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Semester 1

Manufacture 3 (MECE09032)

Subject

Mechanical Engineering

College

SCE

Credits

20

Normal Year Taken

3

Delivery Session Year

2022/2023

Pre-requisites

Design and CAD

Course 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.

Course Description

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. Lectures:Course SyllabusCourse Overview1. Introduction. Processing overview. Materials-process matrix.2. Microstructure and properties, Mechanical properties, length scales, examples3. Materials Selection, Ashby approach using materials selection maps, Processes4. 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 casting5. 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 glasses8. Manufacture with plastics and composites, Plastic forming processes, compression moulding, blow moulding, extrusion, vacuum forming.9. Ceramic and glass processing10. Finishing and Surface treatments: Chemical cleaning, Ultrasonic cleaning, electropolishing, electroplating, and vapour deposition.11. Joining, Fastening, Welding, MIG, TIG, laser, EBM, Bonding12. Process Selection, How to select a process. Labs:Wk2 Introduction and Parametric ModellingWk3 Assembly ModellingWk4 Finite Element AnalysisWk5 DraftingWk6 CurvesWk7 SurfacesWk8 Direct ModellingWk9 Standard PartsWk10 ExplodeRenderAnimateWk11 Revision ExerciseCoursework: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.Exam:3 questions on methods of manufacturing exam [50 %]. Accreditation of Higher Education Programmes (AHEP)SM3b, EA1b, EA2, EA3b, D3b, P2, P4, P6, G3, EA4b

Assessment Information

Written Exam 50%, Coursework 50%, Practical Exam 0%

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