Module MATERIALS AND MANUFACTURING PROCESSES SI MODULE CODE CREDITS 20 LEVEL 4 JACS CODE

Transcription

1 MODULE DESCRIPTOR TITLE MATERIALS AD MAUFACTURIG PROCESSES SI MODULE CODE CREDITS 20 LEVEL 4 JACS CODE J511 SUBJECT GROUP Automation and Operations Engineering DEPARTMET Engineering and Mathematics MODULE LEADER David Clegg MODULE STUD HOURS (based on 10 hours per credit)* Scheduled Learning and Teaching Activities Placement (if applicable) Independent Guided Study 48 /A MODULE AIM Total umber of Study Hours Understanding the fundamental language of materials and manufacturing processes is critical to the development of an engineer. The aims of the module are as follows: (i) (ii) (iii) (iv) To provide understanding of the structure of engineering metals, polymers and ceramics; and provide an understanding of the load bearing of materials and how to assess them. To enable the student to consider and select materials for engineering applications. To provide an understanding of the processing routes appropriate to specific materials and develop the capability to optimise selected manufacturing processes To provide a capability to make an informed choice of manufacturing processes and an understanding of cost build-up of those processes. MODULE LEARIG OUTCOMES By engaging successfully with this module a student will be able to (i) (ii) (iii) (iv) Analyse the structures, properties and behaviour of load bearing materials (typically; metals, polymers and ceramics). Select materials for engineering applications on the basis of their properties. Select manufacturing processes on the basis of material properties, quantities, target cost and quality of the product. Optimise a manufacturing process by identifying key factors affecting process effectiveness and efficiency.

2 IDICATIVE COTET The module will be taught using a combination of lectures, tutorials and laboratories where the fundamentals of materials and manufacturing processes will be discussed and investigated. Typical content includes: A. STRUCTURE OF METALS, CERAMICS AD POLMERS The crystalline nature of metals and alloys, their microstructure and properties. The metallic bond and the crystalline nature of metals; Atomic packing in bcc, fcc and cph crystal structures; Relationship between atomic / crystal structure and the physical / mechanical properties of metals; Principles of alloying of metals to modify properties; Introduction to commercially important alloys. The molecular structure of polymers, their microstructure and properties. Structure of organic polymeric molecules; crystalline and amorphous polymers; Thermoplastic polymers - physical and mechanical properties; Constitution of commercially important thermoplastics; Thermo-setting polymers - physical and mechanical properties. Examples of commercially important thermosetting polymers. The structure and properties of engineering ceramic materials. Definition of a ceramic; reviews the uses and characterising properties of commercially important ceramic materials; molecular structure and bonding in crystalline ceramic materials. Effect of micro-structural profile on the theoretical and actual properties of crystalline ceramic materials; comparison of behaviour of crystalline metallic and ceramic materials. B. MECHAICAL PROPERTIES Mechanical properties and tests for the determination of selected properties. Elastic and plastic properties; Strength and ductility; Stress-strain curves; Tensile testing; Hardness testing; Impact testing; Toughness; Creep testing; Fatigue testing. The relationship between mechanical properties and the structure of engineering materials. Analysis of stress and strain; Tensile and compressive stresses; ield and tensile strength; Hardness and wear resistance; Concepts of slip and work hardening; Factors affecting flow stress; Reheating of cold worked metals; Mechanical properties of commercial metals and alloys, polymers and ceramic materials. The selection of materials for engineering components at an introductory level. Basis for materials selection; Design-limiting properties of metals, ceramics and polymers; Establishment of service requirements; Selection for mechanical properties and failure analysis; Case studies in materials selection C. PRIMAR MAUFACTURIG PROCESSES The Principal Extraction Routes. Source of ores used in the extraction of metals and ceramics; Classification of fuels; Main extraction processes for metals; Refractories and polymers. Solidification Processes in Metals, Ceramics and Polymers. Production of ingots and casting; Continuous casting; Polymer Production

