MSc Manufacturing and Welding Engineering Design

Course Information Package

Course Unit TitleADVANCED MANUFACTURING PROCESS
Course Unit CodeMDMD505
Course Unit DetailsMSc Manufacturing and Welding Engineering Design (Electives Courses) -
Number of ECTS credits allocated8
Learning Outcomes of the course unitBy the end of the course, the students should be able to:
  1. Use advanced manufacturing processes and techniques for machining materials.
  2. Able to select proper tool material and cutting parameters for maximum productivity.
  3. Use advanced forming and shaping processes for production of complicated parts.
  4. Able to use powder metallurgy, sintering and predict mechanical properties of sintered mechanical parts.
  5. Able to select Chemical Machining or Electrochemical Machining for manufacturing specials mechanical parts and tools.
  6. Explain Electrical-Discharge Machining and Wire EDM cutting.
  7. Describe laser technology, Electron-Beam Machining, Plasma-Arc Cutting and Water-Jet
  8. Machining and how they are been used in manufacturing.
  9. Describe abrasive-Jet Machining and Micromachining. Analyze the Economics of Advanced Machining Processes.
Mode of DeliveryFace-to-face
PrerequisitesNONECo-requisitesNONE
Recommended optional program componentsNONE
Course Contents

Advanced material removal processes.  Turning, Milling and Gear Manufacturing, Cutting-Tool Materials and Cutting Fluids, Machining and turning centers, x-axis CNC machines, Machine-Tool Structures, High-speed Machining, Hard Machining, Machining Economics, Machinability, Specification and selection of Machine Tools. Tool Management. Coating applications in manufacturing. FEM simulation of machining and cutting processes.

 

Advanced Forming and Shaping Processes.  Metal-Forging Processes, Forgeability of Metals; Forging Defects, Die Design, Die Materials and Lubrication, Metal Extrusion, Hot and cold Extrusion,  Extrusion Defects, Extrusion Equipment, The Drawing Process, Drawing Practice, Drawing Defects and Residual Stresses, Sheet-Metal Forming Processes and Equipment, Bending sheets plates and tubes, Powder Metal Processing and Equipment, Production of Metal Powders, Compaction of Metal Powders, Sintering, Finishing Operations and Design Considerations.

Advanced Casting Processes and Equipment.  Solidification of Metals, Fluidity of Molten Metal, Expendable-pattern Casting Processes, Permanent-mold, Casting Processes, Inspection of Castings, Melting Practice and Furnaces, Design Considerations in Casting, Casting Alloys

 

Material removal processes by high temperature like Electrical discharge machining. Laser beam machining. Plasma arc machining. Electron beam machining.

 

Material removal techniques by mechanical abrasion like Abrasive jet maching (AJM), Water jet machining (WJM), Abrasive water jet machining (AWJM).

 

Material removal techniques by chemical reactions like, Electrochemical machining (ECM) and Electro discharge machining (EDM).

 

Laboratory Work: Individual or small group modelling performed with the use of modern software.

Recommended and/or required reading:
Textbooks
  • Manufacturing Engineering and technology, Six Edition, Serope Kalpakjian, Steven R. Schmid, Prentice Hall
  • Manufacturing Processes for Engineering Materials, Fifth Edition, Serope Kalpakjian, Steven R. Schmid, Prentice Hall
References
  • Fundamentals of Modern Manufacturing: Materials, Processes, and Systems by Mikell P. Groover, John Wiley & Sons, 2nd edition 2001.
  • Metal Cutting and High Speed Machining by D. Dudzinski, A. Molinari, H. Schulz, Plenum Pub Corp, 2002.
  • Applied Manufacturing Process Planning: With Emphasis on Metal Forming and Machining by Donald H. Nelson, George, Jr. Schneider, Prentice Hall, 1st edition, 2000.
Planned learning activities and teaching methodsThe material is mostly presented by lectures and demonstration of manufacturing methods. Student evaluation is based on assignments or mini projects, tests and final exam. Lecture notes and presentations are available through the web for students to use in combination with the textbooks. Furthermore theoretical principles are explained by means of specific examples and solution of specific problems.
Assessment methods and criteria
Assignments40%
Final Exam60%
Language of instructionEnglish
Work placement(s)NO