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MEC2202 Manufacturing Processes

Semester 1, 2021 On-campus Toowoomba
Short Description: Manufacturing Processes
Units : 1
Faculty or Section : Faculty of Health, Engineering and Sciences
School or Department : School of Mechanical and Electrical Engineering
Student contribution band : Band 2
ASCED code : 030101 - Manufacturing Engineering
Grading basis : Graded


Examiner: Hao Wang


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


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. 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.


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 performance of the finished component;
  3. analyse the practical applications of a variety of forming and machining processes and identify the right processes based on the requirements and resources available;
  4. interpret the geometry of tooling used on various metal cutting machines;
  5. analyse the effects of heat, lubrication, various cutting tool materials, and various cutting parameters on the metal cutting process.


Description Weighting(%)
1. 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.
2. Metal Forming Processes

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

Metal and ceramic powders, pressing, sintering, product types, product characteristics.
4. 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.
5. Welding Processes

Fusion welding, solid state welding.
6. Rapid Prototyping (3D Printing)

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

Chip formation, types of chips, basic cutting angles, heat zones, tool wear, lubricants, tool materials.
8. Turning, Boring and Drilling Operations

Orthogonal and oblique cutting, basic processes.
9. Milling, Broaching and Sawing Operations

Types of operations, types of cutters.
10. Grinding Operations

Grinders, types of grinding operations.
11. Non Traditional Machining Processes

Mechanical energy process, electrochemical machining, thermal energy processes and chemical machining.

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). (

Please contact us for alternative purchase options from USQ Bookshop. (

Groover, MP 2016, Fundamentals of modern manufacturing: materials, processes and systems, 6th edn, Wiley, Hoboken, NJ.

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.
Black, JT & Kohser, RA 2017, DeGarmo's materials and processes in manufacturing, 12th edn, Wiley, Chichester.
Kalpakjian, SR & Schmid, S 2014, Manufacturing engineering and technology, 7th edn, Prentice Hall, New Jersey.

Student workload expectations

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
QUIZZES (10) 200 20 06 Mar 2021 (see note 1)
ASSIGNMENT 1 200 20 12 Apr 2021
ASSIGNMENT 2 200 20 17 May 2021
OPEN EXAMINATION - ONLINE 400 40 End S1 (see note 2)

  1. This due date is only for the first quiz, the rest of the due dates will be made available by the Examiner on StudyDesk.
  2. This will be an online exam. Students will be provided further instruction regarding the exam by their course examiner via StudyDesk. The examination date will be available via UConnect when the Alternate Assessment Schedule has been released.

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:
    Students should refer to the Assessment Procedure (point 4.2.4)

  4. Requirements for student to be awarded a passing grade in the course:
    Due to COVID-19 the requirements for S1 2021 are:
    To be assured of receiving a passing grade a student must achieve at least 50% of the total weighted marks available for the course.

    Requirements after S1 2021:
    To be assured of receiving a passing grade a student must obtain at least 50% of the total weighted marks available for the course (i.e. the Primary Hurdle), and have satisfied the Secondary Hurdle (Supervised), i.e. the end of semester examination by achieving at least 40% of the weighted marks available for that assessment item.

    Supplementary assessment may be offered where a student has undertaken all of the required summative assessment items and has passed the Primary Hurdle but failed to satisfy the Secondary Hurdle (Supervised), or has satisfied the Secondary Hurdle (Supervised) but failed to achieve a passing Final Grade by 5% or less of the total weighted Marks.

    To be awarded a passing grade for a supplementary assessment item (if applicable), a student must achieve at least 50% of the available marks for the supplementary assessment item as per the Assessment Procedure (point 4.4.2).

  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:
    Due to COVID-19 the requirements for S1 2021 are:
    An Open Examination is one in which candidates may have access to any printed or written material and a calculator during the examination.

    Requirements after S1 2021:
    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:
    Normally Deferred and Supplementary Examinations are held in the next Examination period. In S1 2021 selected courses will pilot an early Deferred and Supplementary Examination period held within 30 business days of results release. The list of courses involved can be found at

  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

Assessment notes

  1. Students must familiarise themselves with the USQ Assessment Procedures (

  2. Referencing in Assignments must comply with the Harvard (AGPS) referencing system. This system should be used by students to format details of the information sources they have cited in their work. The Harvard (APGS) style to be used is defined by the USQ library’s referencing guide. These policies can be found at

Date printed 18 June 2021