Course syllabus
MPR034 Manufacturing Processes
Course Handbook
MPR034 Manufacturing Processes, SP1, 2021/2022, 7.5 credits
M.Sc. Programme in Production Engineering
Examiner Peter Krajnik (PK)
031-772 1311
Lecturers Peter Krajnik (PK)
Gustav Holmqvist (GH)
Peter Hammersberg (PH)
Amir Malakizadi (AM)
Guest
instructors Helmi Attia (HA) – National Research Council Canada
Boris Zhmud (BZ) – Applied Nano Surfaces Sweden AB
Mohammadali Kadivar (MK) – Furtwangen University, Germany
Bülent Tasdelen (BT) – Kistler, Switzerland
Course purpose
The objectives of the course are to provide the students with an understanding of the principles and with an overview of recent developments in processes applied to the manufacture of engineering components, mainly in metals, but also in composites. The purpose is further to introduce some typical work tasks manufacturing engineers will experience; process development, selection and optimisation, quality-related problem solving, requirements specification and production economics.
Learning outcomes
After the course, the student should be able to:
- Describe a variety of manufacturing processes of different scales with respect to applications, economics and sustainability.
- Explain the role of manufacturing processes in a wider production-system context, including the roles of machine tools, tooling solutions and automation with respect to a certain production volume.
- Understand and explain the link between the basic function of a manufacturing process, the tools used and its resulting quality features (for instance obtained tolerances and surface integrity of components).
- Make a basic selection of a manufacturing process in the context of a production value chain for a manufactured component.
- Describe how some of the most common components and products in the industry are manufactured.
- Describe fundamental mechanics and capabilities of manufacturing processes.
Contents
The course covers most common as well as non-conventional manufacturing processes and integrates knowledge related to their development and potential impact with respect to materials, economics and sustainability. The students should have basic knowledge of basic manufacturing operations in metal cutting and metal forming, hence more focus is given on advanced applications and case studies from the industry. This includes advanced sheet metal forming, high-performance metal cutting and precision machining including grinding and fine-finishing technologies. A part of the course deals with non-conventional machining using for example laser beam technology, waterjet, electrical discharge machining and micro machining. The course also includes joining processes with a focus on sheet-metal joining. Contemporary topics include manufacturing of composites and digitalization of manufacturing processes.
Organisation and structure
- The course is hybrid – combining in-person and remote learning. Majority of the lectures will be synchronous, i.e. delivered live (either in-class, online, or both at the same time / streamed from the classroom). Two of the lectures will be pre-recorded. Synchronous lectures will be streamed via the following Zoom link:
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Zoom link: |
Password: |
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Click Zoom link in "Schedule" below |
MPR034 |
- The asynchronous learning period when you are not in classroom will give you additional time and flexibility to further learn the topics concerned based on your interest. Here you will have the possibility to revisit the screencasts, watch additional videos, read papers, and engage in discussions.
- Moreover, there are four assignments which are associated with the lectures.
- The course includes 42h of lectures, and >30h of assignment-related work.
Assignments
The following compulsory assignments are included in the course (1.5 credits):
Assignment 1: Process selection and comparison
Questions: Gustav Holmqvist, gustav.holmqvist@chalmers.se
First, a computer exercise is conducted on your own, using a process-screening software, Granta. The software will be made available to download or can be found in computer rooms. Results are reported by answering a set of questions in a short report.
The second part is concerned with a comparison of two processes based on published research literature. Note that this is quite a large and time-consuming hand-in (report). Assignment is made in groups of four students.
Feedback: Passed/Rework
Assignment 2: Abrasive waterjet cutting
Questions: Gustav Holmqvist, gustav.holmqvist@chalmers.se
In this assignment calculations of part cost and machine selection will be made for a use-case part. Assistance will be provided via a non-compulsory demonstration lab in smaller groups. The demos are scheduled to take 45 min and are done in groups of four students. In the demo lab the actual part is cut. The lab will be scheduled during study week 4 and 5. All files from last year (when the lab was only remote/digital) will be provided including movies of test cuts, etc. If you decide to take the lab it is recommended that you have started the assignment prior to taking the lab. The assignment is also made in groups of four students. Assignment completion requires handing-in a report along with an Excel-sheet with calculations.
