Handbook 1996 : Faculty of Engineering (Volume 4 page 116)
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Credit points: 50.00
Coordinator: Assoc. Prof. E. J. A. Armarego
Contact: 156 hours of lectures and 130 hours of tutorials, practice classes and laboratory work
Timetable: Double semester.
Objectives:
Advanced Manufacturing Processes: 1) Metal Forming - On completion, students will be prepared for a career in the manufacturing industry with an in-depth knowledge of methods used in the theory of plasticity and lubrication, and will have developed a software package for a typical net-shape forming operation. 2) Casting Moulding and Powder Metallurgy Processes - Students will on completion, understand the processes of moulding and casting as practiced by industry and be able to identify and use methods for detecting defects and improving process performance. 3) Material Removal - Upon completion, students should: understand a) the basic cutting action, performance, capabilities and latest developments in abrasive processes; b) the development and computerisation of fundamental mechanics of cutting models for major machining operations such as drilling; c) the fundamentals of tool wear, tool-life and computer based optimisation of single and multipass machining operations for use in process planning. Manufacturing Management: 1) Operations Research 1. By the end of this subject students should be able to apply linear, integer, goal and non-linear programming models to solve a range of optimisation problems; apply network analysis to project management; appreciate the significance of a heuristic problem solving approach and be able to use the techniques of smoothing and decomposition time series methods and regression models in forecasting. 2) Operations Research 2. By the end of the subject students should be able to apply a range of deterministic and stochastic models to inventory problems; use decision theory to analyse decision making under risk: use queuing models to determine the behaviour of service facilities; solve equipment replacement and other problems using Markov processes and appreciate the significance of a game theoretic approach to the negotiation process. 3) Quality Management: On completion, students should be able to understand what constitutes a quality system; develop strategies for implementing a quality system and its components; identify quality costs and use them for the economic analysis of quality projects; understand and quantify the relationships between process capability and tolerances; design a "single" sampling scheme to meet stated requirements; analyse and assess all types of sampling schemes; design, analyse and interpret process control charts; design, analyse and interpret CUSUMS for process control; appreciate the influence of reliability on quality; understand the various approaches to the management of reliability and perform basic reliability analyses. 4) Manufacturing Systems and Control. On completion, students are expected to comprehend the applications of computers in manufacturing systems, to have knowledge of alternative software procedures, to understand the value of integrated manufacturing systems, to identify systems and their interactions through knowledge of the concepts and to gain experience in applying these to case studies. 5) Work Organisation and Design 2. On completion, students will understand in detail problems of workplace design, industrial accidents, task analysis and the working environment (including lighting, thermal effects and noise) and to develop a consciousness for the effective design of workplaces for the human operator.
Content:
Advanced Manufacturing Processes 1) Metal Forming. Analysis of metal-shaping processes. Heading, extrusion, forging. Methods of lubrication. Recent developments. Applications of CAD/CAM. 2) Casting and Powder Metallurgy. Processes: Sand casting, permanent mould casting, pressure die casting, continuous casting. Powder metallurgy processing. Design factors: Solidification, porosity, feeding, running and gating, geometric factors. Simulation software. 3) Material Removal. Abrasive processes: Grinding, honing, lapping and superfinishing. Bulk material removal Processes: Mechanics of cutting, analyses of single and multiple edge tool processes. Machining with form tools, turning, drilling, milling and threading. Wear theories and tool-life. Machinability of materials. Computer aided prediction of machining performance. Economics of material removal processes: Optimization of process variables for single- and multi-pass turning, drilling, milling and grinding operations. Canned cycles for CNC machine tool controllers. Manufacturing Management 1) Operations Research 1 - a) Optimization: Problem solving, algorithms and heuristics. Linear programming, sensitivity analysis. Integer, goal and non-linear programming. Network analysis for project management. b) Forecasting: Smoothing methods: averaging and exponential. Simple and multiple regression. Decomposition methods for time series. 2) Operations Research 2. Decision making under risk. Inventory control models. Queues. Markov processes. Game theory. 3) Quality Management - Total Quality Management: Process variability - measures and interaction with design. Quality, productivity and cost relationships. Quality systems. Alternate systems approaches. Quality Control: Control function. Theory of sampling. The Operating Characteristic curve. The use of statistical distributions. Sampling scheme design. Quality Improvement: Process capability and improvement studies. Control charts. State of statistical stability. Computerization of process monitoring. CUSUMS. Experimental design for quality improvement. Reliability and Maintenance Management: failure determination and measures. Effect of failures on quality. Failure frequency distributions. Reliability and maintenance. 4) Manufacturing Systems and Control: NC and CNC manufacturing systems: hardware and software interpolators, control of point-to-point and contouring systems, design considerations. PLCs. Adaptive control systems: estimation theory and system identification with applications to machine tools, welding and forming. Computer-integrated manufacturing systems: hierarchical distributed control systems, part family formation and manufacturing cell design, materials handling and control; interfaces with CAD systems. 5) Work Organization/Design. Task/activity analysis methods in industry: Allocation of tasks to humans and machines. The work environment: Effect on task performance. Anthropometry of workplaces. Robots in industry: Comparison with human performance. Allocation of tasks. Safety issues.
Assessment:
Laboratory and tutorial work, assignments and occasional tests, to a maximum of 30,000 words, or equivalent. Advanced Manufacturing Processes A two-hour paper for part (1), end of first semester. No written paper for part (2). One three-hour paper for part (3), end of second semester. Manufacturing Management A three-hour paper for part (1), end of first semester. A two-hour paper for part (2) at the end of second semester. One three-hour paper for part (3), end of second semester. One two-hour paper for part (4), end of second semester. No written paper for part (5).
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Handbook 1996 : Faculty of Engineering (Volume 4 page 116)
Status: Official 1996 Date created: Oct 9 1995 Last modified: Oct 9 1995 Authorised by: Academic Registrar Email enquiries: Course_Information@registrar.unimelb.edu.au
Maintained by: Dept. of Mechanical and Manufacturing Engineering, Faculty of Engineering.
Copyright © University of Melbourne 1995,1996.