MECHENG 747 : Manufacturing and Industrial Processes

Engineering

2024 Semester Two (1245) (15 POINTS)

Course Prescription

Analysis and design of manufacturing processes, with a focus on techniques to manipulate metals and polymers. Application of solid mechanics, fluid mechanics and heat transfer to current additive, subtractive, forming and injection/casting manufacturing technologies. Topics include: bulk and sheet forming, extrusion, injection moulding, 2D and 3D printing processes.

Course Overview

MODULE 1: Polymer Processing
Basic polymer science
     o    Polymer morphology
     o    Molecular structure versus properties
     o    Thermoplastics versus thermosets
     o    Macroscopic polymer properties (viscoelasticity and melt rheology)
     o    Property characterisation

Introduction to common processing techniques
     o    Extrusion
        * Profile extrusion
         * Sheet extrusion
         * Blown-film extrusion
         * Filament extrusion and spinning
     o    Injection moulding
     o    Blow moulding
     o    Thermoforming

MODULE 2: Additive Manufacturing
Introducing physical concepts that underpin additive manufacturing techniques
•    Surface energy, and liquid behaviour on surfaces
•    Rheology of solutions/suspensions and phase change
•    Powder flow characteristics and powder consolidation

Working principles and analysis of common additive manufacturing techniques, including:
•    Material extrusion
•    Vat polymerisation
•    Powder bed fusion and binding
•    Inkjet printing

MODULE 3: Plasticity in Metals
Introduction and background
     o    Fundamentals of metal forming
     o    Plastic behaviour of metals

MODULE 4: Bulk Metal Forming
Bulk metal forming processes and their analyses
     o    Extrusion and wire drawing (uniform energy method)
     o    Concepts of redundant work and mechanical efficiency
     o    Optimum die design and dead metal zone
     o    Forging and rolling (force equilibrium method)
     o    Friction hill; roll flattening and defects in rolling

MODULE 5: Sheet Metal Forming
Introduction to sheet metal forming
     o    Strain space and stress space; concept of forming limit diagram
     o    Sheet bending and spring-back
    

Course Requirements

Prerequisite: MECHENG 340

Capabilities Developed in this Course

Capability 2: Sustainability
Capability 3: Knowledge and Practice
Capability 4: Critical Thinking

Learning Outcomes

By the end of this course, students will be able to:
  1. Develop an understanding of the basic theory of plasticity and forming processes for manufacturing with metals (both bulk and sheet), and the capability to analyse components of simple geometry. (Capability 3.1)
  2. Understand the plastic flow of metallic solids, and the capability to calculate deformation in simple loading cases (Capability 3.1)
  3. Understand the physical principles that underpin additive manufacturing and the working principles of some common additive manufacturing processes (Capability 3.1 and 4.1)
  4. Understand the relationship between polymer structure and macroscopic behaviour, how the structure can degrade upon processing, and the implications this has for recyclability. (Capability 2.1, 3.1 and 4.1)
  5. Analyse simple problems involving viscous flows (Capability 4.1)
  6. Understand processes available to manufacture plastic components, and the ability to carry out hand calculations on processing times and forces. (Capability 3.1 and 4.1)

Assessments

Assessment Type Percentage Classification
Examination 50% Individual Examination
Test 20% Individual Test
Laboratory Assignment 20% Individual Coursework
Metal Forming Assignment 10% Individual Coursework
Assessment Type Learning Outcome Addressed
1 2 3 4 5 6
Examination
Test
Laboratory Assignment
Metal Forming Assignment

The Test and the Examination are in-person, paper-based, invigilated, closed book, restricted calculators assessments. The minimum pass mark for the course is 20/50 (i.e. 40%) in the Examination, in addition to 50/100 (i.e. 50%) for the whole course. If these conditions are not met, the final grade will be capped at D+.

Workload Expectations

This course is a standard 15 point course and students are expected to spend 10 hours per week involved in each 15 point course that they are enrolled in.

For each week in this course, you can expect, on average, 3 hours of lectures, 4 hours of reading and thinking about the content and 3 hours of work on assessments.

Delivery Mode

Campus Experience

Attendance is expected at scheduled activities, including Laboratory Assignment, to complete components of the course.
Lectures will be available as recordings. Other learning activities, including laboratory demonstrations, will not be available as recordings.
The course will not include live online events.
Attendance on campus is required for the Test and the Examination.
The activities for the course are scheduled as a standard weekly timetable.

