components which are produced using common manufacturing techniques.
3 questions on methods of manufacturing exam [50 %].
Accreditation of Higher Education Programmes (AHEP)
SM3b, EA1b, EA2, EA3b, D3b, P2, P4, P6, G3, EA4b
Information for Visiting Students
|Pre-requisites||Design and CAD
|High Demand Course?
Course Delivery Information
|Academic year 2021/22, Available to all students (SV1)
|Learning and Teaching activities (Further Info)
Lecture Hours 30,
Seminar/Tutorial Hours 10,
Supervised Practical/Workshop/Studio Hours 20,
Programme Level Learning and Teaching Hours 4,
Directed Learning and Independent Learning Hours
|Assessment (Further Info)
|Additional Information (Assessment)
||Both coursework components will allow for feedback to be given. Also there will be a drop-in hour each to facilitate feedback.
||Hours & Minutes
|Main Exam Diet S1 (December)||1:30|
|Resit Exam Diet (August)||1:30|
On completion of this course, the student will be able to:
- Understand the principles and techniques of casting, forming, joining and finishing operations and be able to determine their suitability.
- Calculate and understand appropriate single-point machining relationships taking tool material and machine constraints into consideration.
- Understand the principles and appropriateness of non-traditional machiing processes.
- Select a suitable manufacturing process in order to achieve the specified product performance and design criteriom while considering cost.
- Create 3D computer models of mechanical assemblies, do a basic FE analysis on these and be able to produce documentation such as drawings, rendered images and associated bills of materials and parts lists.
|Principles of modern manufacturing, Mikell Groover, 4th Ed, Wiley 2011|
|Graduate Attributes and Skills
|Keywords||manufacturing,computer aided design,CAD
|Course organiser||Dr Anthony Callanan
Tel: (0131 6)51 7071
|Course secretary||Mrs Michelle Burgos Almada