70445 MANUFACTURING PROCESSES

Year	No.	Offer	Mode	Description			Cred. Pts
98	70445 	S2  	X 	MANUFACTURING PROCESSES   	1.00

Contents

• Staffing
• Pre-requisite(s)
• Synopsis
• Objectives
• Topics
• Texts
• Recommended References
• Student Workload
• Assessment Details
• Other Requirements

STAFFING:

PRE-REQUISITE(S)

70245

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  unit  provides an introductory study of manufacturing  processes
and is complemented by further studies at higher levels of the course.
Various  material  forming and cutting processes are  considered,  and
theoretical  knowledge is reinforced by practical  demonstrations  and
videos.

OBJECTIVES:

A student who successfully completes this unit will be able
to:

1. explain the principles associated with basic operations
   involving the forming, machining and welding of engineering
   materials;
   
2. indicate the advantages and limitations of each process and
   its influence on the properties of the material in the
   finished component;
   
3. describe the basic processes used in performing forming,
   machining and welding operations on engineering materials;
   
4. outline the practical applications of a variety of forming and
   machining processes;
   
5. analyse the costs of various manufacturing processes in terms
   of fixed and variable costs and break even point;
   
6. apply practical design methods to materials working
   techniques;
   
7. explain the geometry of tooling used on various metal cutting
   machines;
   
8. describe the effect of heat, lubrication and various cutting
   tool materials on the metal cutting process;
   
9. write 2.5-D programmes for computer numerical controlled
   machines.
   

TOPICS:

 Description                                                    Weighting(%)

FORMING OPERATIONS
Manufacturing Costs                                                   5.00
. Fixed and variable costs, break even point, process
  comparison.

Casting Processes                                                     12.00
. Metal behaviour, sand casting, shell moulding, full mould
  process, die casting, centrifugal casting, investment
  casting.  Casting Alloys.  Design for casting.  Casting
  defects.  Process comparison.

Working Processes                                                     18.00
. Hot and cold working processes, rolling, forging,
  extrusion, drawing, pressing, deep drawing.
  Characteristics defects in wrought products.

Powder Metallurgy                                                     5.00
. Metal and ceramic powders, pressing, sintering, product
  types, product characteristics.

Processing of Polymers, Ceramics and Composites                       5.00
. 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.

Welding Processes                                                     8.00
. Fusion welding, pressure welding.
CUTTING OPERATIONS

Jigs and Fixtures                                                     5.00
. Principles of location, principles of jigs and fixtures
  design.  Drill jigs, milling fixtures, grinding fixtures,
  turning fixtures and welding fixtures.

Principles of Metal Cutting                                           7.00
. Chip formation, types of chips, basic cutting angles,
  heat zones, tool wear, lubricants, tool materials.

Turning Operations                                                    5.00
. Orthogonal and oblique cutting, basic processes.

Introduction to Numerical Control                                     6.00
. Basic principles, applications.

Milling Operations                                                    5.00
. Types of operations, types of cutters.

Broaching Operations                                                  3.00
. Types of broaches, broaching operations.

Shaping and Planing                                                   3.00
. Types of shapers and planers, basic operations.

Grinding Operations                                                   3.00
. Grinders, types of grinding operations.

Drilling Operations                                                   3.00
. Types of drills, basic operations.

Generation of Forms                                                   3.00
. Making of screw threads and gears.

Non Traditional Machining Processes                                   4.00
. Electrodischarge machining, chemical machining.

TEXT and MATERIALS to be PURCHASED:

RECOMMENDED REFERENCE MATERIALS:

Doyle L E et al, "Manufacturing Processes and Materials for
Engineers", 3rd Edition, Prentice Hall, 1985.

Edwards L and Endean M, "Manufacturing with Materials",
Butterworths, 1990.

De Garmo E P, Temple Black J and Kohser R A, "Materials and Processes
in Manufacturing", 8th edition, MacMillan Publishing Co, New York,
1988.

STUDENT WORKLOAD REQUIREMENTS:

	ACTIVITY				HOURS
Directed Study                                	56
Private Study                                 	89
Examinations                                  	4
Assessments                                   	6

ASSESSMENT DETAILS:

No  *F/S Marks     Due        Description                              Wtg(%)    LBL WWW
1   S    150.00    28/08/98  ASSIGNMENT (FORMING)                      15.00     Y   N
2   S    150.00    09/10/98  ASSIGNMENT (CUTTING)                      15.00     Y   N
3   S    350.00    END S2    2 HOUR CLOSED EXAM (FORMING)              35.00     N   N
4   S    350.00    END S2    2 HOUR CLOSED EXAM (CUTTING)              35.00     N   N

OTHER REQUIREMENTS:

1    In  order to successfully complete the unit students must achieve
     50% of the total possible marks for the unit and at least 50%  of
     the total marks for each examination.
2    A  closed examination is an examination where the candidates  are
     allowed  to bring only writing and drawing instruments  into  the
     examination.
3    Because  it is normal practice to release model answers  promptly
     after the due date, for this unit the penalty for late submission
     of assignment work will normally be the loss of all marks for the
     assignment.
4    The   Faculty  of  Engineering  and  Surveying  will  NOT  accept
     submission  of  hand written or typed assignments  by  facsimile,
     email  or computer diskette. Students in remote locations who  do
     not  have regular access to postal services may be given  special
     consideration.
5    In  the event that a due date for an assignment falls on a  local
     public  holiday  in their area, such as a Show holiday,  the  due
     date  for  the assignment will be the next day. Students  are  to
     note  on the assignment cover the date of the public holiday  for
     the Unit Leader's convenience.
6    A  minimum  standard of communication skills must be demonstrated
     in order for a passing grade to be achieved.