436-412 Manufacturing Science 2

Students are expected to be familiar with the material of 436-363 Manufacturing Studies 2 and 436-364 Manufacturing Science 1.

Unit 1, Metal Forming: Upon completion, students should be prepared for a career in the manufacturing industry, with an in-depth knowledge of methods used in the theory of plasticity and lubrication. There will be an assignment in designing a manufacturing process for a typical net-shape forming operation. It is expected that students will understand the principles of designing tools for metal forming.

Topics covered include a selection from principles and applications of plasticity theory; analysis of metal forming processes such as heading, extrusion and forging; friction in metal forming; lubrication; non-traditional methods of metal forming; high energy rate and high velocity forming; applications of CAD/CAM; and experimental verification of forming parameters.

Unit 2, Material Removal: Upon completion, students should understand: the basic cutting action, performance, capabilities and latest development in abrasive processes; the development and computerisation of fundamental mechanics of cutting models for the major machining operations such as milling for tool design and performance prediction.

Topics covered include a selection from abrasive processes: grinding, honing, lapping and super finishing; bulk material removal processes: mechanics of cutting; analyses of single point and multi-point tool processes; machining with form tools, turning, drilling, milling and rotary tool operations.

Two 2-hour examinations (50%), assignments, tutorial problem sheets and laboratory reports not exceeding 15 pages including computations, diagrams, tables and computer output (50%). Students will be notified of the weighting of the non-examination assessment components at the beginning of semester.