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MEC2202 Manufacturing Processes

Semester 1, 2013 On-campus Toowoomba
Units : 1
Faculty or Section : Faculty of Engineering & Surveying
School or Department : Mechanical and Mechatronic Engineering
Version produced : 25 April 2014

Contents on this page

Staffing

Examiner: Hao Wang
Moderator: Harry Ku

Requisites

Pre-requisite: MEC1201 or Students must be enrolled in one of the following Programs: MEPR

Synopsis

Manufacturing involves the transformation of raw materials from their initial form into finished, functional products. Man achieves this transformation by numerous methods utilising a variety of processes each designed to perform a specific function in the transformation process. Inherent in the design and operation of processes must be a knowledge of the properties of engineering materials and specific methods to utilise these properties during the various stages of the manufacturing process. Because of the competitive nature of the manufacturing industry, engineers are constantly striving to create new materials, better transformation methods and processes which are cheap to operate, efficient, fast and accurate. Small batch production predominates in Australia and manufacturing methods and processes best suited for this type of production have to be designed and installed to achieve the greatest possible productivity. This course provides an introductory study of manufacturing processes and is complemented by further studies at higher levels of the program. Various material forming and cutting processes are considered, and theoretical knowledge is reinforced by practical demonstrations and videos.

Objectives

The course objectives define the student learning outcomes for a course. On completion of this course, students should be able to:

  1. examine the principles associated with basic operations involving the forming, machining and welding of engineering materials;
  2. interpret the advantages and limitations of each process and its influence on the properties of the material in the finished component;
  3. analyse the basic processes used in performing forming, machining and welding operations on engineering materials;
  4. analyse the practical applications of a variety of forming and machining processes;
  5. analyse and formulate the costs of various manufacturing processes in terms of fixed and variable costs and break even point;
  6. formulate practical design methods to materials working techniques;
  7. interpret the geometry of tooling used on various metal cutting machines;
  8. analyse the effects of heat, lubrication and various cutting tool materials on the metal cutting process.

Topics

Description Weighting(%)
1. Manufacturing Costs


Fixed and variable costs, break even point, process comparison.
10.00
2. Casting Processes


Metal behaviour, sand casting, shell moulding, full mould process, die casting, centrifugal casting, investment casting. Casting Alloys. Design for casting. Casting defects. Process comparison.
9.00
3. Working Processes


Hot and cold working processes, rolling, forging, extrusion, drawing, pressing, deep drawing. Characteristics defects in wrought products.
8.00
4. Powder Metallurgy


Metal and ceramic powders, pressing, sintering, product types, product characteristics.
5.00
5. Processing of Polymers, Ceramics and Composites .


Injection moulding, compression moulding, blow moulding, extrusion, calendaring, forming of clay products, jiggering, slip casting, dry pressing, drying, firing, filament winding, pultrusion, lamination, autoclave curing, braiding.
8.00
6. Welding Processes


Fusion welding, pressure welding.
8.00
7. Rapid Prototyping


Liquid - solid and powder-based rapid prototyping systems.
8.00
8. Principles of Metal Cutting


Chip formation, types of chips, basic cutting angles, heat zones, tool wear, lubricants, tool materials.
7.00
9. Turning Operations


Orthogonal and oblique cutting, basic processes.
10.00
10. Milling Operations


Types of operations, types of cutters.
8.00
11. Broaching Operations


Types of broaches, broaching operations.
3.00
12. Shaping and Planing


Types of shapers and planers, basic operations.
3.00
13. Grinding Operations


Grinders, types of grinding operations.
3.00
14. Drilling Operations


Types of drills, basic operations.
3.00
15. Generation of Forms


Making of screw threads and gears.
3.00
16. Non Traditional Machining Processes


Electrodischarge machining, chemical machining.
4.00

Text and materials required to be purchased or accessed

ALL textbooks and materials available to be purchased can be sourced from USQ's Online Bookshop (unless otherwise stated). (https://bookshop.usq.edu.au/bookweb/subject.cgi?year=2013&sem=01&subject1=MEC2202)

Please contact us for alternative purchase options from USQ Bookshop. (https://bookshop.usq.edu.au/contact/)

  • Groovers, MP 2010, Fundamentals of modern manufacturing: materials, processes and systems, 4th edn, Wiley, New York.

Reference materials

Reference materials are materials that, if accessed by students, may improve their knowledge and understanding of the material in the course and enrich their learning experience.
  • De Garmo, EP, Temple Black, J & Kohser, RA 2007, Materials and processes in manufacturing, 10th edn, Wiley, New York.
  • Kalpakjian, S & Schmid, S 2005, Manufacturing engineering and technology, 5th edn, Prentice Hall, New Jersey.

Student workload requirements

Activity Hours
Assessments 12.00
Examinations 2.00
Lectures 26.00
Private Study 89.00
Tutorials 26.00

Assessment details

Description Marks out of Wtg (%) Due Date Notes
GROUP PRESENTATION 150 15 26 Feb 2013 (see note 1)
ASSIGNMENT 150 15 15 Apr 2013
2 HOUR RESTRICTED EXAMINATION 700 70 End S1 (see note 2)

NOTES
  1. The Examiner will advise students of the date and time of their presentation during the semester.
  2. Student Administration will advise students of the dates of their examinations during the semester.