3 D. MECHAICAL AD THERMAL PROCESSIG Hot Metal Working Processes. Rolling; Forging; Extrusion; Heat treatment of Metals; Limitations and applications, loaddeformation relationships and product quality. Cold Metal Working Processes. Rolling; Pressing; Wire Drawing; Bending; Deep Drawing; Limitations and application, load-deformation relationships and product quality. Ceramic and Polymer Processing Methods. Powder Metallurgy Processes; Hot Pressing; Slip casting; Injection Moulding; Compression and Transfer Moulding; Blow and Vacuum Moulding. Advanced Machining Processes. Laser Cutting; Water Jet; EDM; Wire EDM; Electro Chemical Milling. Methods of Joining Materials. Joining techniques; Welding - gas and electric; brazing; soldering; fastening. Automation Technologies. Introduction to robotics and production lines. LEARIG, TEACHIG AD ASSESSMET - STRATEG AD METHODS Students will be supported in their learning, to achieve the above outcomes, in the following ways The available class contact time will be equally divided between study of engineering materials and manufacturing technology. Lectures will be given to the entire cohort, adequately supported by visual aids and, conducted in an auditorium with state of the art audio-visual facilities. Tutor led seminars for small groups with opportunity for tutor-learner interaction. Programme of laboratory experiments (group work, hands-on skills). There will be a Blackboard VLE or equivalent to sustain learner interest/engagement. ASSESSMET TASK IFORMATIO o.* Short Description of 1 Portfolio of Laboratory based assessments with staged submissions SI Code EX/CW/PR Weighting % Word Count or Exam Duration** CW 50% 2000 words 2 Examination EX 50% 3hrs In-module retrieval available FEEDBACK Students will receive feedback on their performance in the following ways Feedback will be given during tutorial/seminar sessions where the students will have the opportunity to work through example problems, ask questions and will be encouraged to reflect on their experience.

4 Informal group feedback is typically provided during the session following submission of an assignment, with individual feedback provided in accordance with current University policy. Indicative feedback, gathered from the most common comments, is provided for each Laboratory exercise normally within two weeks of the submission of the assessment. This verbal feedback is typically drawn from a sample of ten or so submissions. It is used to provide prompt timely feedback enabling each student to reflect upon what they submitted and thus not make the same mistake on subsequent laboratories (e.g. referencing) and whether the omissions they made were common across the cohort. LEARIG RESOURCES FOR THIS MODULE (ICLUDIG READIG LISTS) Lecture and tutorial notes will be available on the university's virtual learning environment system (Blackboard, or equivalent). Students should also take their own notes in lectures and tutorials and are encouraged to develop their understanding of the subject by reading recommended texts that are available from the University library. KALPAKJIA, Serope, and SCHMID, Steven (2013), Manufacturing Engineering and Technology, 7/e, Pearson Education, 18 Apr ISB , CALLISER, William D (2001), Fundamentals of Materials Science and Engineering, 5th Edition, John Wiley & Sons, Inc. ISB X REVISIOS Date March 2014 May 2014 Reason Comply with regulations Modification to approved provision

5 SECTIO 2 MODULE IFORMATIO FOR STAFF OL MODULE DELIVER AD ASSESSMET MAAGEMET IFORMATIO MODULE STATUS - IDICATE IF A CHAGES BEIG MADE EW MODULE EXISTIG MODULE - O CHAGE Title Change Level Change Credit Change Assessment Pattern Change Change to Delivery Pattern Date the changes (or new module) will be implemented MODULE DELIVER PATTER - Give details of the start and end dates for each module. If the course has more than one intake, for example, September and January, please give details of the module start and end dates for each intake. Module Begins Module Ends Course Intake 1 01/10/ /06/2014 Course Intake 2 01/10/ /06/2015 Course Intake 3 01/10/ /06/2016 Is timetabled contact time required for this module? Are any staff teaching on this module non-shu employees? If yes, please give details of the employer institution(s) below What proportion of the module is taught by these non-shu staff, expressed as a percentage? MODULE ASSESSMET IFORMATIO Indicate how the module will be marked *Overall PERCETAGE Mark of 40% *Overall PASS / FAIL Grade *Choose one only module cannot include both percentage mark and pass/fail graded tasks SUB-TASKS Will any sub-tasks (activities) be used as part of the assessment strategy for this module? If sub-tasks / activities are to be used this must be approved within the Faculty prior to approval. Subtask / activity marks will be recorded locally and extenuating circumstances, extensions, referrals and deferrals will not apply to sub-tasks / activities. FIAL TASK According to the Assessment Information shown in the Module Descriptor, which task will be the LAST TASK to be taken or handed-in? (Give task number as shown in the Assessment Information Grid in Section 1 of the Descriptor) o. 2 O-STADARD ASSESSMET PATTERS MARK 'X' I BOX IF MODULE ASSESSMET PATTER IS O STADARD, eg MODEL B, ALL TASKS MUST BE PASSED AT 40%. B: on-standard assessment patterns are subject to faculty agreement and approval by Registry Services - see guidance. notes.