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The University of Southampton
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SESG3024 Manufacturing and Materials

Module Overview

This module manufacturing and materials is intended to develop a deeper understanding of the relationship between design, manufacturing processing and materials properties. This module discusses various manufacturing methods including casting, forming, welding, cutting, 3D printing, and composite/polymer manufacturing. For each manufacturing method, the aspects covered include: aesthetics, principles, choices of materials, choice of processes, properties of materials, advantages and disadvantages, process economics. Examples are drawn from manufacturing processes mainly used in aerospace, automotive and marine industries.

Aims and Objectives

Learning Outcomes

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

  • Salient features of major manufacturing processes in metals, polymers, composites, including customer and user needs and the importance of considerations such as aesthetics
  • Advantages and disadvantages of each process as a method of producing a component or structure with appropriate properties for service, including awareness of quality issues.
  • Material behaviour in manufacturing processes.
  • The relation between manufacturing, material selection and sustainable engineering and development.
Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

  • Critically analyse alternative manufacturing processes.
  • Identify design features influencing manufacturing process choice.
  • Ensure fitness for purpose for all aspects of manufacturing with materials including production, operation, maintenance and disposal.
Transferable and Generic Skills

Having successfully completed this module you will be able to:

  • Interpret component/manufacturing processes in a wider context.
Subject Specific Practical Skills

Having successfully completed this module you will be able to:

  • Select a manufacturing process to make a given component.
  • Select a welding process to make a given joint in a given material.
  • Use CES EduPack software to screen suitable materials and manufacturing process for designed products.

Syllabus

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

Learning and Teaching

Teaching and learning methods

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.

TypeHours
Lecture24
Follow-up work30
Completion of assessment task25
Practical classes and workshops3
Tutorial12
Preparation for scheduled sessions25
Revision31
Total study time150

Resources & Reading list

S. Kalpakjian and S.R. Schmid,. Manufacturing Processes for Engineering. 

Ian Gibson, David Rosen, Brent Stucker,. Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. 

Sanjay Mazumdar. Composites Manufacturing: Materials, Product, and Process Engineering. 

L Edwards, M Endean. Manufacturing with Materials. 

S. Kalpakjian and S.R. Schmid. Manufacturing Engineering and Technology. 

M. P. Groover,. Fundamentals of Modern Manufacturing, Materials, Processes and Systems. 

Materials.

Assessment

Summative

MethodPercentage contribution
Coursework 20%
Examination  (120 minutes) 70%
Test 10%

Repeat

MethodPercentage contribution
Examination 100%

Referral

MethodPercentage contribution
Examination 100%

Repeat Information

Repeat type: Internal & External

Linked modules

Pre-requisite: FEEG2005

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