electiveHQ

This module introduces the field of manufacturing engineering, where the following topics constitute the syllabus: - Relationship between design, materials and manufacturing; - Introduction to engineering materials; primary and secondary processing of metals; trends in manufacturing e.g. Industry 4.0; - Forming of metals: plasticity and work hardening; temperature effects; hot and cold forming; grain structures; recrystallisation; annealing; analysis of sheet rolling, wire drawing, and extrusion processes; characteristics/design of rolling mills; - Casting of metal alloys: casting methods e.g. sand casting, investment casting, permanent mould casting; influence of fluid flow and heat transfer in casting; microstructure and grain growth; alloy phase diagrams; - Subtractive manufacturing: mechanics of machining; machine tools and their automation; cutting tools and cutting tool materials; tool behaviour and tool life; non-traditional machining processes e.g. electrical discharge machining; - Moulding & forming of polymers; - Computer Aided Design and Manufacturing; history of Computer Numerical Control; G-code; capabilities of machining centres; - Additive manufacturing technologies: introduction to 3-D printing; fusion deposition modelling; selective laser sintering; stereolithography; laminated-object manufacturing; - Joining methods: welding methods e.g. fusion (oxyfuel gas, shielded metal-arc, gas metal-arc, gas tungsten-arc), solid-state (spot/resistance, friction), brazing, and soldering; heat-affected zone of welded joints; residual stresses of welded joints; adhesive bonding; mechanical fastening; - Surface engineering: metrology; plasma treatment; physical vapour and chemical vapour deposition; contact angle measurement; optical microscope, micro-hardness tests; - Economics of production: process design and analysis; competitiveness and productivity in production. The lecture sessions, providing the theory and analysis of manufacturing methods, are complemented by four laboratory sessions (participation deemed compulsory), providing the student with a hands-on experience of manufacturing methods, and a requirement to demonstrate a knowledge of the health & safety procedures associated with manufacturing processes.