436-413 Manufacturing Science 3

436-363 Manufacturing Studies 2 and 436-412 Manufacturing Science 2, or equivalents

Unit 1, Casting Processes: Upon completion, students should understand the processes of moulding, casting and powder metallurgy as practised by industry and be able to identify and use methods for detecting defects and improving process performance.

Topics covered include sand casting, investment casting, permanent mould casting, pressure die casting, semi-solid casting and continuous casting; design factors: feeding, running and gating, solidification, solidification contraction and porosity; geometric factors; simulation software; and powder metallurgy processing.

Unit 2, Material Removal: Upon completion, students should understand the fundamentals of tool wear, tool-life and computer-based optimisation of single and multi-pass machining operations for use in process planning.

Topics covered include wear theories and tool-life; machinability of materials; computer-aided prediction of machining performance; economics of material removal processes: objective functions and constrained optimisation of process variables for single and multi-pass machining operations such as turning, drilling and milling; and computer-aided optimisation for off-line process planning and canned cycles for CNC machine tool controllers.

Laboratory, tutorial work and assignments not exceeding 20 pages including computations, diagrams, tables and computer output (67%), and tests (33%). Students will be notified of the weighting of the non-test assessment components at the beginning of semester.