MANUFACTURING PROCESS EAT 227
WEEK 0 INTRODUCTIONS
1
Learning outcome
1. 2. 3. 4. 5. 6. 7.
Appreciate the diversity of processes involved in successful and economic materials and component manufacture. To understand the inter-relations between material, process, design/shape, performance and economics Understand, analyse, and discuss the specific features of processes associated with the manufacture of metals, ceramics, glasses, polymers and polymer composite components Establish and interpret the natures and effects of important process variables Deal with aspects of manufacturing processes in a qualitative manner Appreciate the range of techniques available for the forming and joining of engineering materials and be able to select process to optimise both bulk and surface properties. Undertake process selection exercises and understand the underlying methodology. Select appropriate manufacturing/processing strategies on the basis of given requirements.
Process selection
General review of the nature of manufacturing technologies availables. General review of the nature and properties of common engineering materials. Inter-dependence of chosen material, process, design/shape and economics.
2.
Manufacturing with metals
Casting: to include as-cast structures, control of grain structures, segregation, porosity;types of casting processes;heat treatment of casting and fabricated structures. Mechanical forming: to include rolling, forging, drawing, extrusion, presswork, etc; mechanics, work analysis, friction, redundant work;influences on formability/ Cutting, machinability, cutting tools. Surface treatment: to include case hardening, nitriding, carbonitriding, plating, nickel and chromium electroplating, galvanising, painting.
Manufacturing with ceramics
Powder technology Shaping processes Characteristic and application of Cold pressing Casting molding Extrusion Injection molding Hot pressing Reaction bonding Vapour processes Devitrification Drying and firing processes, sintering mechanisms.
4.
Manufacturing with glass
Glass forming materials Batch and enamels, glaze technology Melting Shaping processes for glass components annealing Manufacture of common types of glass fibre, including fibre optic materials
Manufacturing with polymers
Nature of thermoplastic and thermosetting polymers. Processability of thermoplastics and thermosets. Physical and chemical changes during processing. Common thermoplastic forming processes: to include injection moulding, extrusion, blow moulding, film blowing and thermoforming, Common thermoset forming processes: to include compression moulding and transfer moulding. Effects of mixing and compounding. Polymer met rheology and its importance in polymer processing. Quantitative treatment of melt viscosity ( as a function of temperature and shear rates).
6.
Manufacturing with polymer composites
Nature of polymer composites: thermoplastic and thermosetting polymer matrix composites. nature of unsaturated polyesther resin/glass composite systems Lay-up techniques: to include contact, vacuum bag, pressure bag and autoclave moulding Matched die moulding Spray-up Filament winding Injection moulding