Learning Resources

Course materials are made available in a learning and collaboration tool called Canvas which also includes reading lists and lecture recordings (where available).

Please remember that the recording of any class on a personal device requires the permission of the instructor.

There is no prescribed text. The following are recommended books from where the metal forming course content has been developed.
1. Metal Forming: Mechanics and Metallurgy
William F. Hosford & Robert M. Caddell
Fourth edition, 2011, Cambridge University Press, e-book.

2. Mechanics of Sheet Metal Forming
Z. Marciniak, J.L. Duncan & S.J. Hu
Second edition, 2002, Oxford: Butterworth-Heinemann, e-book.

These books can be accessed in electronic format via www.library.auckland.ac.nz/ebooks

Health & Safety

Students are expected to adhere to the guidelines outlined in the Health and Safety section of the Engineering Undergraduate Handbook.

Student Feedback

At the end of every semester students will be invited to give feedback on the course and teaching through a tool called SET or Qualtrics. The lecturers and course co-ordinators will consider all feedback and respond with summaries and actions.

Your feedback helps teachers to improve the course and its delivery for future students.

Class Representatives in each class can take feedback to the department and faculty staff-student consultative committees.

The course has been more streamlined and better ordered, based on student feedback. The course content has also been revised to make it more relevant, taking into account current manufacturing technologies.

Other Information

The use of Generative AI tools (such as Chat GPT) is not permitted in this course.

Academic Integrity

The University of Auckland will not tolerate cheating, or assisting others to cheat, and views cheating in coursework as a serious academic offence. The work that a student submits for grading must be the student's own work, reflecting their learning. Where work from other sources is used, it must be properly acknowledged and referenced. This requirement also applies to sources on the internet. A student's assessed work may be reviewed for potential plagiarism or other forms of academic misconduct, using computerised detection mechanisms.

Class Representatives

Class representatives are students tasked with representing student issues to departments, faculties, and the wider university. If you have a complaint about this course, please contact your class rep who will know how to raise it in the right channels. See your departmental noticeboard for contact details for your class reps.

Inclusive Learning

All students are asked to discuss any impairment related requirements privately, face to face and/or in written form with the course coordinator, lecturer or tutor.

Student Disability Services also provides support for students with a wide range of impairments, both visible and invisible, to succeed and excel at the University. For more information and contact details, please visit the Student Disability Services’ website http://disability.auckland.ac.nz

Special Circumstances

If your ability to complete assessed coursework is affected by illness or other personal circumstances outside of your control, contact a member of teaching staff as soon as possible before the assessment is due.

If your personal circumstances significantly affect your performance, or preparation, for an exam or eligible written test, refer to the University’s aegrotat or compassionate consideration page https://www.auckland.ac.nz/en/students/academic-information/exams-and-final-results/during-exams/aegrotat-and-compassionate-consideration.html.

This should be done as soon as possible and no later than seven days after the affected test or exam date.

Learning Continuity

In the event of an unexpected disruption, we undertake to maintain the continuity and standard of teaching and learning in all your courses throughout the year. If there are unexpected disruptions the University has contingency plans to ensure that access to your course continues and course assessment continues to meet the principles of the University’s assessment policy. Some adjustments may need to be made in emergencies. You will be kept fully informed by your course co-ordinator/director, and if disruption occurs you should refer to the university website for information about how to proceed.

Student Charter and Responsibilities

The Student Charter assumes and acknowledges that students are active participants in the learning process and that they have responsibilities to the institution and the international community of scholars. The University expects that students will act at all times in a way that demonstrates respect for the rights of other students and staff so that the learning environment is both safe and productive. For further information visit Student Charter https://www.auckland.ac.nz/en/students/forms-policies-and-guidelines/student-policies-and-guidelines/student-charter.html.

Disclaimer

Elements of this outline may be subject to change. The latest information about the course will be available for enrolled students in Canvas.

In this course students may be asked to submit coursework assessments digitally. The University reserves the right to conduct scheduled tests and examinations for this course online or through the use of computers or other electronic devices. Where tests or examinations are conducted online remote invigilation arrangements may be used. In exceptional circumstances changes to elements of this course may be necessary at short notice. Students enrolled in this course will be informed of any such changes and the reasons for them, as soon as possible, through Canvas.