Course syllabus
MPR034 Manufacturing Processes
Course Handbook
MPR034 Manufacturing Processes, SP1, 2022/2023, 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 (PHA)
Amir Malakizadi (AM)
Lab
instructor Philipp Hoier (PHO)
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. The course gives the students a fundamental, integrated, in-depth understanding of manufacturing processes which can be utilized for enhancing and optimizing real-world operations in industry. The students gain knowledge in the underlying mechanics in the metal cutting and forming zones and insight into important areas of associated technologies such as machine tools and metalworking fluids. The purpose is to further introduce to the students some typical challenges manufacturing engineers will experience in practice; process development, selection and optimization, 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 metalworking fluids 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, and electrical discharge machining. The course also includes joining processes with a focus on sheet-metal joining. Contemporary topics include manufacturing of gears, which are a big part of the Swedish automotive industry despite its shifting to E-mobility.
Organization and structure
- The course is in-person and takes place at Chalmers campus Johanneberg. This refers both to lectures and labs in the Material Processing Laboratory.
- 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 lecture handouts, read papers (not obligatory), and engage in discussions.
- Moreover, there are two labs which are associated with the lectures.
- The course includes 36h of lectures, and >30h of assignment-related work.
Labs & Assignments
The following compulsory labs and 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 and assessment: Written, Passed/Rework.
Assignment 2: 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 and assessment: Correct answers will be uploaded for your own review
Assignment 3: Grinding lab (incl. lab report): The role of specific energy in grinding
Questions: Philipp Hoier, hoierp@chalmers.se
* Lab participation compulsory
The aim of the grinding lab is to conduct a series of surface grinding tests while varying the grinding parameters. During the tests, the power of the main spindle will be measured via a trace function of the machine CNC control; recording the time change of electrical power consumption in the servo drive. Using these measurements, during the remote part of this exercise, you will need to determine the specific grinding energy curve and discuss its implications in relation to the used grinding parameters.
Feedback: Oral/Written
Bonus assignment: Enhancing learning through reading
Questions: Peter Krajnik, krajnik@chalmers.se
* Not compulsory
The aim of the reading assignment is to learn to read academic articles – and build basic interpretations. Moreover, the reading assignment will give the students an insight into academic/disciplinary debates. This assignment is not compulsory. No report needed. No deadline. But you can earn 10 bonus points on the exam, as the bonus exam questions will be derived from this article.
Feedback: Oral/Debate
Course home page
PDF handouts from lectures, 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 assignment reports is made via Canvas.
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. Presentations, i.e. lecture handouts will provide the necessary insight into the state of knowledge of the manufacturing processes. 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 group assignment reports and participation in the (i) machining and (ii) grinding labs.
For final course approval the exam as well as the completed assignments are required.
Schedule
|
Study week |
Date |
Time |
Topic |
Classroom |
Teacher |
|
1 |
Tue 30/8 |
09:00-09:45 |
Course introduction |
HC1 |
PK |
|
10:00-11:45 |
Principles of manufacturing |
PK |
|||
|
Wed 31/8 |
08:00-09:45 |
Metal-cutting & metal-forming machines |
HC3 |
PK |
|
|
|
Fri 2/9 |
10:00-11:45 |
Quality & robustness of manufacturing processes |
HA3 |
PHA |
|
2 |
Tue 6/9 |
10:00-11:45 |
Manufacturing process selection and sustainability |
HC1 |
GH |
|
Wed 7/9 |
08:00-09:45 |
Waterjet machining |
HC3 |
GH |
|
|
Fri 9/9 |
10:00-11:45 |
Machinability of materials |
HA3 |
AM |
|
|
3 |
Tue 13/9 |
09:00-11:45 |
Machining processes 1 |
HC3 |
PK |
|
Wed 14/9 |
08:00-09:45 |
Machining processes 2 |
HC3 |
PK |
|
|
|
Fri 16/9 |
10:00-11:45 |
Metalworking fluids |
HA3 |
PK |
|
4 |
Tue 20/9 |
10:00-11:45 |
Laser machining & EDM |
HC3 |
GH |
|
Wed 2219 |
08:00-09:45 |
Sheet-metal forming 1 |
HC3 |
GH |
|
|
|
Fri 23/9 |
10:00-11:45 |
Sheet-metal forming 2 |
HA3 |
GH |
|
5 |
Tue 27/9 |
09:00-11:45 |
Grinding processes |
HC3 |
PK |
|
Wed 28/9 |
08:00-09:45 |
Abrasive fine-finishing processes |
HC3 |
PK |
|
|
|
Fri 30/9 |
10:00-11:45 |
Processes for manufacturing of gears |
HA3 |
PK |
|
6 |
Tue 4/10 |
10:00-11:45 |
Joining processes 1 |
HA2 |
GH |
|
|
Wed 5/10 |
08:00-09:45 |
Joining processes 2 |
HC3 |
GH |
|
7 |
Tue 11/10 |
10:00-11:45 |
Grinding lab (Group 1-2) |
Material-processing lab |
PHO |
|
|
Wed 12/10 |
08:00-11:45 |
Grinding lab (Group 3-6) |
Material-processing lab |
PHO |
|
Fri 14/10 |
10.00-11.45 |
Grinding lab (Group 7-8) |
Material-processing lab |
PHO |
|
|
8 |
Tue 19/10 |
10.00-11.45 |
Course summary |
HA2 |
PK |
- Changes will be notified in Canvas or by email to all registered/participating students