1. Introduction
This module covers a broad range of important manufacturing methods and is designed to give students a good understanding of both traditional and newer processes.

2 Assessment
This module is assessed by course work (30%) and examination (70%).
The course work consists of two components:
A laboratory, carrying 10% of the module marks and a written assignment worth 20% of the module marks, see below.

3 Learning Support Materials

Principles of Metal deformation
Forming Processes
.....Plane strain yielding
.....Axisymmetric compression of a cylinder applet
.....Relationship between coefficient of friction and frictional shear factor
3.2.1 Material Properties - laws governing metal flow
3.2.2 Stress - Strain Curves
3.2.3 Work and Efficiency in Metal Forming
3.2.4 Friction between workpiece and tools
3.2.5 Redundant Work and 3.2.6 Relationship Between Hardness and UTS

3.4 Processes
The main processes can be grouped under the following headings:
3.4.1 Forging
2. Rolling, example on cold rolling: Page 1, Page 2, Page 3
3.4.3 Extrusion and 3.4.4 Drawing
3.4.4b Wire drawing: Pressure on the die and axisymmetric yielding
3.4.5 Sheet metal processing

Diagrams / Notes on Single Point Metal Cutting. pass word protected.

Cutting tool materials and Taylor tool life equation click here

Link to notes on Non Traditional Manufacturing Processes

Power Point notes on Micro Machining. pass word protected.

Notes on CNC Machining. pass word protected.

Notes on DFM and DFA. pass word protected.

Notes on Surface Roughness. pass word protected.

Powder Processing: Read the appropriate chapters in references 2 and / or 3, below.

Notes on Mohr's circle for stress analysis.

4. Course Work

4a Laboratory Class Sessions - Smeaton 001 - Wednesdays 13.00 - 15.00

Axisymmetric Compression of an Aluminium Cylinder to Determine 'K' and 'n'.

Only a brief report is required for this assignment containing results, graph, calculations and and a maximum of 600 words (1 page) of discussion.

28th January 2009........Family names beginning.......A - D

11th February 2009........Family names beginning.......E - M

25th February 2009........Family names beginning.......P - Z

Due date for first assignment: 11.00 am on Monday 30th March 2009.

4b Written Assignment
Students will be assigned one of the following and are required to write a report describing the key features and applications. Reports should be about 2500 words long and should include pictures, diagrams etc as appropriate.

Topics
i) Abrasive water jet cutting
ii) Chemical machining
iii) Electro - chemical machining (ECM)
iv) Electrical discharge machining (EDM)
v) Laser processing
vi) Ultrasonic machining (USM)
vii) Cubic boron nitride cutting tools (CBN)
viii) Tungsten carbide tools
ix) Explosive forming / processing

Due date second assignment: 11.00 am on Friday 3rd April 2009

5. Tutorial Questions
For supplementary questions, click here

6. References
1. 'Metals Handbook', ASM, 2nd, Desk ed., 1998.
2. 'Introduction to Manufacturing Processes', J A Schey, McGraw-Hill Int. Eds., 1987.
3. 'Manufacturing Engineering and Technology', S Kalpakjian and S R Schmid, Prentice Hall Int., 2001.
4. 'Manufacturing Processes and Equipment', G Tlusty, Prentice Hall, 2000.
5. 'Mechanical Metallurgy', G E Dieter, McGraw-Hill, Int. Student Ed., 1988.
6. 'An Introduction to the Principles of Metalworking', G W Rowe, E Arnold, 1965.
7. 'Metal Machining', T Childs et. al., Butterworth-Heinemann, 2000.

David Grieve, 16th March 2009.