Feedback: Passed/Rework
Assignment 3: Scientific Reading
Questions: Peter Krajnik, peter.krajnik@chalmers.se
Read the article on “Grinding and fine finishing of future automotive powertrain components”: https://doi.org/10.1016/j.cirp.2021.05.002 (Links to an external site.) and self-reflect on aspects described in the assignment”. You may divide up lengthy reading with your classmates. During the debriefing session scheduled on the 13 October 2021, the instructor will summarize the topic in a presentation. Then, you (i.e., your group) will be given an opportunity to reflect on your learning experience which will be shared with your peers – either by oral exchange, a presentation, or a short-written report/”essay”
Feedback: Oral/Written
Assignment 4: Deep Drawing (sheet metal forming)
Questions: Gustav Holmqvist, gustav.holmqvist@chalmers.se
This is an assignment where input data will be provided to you. Some basic theoretical calculations for deep drawing will be made and formability evaluated. You will work on this assignment on your own; but the hand-in is made in groups of two students. Registration for groups will be made on-line through the course home page.
Feedback: Correct answers will be uploaded for your own review
Course home page
PDF handouts from lectures, screencasts, latest version of the course handbook, notifications about lectures as well as literature can be found on the course homepage. Registration for assignments as well as hand-in of reports is made here.
Literature
There are no textbooks required for this course. For each lecture there will be teaching material made available on the course home page in Canvas. Presentation/lecture handouts, recorded screencasts and video instructions will provide the necessary insight into the state-of-the-art of the manufacturing methods. Supplementary readings (e.g. research articles) will be provided in the form of PDF-files.
Examination
The course is examined via a written exam which determines the course grade. Review questions for the exam will be provided at the end of each lecture.
The labs / assignments are reported separately in Ladok (and give 1.5 credits in total). Here the obligatory requirements refer to approval of all four group assignment reports.
For final course approval the exam as well as the completed assignments are required.
Schedule
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Study week |
Date |
Time |
Topic |
Classroom |
Teacher |
|
1 |
Tue 31/8 |
09:00-09:45 |
Course introduction |
PK |
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|
10:00-11:45 |
Principles of manufacturing |
PK |
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Wed 1/9 |
08:00-09:45 |
PH |
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Fri 3/9 |
10:00-11:45 |
Manufacturing process selection and sustainability |
GH |
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2 |
Tue 7/9 |
10:00-11:45 |
Metal-cutting & metal-forming machines |
PK |
|
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Wed 8/9 |
08:00-09:45 |
Manufacturing & machining of composites |
Pre-recorded lecture |
HA |
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Fri 10/9 |
10:00-11:45 |
Digitalization of manufacturing processes |
Only online; https://chalmers.zoom.us/j/3197615767 |
BT |
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|
3 |
(own time) |
Laser machining & EDM |
Pre-recorded lecture |
GH |
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Tue 14/9 |
09:00-11:45 |
Waterjet machining; (+lab intro & follow-up) |
EC; https://chalmers.zoom.us/j/3197615767 | GH |
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Wed 15/9 |
08:00-09:45 |
Machining processes 1 |
PK |
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Fri 17/9 |
10:00-11:45 |
Machining processes 2 |
Pre-recorded lecture |
PK |
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4 |
Tue 21/9 |
10:00-11:45 |
Machinability of materials |
AM |
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Wed 22/9 |
08:00-09:45 |
Grinding processes |
PK |
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Fri 24/9 |
10:00-11:45 |
Abrasive fine-finishing processes |
PK |
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5 |
Tue 28/9 |
09:00-11:45 |
Sheet-metal forming 1 |
GH |
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Wed 29/9 |
08:00-09:45 |
Sheet-metal forming 2 |
GH |
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Fri 1/10 |
10:00-11:45 |
Mechano-chemical surface finishing |
Only online; https://chalmers.zoom.us/j/68032250767 |
BZ |
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6 |
Tue 5/10 |
10:00-11:45 |
Joining processes 1 |
GH |
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Wed 6/10 |
08:00-09:45 |
Joining processes 2 |
GH |
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7 |
Tue 12/10 |
10:00-11:45 |
Processes for manufacturing of gears |
PK |
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Wed 13/10 |
08:00-11:45 |
Debriefing on Assignment 3: Scientific Reading |
Gustav Dalén-salen, Chalmers Tvärgata 5 (Room3001) |
PK |
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Fri 15/10 |
10.00-11.45 |
Micro-machining processes |
Pre-recorded lecture |
MK |
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8 |
Tue 19/10 |
10.00-11.45 |
Course summary |
PK |
- Changes will be notified in Canvas or by email to all registered/participating students