ECTS credits Module Module title

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1 Module author: Bill Reddington Module Description: This describes the principals and philosophies of modern manufacturing which will form the basis of subsequent s on manufacturing technology in further years of the course. The first part of the course introduces the student to the technology of manufacture and introduces the students to the philosophy of design for manufacturing, casting, flow forming processes, sintered particulate processes, plastic moulding processes, cutting processes, measurement and inspection, and advanced manufacturing engineering (AMT). The first part of the course introduces the student to the technology of manufacture and introduces the students to the philosophy of design for manufacturing, casting, flow forming processes, sintered particulate processes, plastic moulding processes, cutting processes, measurement and inspection, and advanced manufacturing engineering (AMT). The is structured as follows: Knowledge Breadth: Using familiar parts and assemblies students will be introduced to the philosophy of design to manufacture. Most modern manufacturing methods will be discussed and examined for advantages/ disadvantages, cost, ethics waste and effect on the environment. The importance of proper management safety and quality will be examined in detail. An overview of current best practice, in manufacturing through-out the world will be examined. (1-14) * Knowledge Kind: By carrying out a series of assignments both individually and in small teams, the students will examine familiar assemblies and redesign for manufacture and assembly. They will compare alternative manufacturing processes and asses each for suitability and cost. ( 1-14) Know-how and Skill Range: The student will demonstrate their ability to choose from a wide range of alternative and feasible manufacturing processes. (2-6) They will be capable of selecting form a wide range of measurement equipment and cutting tools. (6, 8) Be aware of the various manufacturing management techniques found in modern manufacturing. (10-12) Be familiar with the various safety acts and legislation. (13 14)) Know-how and Skill Selectivity: The students will; Select from feasible and alternative manufacturing processes. (3-5) Sect specify cutting tools for various manufacturing processes. (7) Specify correct measurement methods for various components and manufacturing processes (8) Competence The students will; Write simple CNC and robotic programs. (9) Use modern measurement equipment and calculate key dimensions tolerances and errors in measurement.(8) Calculate forces in cutting and energy power consumption. (7) Demonstrate their ability to use a milling machine and lathe. (6) * Related learning outcomes shown in parentheses.

2 Module aim: The aim of this is to give the student a broad introduction to the principals and practice of engineering manufacturing processes found in modern industry. In particular the importance of the philosophy of design for manufacture is highlighted throughout the. Learning Outcomes: On completion of this, the learner will be able to: 1. Apply the philosophy of Design for manufacture in the design of common manufacturing products. 2. Recommend specific casting process, outlining the advantages / disadvantage of each. 3. Understand the importance of forging and distinguish between the various methods. 4. Recognise what components should be manufactured using sintered particle processes. 5. Select specific plastic injection moulding processes for different manufactured products. 6. Describe the various cutting process such as sheet metal, milling/ turning and EDC/ECM. 7. Calculate the cutting forces, and power consumption in manufacturing operations. 8. Be capable of using modern measurement and inspection equipment. 9. Recognise the need for advanced manufacturing technology and be aware of the different AMT technologies. 10. State the importance of management in manufacturing enterprises. 11. List the primary cost elements found in manufacturing. 12. Recognise the importance of quality and reliability to the success of manufacturing companies. 13. Be able to state the key requirements of common health and safety legislation. 14. Identify the needs to design with considerations of waste and recycling. Learning and Teaching Methods: The following learning and teaching methods will be employed in this : Lectures: Use overhead notes projected by overhead projector from laptop computer. Web The students will be expected to carry out various assignments which will require them to use the WEB Laboratory The students will be given six laboratory assignments under the following headings; 1. Redesign of assembly taking into account the philosophy of DFMA 2. Flow-Forming process 3. Injection Moulding 4. CNC Programming 5. Measurement 6. Machining / Probing

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4 Module content: Technology of Manufacture Design for manufacture and assembly: Philosophy of Design for manufacture, Manufacturing issues, Handling and assembly, Case studies Casting Processes: Sand Casting, Shell Moulding, Investment Casting, Die Casting Flow-Forming Processes: Forging, Press Bending, Deep drawing, Die Pressing, Spinning & Flow turning Sintered Particulate processes: Powders, Compaction, Sintering, Die Design Plastic Moulding Processes: Materials, Polymerisation, Flash moulding, Transfer Moulding, Injection moulding Cutting Processes: Sheet metal, Lathes, CNC, Die heads, Transfer machining, EDM, ECM, Chemical machining, Laser Measurement and Inspection: Measuring Equipment, Magnification, Angular measurement, Probing, CMM Advanced Manufacturing Technology: Need for, CNC programming, CAD/CAM, Simulation, Robotics, Cost of automation Management of Manufacture Control of Manufacture: World Class manufacturing, Plant Layout, Group Technology, FMS, MRP, CIM Cost Control: Cost Elements, Cost applications, Break-even analysis Quality in Manufacture: Introduction, Reliability, TQM, Type of Inspection, QC Techniques, Defects, SPC, Statistics, Cost Health & Safety at work: ACTs / Regulations, Safe working practice, Hazards, Safety by design, Risk, Managing safety Waste and recycling: Design for recycling and waste management, sustainability, Reuse, Recycling,Case Studies, Acts Ethics in manufacturing: Profitability and Ethics, Labour costs, outsourcing, Material selection, Health issues, Human dignity Module Assessment: Learner performance in reaching the learning outcomes for this will be assessed by: Method, When Assessed, Max Marks Available, Criteria and Breakdown, Pass Mark Written Paper, End Of Semester, 70%,, 40% Of Maximum Lab / Workshop, Continuously, 30%, 6 Project Assignments, 40% Of Maximum Total,, 100%,, 40% Essential reading: R.L Timmings & SP Wilkinson, 2000, Manufacturing Technology, Vol 2, Longman Supplemental reading: Black S.C, Chiles V., Lissaman A.J., (1996) Principles of Engineering Manufacture Groover Mikell P., (1998) Fundamentals of Modern Manufacturing, Prentice Hall Web references: Further Details: Date of Academic Council approval..

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