Important assessment information

  1. Attendance requirements:
    It is the students' responsibility to attend and participate appropriately in all activities (such as lectures, tutorials, laboratories and practical work) scheduled for them, and to study all material provided to them or required to be accessed by them to maximise their chance of meeting the objectives of the course and to be informed of course-related activities and administration.

  2. Requirements for students to complete each assessment item satisfactorily:
    To satisfactorily complete an assessment item a student must achieve at least 50% of the marks or a grade of at least C-. Students do not have to satisfactorily complete each assessment item to be awarded a passing grade in this course. Refer to Statement 4 below for the requirements to receive a passing grade in this course.

  3. Penalties for late submission of required work:
    If students submit assignments after the due date without (prior) approval of the examiner then a penalty of 5% of the total marks gained by the student for the assignment may apply for each working day late up to ten working days at which time a mark of zero may be recorded. No assignments will be accepted after model answers have been posted.

  4. Requirements for student to be awarded a passing grade in the course:
    To be assured of receiving a passing grade in a course a student must obtain at least 50% of the total weighted marks for the course.

  5. Method used to combine assessment results to attain final grade:
    The final grades for students will be assigned on the basis of the weighted aggregate of the marks (or grades) obtained for each of the summative assessment items in the course.

  6. Examination information:
    In a Restricted Examination, candidates are allowed access to specific materials during the examination. The only materials that candidates may use in the restricted examination for this course are: writing materials (non-electronic and free from material which could give the student an unfair advantage in the examination); calculators which cannot hold textual information (students must indicate on their examination paper the make and model of any calculator(s) they use during the examination).

  7. Examination period when Deferred/Supplementary examinations will be held:
    Any Deferred or Supplementary examinations for this course will be held during the examination period at the end of the semester of the next offering of this course.

  8. University Student Policies:
    Students should read the USQ policies: Definitions, Assessment and Student Academic Misconduct to avoid actions which might contravene University policies and practices. These policies can be found at http://policy.usq.edu.au.

Assessment notes

  1. The due date for an assignment is the date by which a student must despatch the assignment to the USQ. The onus is on the student to provide proof of the despatch date, if requested by the Examiner.

  2. Students must retain a copy of each item submitted for assessment. This must be despatched to USQ within 24 hours if required by the Examiner.

  3. In accordance with University Policy, the Examiner may grant an extension of the due date of an assignment in extenuating circumstances.

  4. If electronic submission of assessments is specified for the course, students will be notified of this in the course Introductory Book and on the USQ Study Desk. All required electronic submission must be made through the Assignment Drop Box located on the USQ Study Desk for the course, unless directed otherwise by the examiner of the course. The due date for an electronically submitted assessment is the date by which a student must electronically submit the assignment. The assignment files must be submitted by 11.55pm on the due date using USQ time (as displayed on the clock on the course home page; that is, Australian Eastern Standard Time).

  5. If the method of assessment submission is by written, typed or printed paper-based media students should (i) submit to the Faculty Office for students enrolled in the course in the on-campus mode, or (ii) mail to the USQ for students enrolled in the course in the external mode. The due date for the assessment is the date by which a student must (i) submit the assessment for students enrolled in the on-campus mode, or (ii) mail the assessment for students enrolled in the external mode.

  6. The Faculty will NOT normally accept submission of assessments by facsimile or email.

  7. Students who do not have regular access to postal services for the submission of paper-based assessments, or regular access to Internet services for electronic submission, or are otherwise disadvantaged by these regulations may be given special consideration. They should contact the examiner of the course to negotiate such special arrangements prior to the submission date.

  8. Students who have undertaken all of the required assessments in a course but who have failed to meet some of the specified objectives of a course within the normally prescribed time may be awarded one of the temporary grades: IM (Incomplete - Make up), IS (Incomplete - Supplementary Examination) or ISM (Incomplete -Supplementary Examination and Make up). A temporary grade will only be awarded when, in the opinion of the examiner, a student will be able to achieve the remaining objectives of the course after a period of non directed personal study.

  9. Students who, for medical, family/personal, or employment-related reasons, are unable to complete an assignment or to sit for an examination at the scheduled time may apply to defer an assessment in a course. Such a request must be accompanied by appropriate supporting documentation. One of the following temporary grades may be awarded IDS (Incomplete - Deferred Examination; IDM (Incomplete Deferred Make-up); IDB (Incomplete - Both Deferred Examination and Deferred Make-up).

  10. Harvard (AGPS) is the referencing system required in this course. Students should use Harvard (AGPS) style in their assignments to format details of the information sources they have cited in their work. The Harvard (AGPS) style to be used is defined by the USQ Library's referencing guide. http://www.usq.edu.au/library/referencing