Manufacturing and Materials

Learning Outcomes

Introduction and Manufacturing Process Selection for Design: An introduction to the module, its teaching staff, its structure and assessment methods. Manufacturing as a shape change operation is introduced. A hierarchical classification for both manufacturing processes and the shape that they can produce is introduced. Performance factors related to manufacturing processes are defined and the influence of the Product Design Specification on the selection of the manufacturing process outlined. Case studies are used to illustrate the concepts. The Cambridge Engineering Selector (CES) EduPack software is introduced and used to access relevant data and select materials and manufacturing processes. Casting Processes: The principles of component production by the liquid metal solidification are outlined. The major metal casting processes are introduced in relation to design, structure, properties, quality and economics, and underlying concepts linked to other fusion/solidification processes (welding and metal fusion additive manufacturing). Joining Processes: Major welding processes are introduced in relation to joint design, quality, defects, service performance and cost. The properties of welds are related to the microstructure, and compared to metal fusion additive manufacturing (AM). Powder Processes: Powder production, characteristics, flow, and compaction are covered. Powder processes are described and concepts linked to powder bed AM techniques. Additive Manufacturing/3D printing: The principles of additive manufacturing are introduced and a generalised processing sequence is described. Key forms of additive manufacturing are covered in terms of design, structure, properties, quality and economics, and underlying concepts linked to similar processes. Polymer and Composites Processing: Polymer and composite materials structure and properties are introduced. Manufacturing processes are introduced in relation to design, structure, properties, quality and economics, and underlying concepts linked to polymer additive manufacturing and casting processes. Adhesive bonding as a joining method for polymers and composites is also described. Metal Forming Processes: Component production using bulk and sheet deformation processes are described. Sheet metal deformation processes such as shearing, bending, stretch forming and deep drawing are presented. Emphasis is placed on the selection of production route in relation to the design, structure/property requirements and formability of the material. Machining and Cutting Processes Single and multiple point cutting processes are discussed and performance parameters established. Tool materials and the economics of tool wear are briefly considered. Revision

Teaching methods include • Lectures on topics above. • Videos on manufacturing and joining processes. • Examples of components made by various manufacturing processes. • CES EduPack Computing lab. • Tutorial question sheets covering underpinning physical concepts as well as process selection and design considerations. • Blackboard tests with detailed feedback designed to help understanding of course material. • For distance learning, lecture notes and recorded lectures will be delivered through Blackboard. Learning activities include • Individual work on question sheets and coursework assignment supported by tutorial sessions.