Course syllabus
MPR034 Manufacturing Processes
Course syllabus
MPR034 Manufacturing Processes, SP1, 2023/2024, 7.5 credits
M.Sc. Programme in Production Engineering
Examiner Peter Krajnik (PK)
031-772 1311
Teachers Peter Krajnik (PK)
Gustav Holmqvist (GH)
Peter Hammersberg (PHA)
Amir Malakizadi (AM)
Guest
lecturers Jannik Henser, Scania (JH)
Magnus Wahlgård, SKF (MW)
Lab
instructor Philipp Hoier (PHO)
Course purpose
The course aims to provide students with a comprehensive understanding of the principles and recent advancements in the manufacturing processes used to produce precision engineering components, primarily in metals. The course will focus on the fundamental aspects of manufacturing processes and will also demonstrate various use cases of their applications. The students will acquire knowledge related to the mechanics involved in metal cutting and forming, as well as insight into important areas of related technologies such as machine tools and metalworking fluids. The objective is to familiarize students with some typical challenges that production engineers encounter in practice, which include process quality and robustness, process selection, and sustainable manufacturing.
Learning outcomes
After completing the course, the student should be able to:
- Describe various manufacturing processes with consideration to their applications, economic viability, and sustainability, across various scales.
- 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 relationship between the basic function of a manufacturing process, the tools utilized, and the resulting quality characteristics (such as obtained tolerances and surface integrity of components).
- Select a manufacturing process in the context of a production value chain for a manufactured component.
- Provide a description of the manufacturing process for some of the most common components in the industry.
- Describe the fundamental mechanics of various manufacturing processes.
Contents
The course covers both conventional and non-conventional manufacturing processes and examines their material, economic, and sustainability aspects. Basic knowledge of metal cutting and forming will be provided with additional emphasis on advanced applications and industry case studies. Processes covered include sheet metal forming, metal cutting, and machining with abrasives – such as grinding and fine-finishing technologies. Additionally, non-conventional processes are discussed, including laser beam, waterjet, and electrical discharge machining. Joining processes are also covered. Contemporary topics include the manufacture of gears and digitalization efforts.
Organization and structure
- The course is an in-person instruction held at Chalmers’ Johanneberg campus. This refers both to lectures and labs in the Material Processing Laboratory.
- The remote learning outside of the classroom provides you with the flexibility to delve deeper into the subject area. During this time, you can revisit the lecture handouts, read papers (not mandatory), and work on the assignments.
- Moreover, there is a mandatory grinding lab associated with the lectures.
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, conduct a computer independently using Granta, a process-screening software. The software can be downloaded or found in computer rooms. Report the results by answering a set of questions in a short report. The second portion of the assignment involves comparing of two processes based on published research literature. Note that this report substantial and time-consuming, completed 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 you will be given input data. Basic theoretical calculations for deep drawing will be performed and formability will be evaluated. You will work on this assignment on your own, but the submission will be done in groups of two students. Registration for groups will be done online through the course home page.
Feedback and assessment: Correct answers will be uploaded for your own review.
Assignment 3: Grinding lab and report: The role of specific energy in grinding
Questions: Philipp Hoier, hoierp@chalmers.se
The aim of the grinding lab is to perform a series of surface grinding tests while varying the grinding parameters. During the tests, the power of the main spindle will be measured using a trace function of the machine’s CNC control; recording the time variation of electrical power consumption in the servo drive. From these measurements you will be required to determine the specific grinding energy curve and discuss its implications in relation to the grinding parameters used.
Feedback: Oral/Written.
Bonus assignment: Enhancing learning through reading
Questions: Peter Krajnik, krajnik@chalmers.se
* Not compulsory
The purpose of the reading assignment is to teach students how to read academic articles and make basic interpretations. In addition, the reading assignment will give the students an insight into manufacturing science. This assignment is not compulsory. No report is needed, but you can earn 10 bonus points on the exam because bonus exam questions will be derived from this article.
Feedback: Result of the exam
Course home page
PDF handouts from lectures, the latest version of the course handbook, lecture announcements, and readings can be found on the course homepage. Signing up for assignments and submitting assignment reports is done through Canvas.
Literature
No textbooks are required for this course. Each lecture will be accompanied by handouts that will be made available on the course homepage in Canvas. Presentations, i.e., lecture handouts, will provide all the necessary teaching material. Supplemental readings (e.g., research articles) will be provided in the form of PDF files.
Examination
The course will be assessed by a written exam which will determine the course grade. Review questions for the exam will be provided at the end of each lecture.
The assignments/lab are reported separately in Ladok (and give a total of 1.5 credits). The mandatory requirements here are approval of all assignment reports.
The exam and completed assignments are required for final course approval.
Schedule
|
Study week |
Date |
Time |
Topic |
Classroom |
Teacher |
|
1 |
Tue 29/8 |
09:00-09:45 |
HC1 |
PK |
|
|
10:00-11:45 |
PK |
||||
|
Wed 30/8 |
08:00-09:45 |
Quality & robustness of manufacturing processes |
HC3 |
PHA |
|
|
|
Fri 1/9 |
10:00-11:45 |
Metal-cutting & metal-forming machines |
HA3 |
PK |
|
2 |
Tue 5/9 |
10:00-11:45 |
Machining processes 1 |
HC1 |
PK |
|
Wed 6/9 |
08:00-09:45 |
Machining processes 2 |
HC3 |
PK |
|
|
Fri 8/9 |
10:00-11:45 |
HA3 |
PK |
||
|
3 |
Tue 12/9 |
09:00-11:45 |
Manufacturing process selection and sustainability |
HC3 |
GH |
|
Wed 13/9 |
08:00-09:45 |
Waterjet machining |
HC3 |
GH |
|
|
|
Fri 15/9 |
10:00-11:45 |
Machinability of materials |
HA3 |
AM |
|
4 |
Tue 19/9 |
10:00-11:45 |
Laser machining & EDM |
HC3 |
GH |
|
Wed 20/9 |
08:00-09:45 |
Sheet-metal forming 1 |
HC3 |
GH |
|
|
|
Fri 22/9 |
10:00-11:45 |
Sheet-metal forming 2 |
HA3 |
GH |
|
5 |
Tue 26/9 |
09:00-11:45 |
Grinding processes |
HC3 |
PK |
|
Wed 27/9 |
08:00-09:45 |
Abrasive fine-finishing processes |
HC3 |
PK |
|
|
|
Fri 29/9 |
10:00-11:45 |
Processes for manufacturing of gears |
HA3 |
JH |
|
6 |
Tue 3/10 |
10:00-11:45 |
Joining processes 1 |
HA2 |
GH |
|
|
Wed 4/10 |
08:00-09:45 |
Joining processes 2 |
HC3 |
GH |
|
7 |
Tue 10/10 |
10:00-11:45 |
Grinding lab (Group 1-2) |
Material-processing lab |
PHO |
|
|
Wed 11/10 |
08:00-11:45 |
Grinding lab (Group 3-6) |
Material-processing lab |
PHO |
|
Fri 13/10 |
10.00-11.45 |
Grinding lab (Group 7-8) |
Material-processing lab |
PHO |
|
|
8 |
Tue 17/10 |
08:00-09:45 |
Grinding lab (Group 1-2) |
Material-processing lab |
PHO |
|
|
Tue 17/10 |
10.00-11.45 |
Course summary |
HA2 |
PK |
|
|
Wed 18/10 |
08.00-10.00 |
Bonus lecture: The power of connectivity in Industry4.0 |
MA |
MW |
- Changes will be announced in Canvas