| CODE | ENR5101 | ||||||||||||
| TITLE | Advanced Manufacturing Processes and Methodologies | ||||||||||||
| UM LEVEL | 05 - Postgraduate Modular Diploma or Degree Course | ||||||||||||
| ECTS CREDITS | 5 | ||||||||||||
| DEPARTMENT | Metallurgy and Materials Engineering | ||||||||||||
| DESCRIPTION | This study-unit first highlights the importance of manufacturing and how it contributes to the third pillar of the integrated product development model. A taxonomy of advanced manufacturing processes and methodologies is provided at the outset of the study-unit so that learners can get the whole range of manufacturing processes available. This taxonomy is based on the type of material being processed. A review of different processes will be provided, encompassing a range of casting processes (e.g. vacuum, investment and die casting), sheetmetal forming and other forming methodologies. The rest of the content in this study-unit will focus specifically on the following: 1) Non-conventional subtractive processes: - Electrodischarge machining (including die sinking and wire) - Electrochemical machining - Electro beam melting - Water jet machining, abrasive water jet machining - Abrasive jet machining, abrasive flow machining, ultrasonic machining 2) Additive Manufacturing: - Rapid prototyping methodologies, such as fused deposition modelling, stereolithography, selective laser sintering and electro beam melting - Rapid tooling – direct and indirect methods, hard/soft tooling - Rapid manufacturing – feasibility, emerging technologies 3) Micro fabrication: - Micro machining (e.g. spark erosion, wire EDM, milling, drilling) - Micro additive manufacturing - Micro ultrasonic machining - Micro laser machining - Micro forming techniques - Micro hybrid machining processes 4) Composite material processing (Info to be included by Dr Buhagiar if necessary) 5) Powder processing - Attributes to powder processing - Basic stages in conventional powder processing - Powder characteristics - Sintering mechanisms - Various powder processing techniques versus product characteristics 6) Joining processes - Fastening, welding and gluing and underlying principles - Mechanism of adhesion - Joint strength/design/configuration/concerns - Adhesive solidification mechanisms and manufacturing system design Besides a description of the underlying working principle of and theory behind each aforementioned process, typical applications where such an advanced manufacturing process can be employed is also provided. In addition, where relevant, different manufacturing processes are compared to assess the feasibility or otherwise of deploying one process with respect to another to fabricate a particular component. Study-unit Aims: The manufacturing of a product is becoming increasingly complex. Traditional manufacturing processes are inadequate for such products. In view of this context, the overall aim of this study-unit is to transfer knowledge to learners on the principles of advanced manufacturing processes and methodologies, which are indispensable in modern product development. Learning Outcomes: 1. Knowledge & Understanding: By the end of the study-unit the student will be able to: - Describe the working principle of a particular advanced manufacturing process. - Describe how the required component geometry can be attained by either a subtractive or an additive manufacturing process. - Describe how different components can be assembled. - Demonstrate awareness of processes and of the availability of alternatives to more traditional methods. 2. Skills: By the end of the study-unit the student will be able to: - Independently select the most appropriate advanced manufacturing process required to fabricate a given component, taking into account material, geometry, accuracy and other relevant factors. - Independently select the most appropriate joining method to assemble different components in a product. Main Text/s and any supplementary readings: - Manufacturing Processes for Engineering Materials, Kalpakjian S. and Schmid, S.R., Prentice Hall, 2007, ISBN-13: 978-0132272711. - Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid Tooling, Pham, D.T. and Dimov, S.S., Springer Verlag, 2011, ISBN-13: 978-1447111825. - Laser Materials Processing, Steen W.M., Springer Verlag, 2001, ISBN 3540761748. - Composite Materials: Engineering and Science, F.L. Matthews and R. D. Rawlings, Chapman and Hall, ISBN 0412559406. - Introduction to Powder Metallurgy: F. Thummler and R. Oberacker, Maney Publishing, 1994, ISBN 0-901716-26-X. |
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| STUDY-UNIT TYPE | Lecture and Independent Study | ||||||||||||
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The University makes every effort to ensure that the published Courses Plans, Programmes of Study and Study-Unit information are complete and up-to-date at the time of publication. The University reserves the right to make changes in case errors are detected after publication.
The availability of optional units may be subject to timetabling constraints. Units not attracting a sufficient number of registrations may be withdrawn without notice. It should be noted that all the information in the description above applies to study-units available during the academic year 2024/5. It may be subject to change in subsequent years. |
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