Course syllabus

Review of exams

You can review your exams:

Tuesday Nov 26: 11.00-11.45, Room Beta.

If this doesn't work and you need to review the exam, contact gustav.holmqvist@chalmers.se

/GH

 

Manufacturing Processes

Course Plan

 

MPR034, SP1, 2019/2020, 7,5hec

Master’s Programme in Production Engineering

 

Examiner                 Gustav Holmqvist (GH)          031-772 5026

                                       gustav.holmqvist@chalmers.se

 

Lecturers                 Gustav Holmqvist (GH)         

                                       Peter Krajnik (PK)

                                       Amir Malakizadi (AM)

                                       Peter Hammersberg (PH)

 

Guest Lecturers    Sören Hägglund, Seco Tools (SH)

                                       Jeff Badger, The Grinding Doc (JB)

                                      

                                      

 

 

Course objectives

The course describes important manufacturing processes being industrially used today. The objective of the course is to put the most important manufacturing processes in to a context of a production environment. The objective is further to introduce and train some important different work tasks engineers in this field will have; process development and optimization, quality problem resolutions, and process selection.

 

 

Learning outcomes

After the course, the student should be able to:

• Describe the most important manufacturing processes with respect to applications, economics and environmental impact.
• Explain the role of manufacturing processes in a production system, including their necessity of appropriate equipment, tooling and automation based on for instance volume of production.
• Understand and be able to explain the link between the basic function of a manufacturing process, the tools used and its resulting product features (for instance tolerances and surface characteristics).
• Make a basic selection of a manufacturing process in the context of a process chain for a finished part.
• Describe how some of the most common parts and products in modern industry are manufactured.
• Understand the role of control limits and specifications limits for process capability analysis.
• Understand the basic industrial practice for measurement system capability determination.

 

 

 

Contents

In the course some of the most important manufacturing methods and processes are described as well as their development and potential with respect to materials selection, economy and environmental considerations. The students are presumed to have basic knowledge of basic manufacturing methods in metal forming and cutting, and the course thus focuses on more detailed knowledge of these as well as more advanced processes. This includes modern sheet metal forming, high-speed machining and precision machining. A part of the course deals with unconventional machining using for example laser beam technology, water-jet and electrical discharge machining. The course includes joining processes with a focus on sheet metal joining and electronics assembly (soldering). Further is given an introduction to quality engineering focusing on process capability and measurement systems analysis. Finally, measurement of parts is included focusing on surface measurement.

 

 

Organisation and structure

• The course is based on lectures where different processes and techniques are presented and discussed.
• In parallel with the lectures, there are three laboratory exercises and four assignments which connect to the lectures. The labs and three of the assignments are linked.
• Preliminary, the course includes 42 h of lectures, 8 h of laboratory work, and 28 h of group assignment work.

 

 

Laboratory exercises and Group assignments

The following is included in the course:

 

Lab 1 and Assignment 1: Abrasive Waterjet Cutting

Supervisor: Gustav Holmqvist

 

Lab 2 and Assignment 2: Process selection and comparison

Questions: Gustav Holmqvist

 

Lab 3 and Assignment 3: Measurement System Analysis (MSA)

Supervisor: Peter Hammersberg, peter.hammersberg@chalmers

 

Assignment 4: Deep Drawing (sheet metal forming)

Questions: Gustav Holmqvist

 

So in total three labs are made. Note that all three labs are accompanied by an assignment that takes some time– it is not just a summary of the lab but also a continuation. For each assignment a report is prepared and handed in (through the course home page). One report by 4 students.

 

Lab 1 is performed in the laboratory of the department (entrance marked Material- och tillverkningsteknik lab). Groups of 8 students, but a group assignment is made in groups of 4. Map to find the lab can be found on last page in this PM.

 

Lab 2 is a computer lab conducted on your own time. The assignment for this lab consists of a summary of computer-lab findings but also a comparison of two processes based on information searching/literature studies. Note that this is quite a large and time-consuming hand-in (report).

 

Lab 3 is scheduled on October 16 with two occasions of your choice, made in classrooms. After this occasion, a computer exercise (assignment 3), is made on your own time (for the hand-in).

 

Assignment 4 on sheet metal forming is made on your own time in groups of 2 and is this year not accompanied by a lab (has been in the past). Assignment 4 can be made and handed in prior to 2 and 3 if wanted.

 

Registration for groups will be made on-line through the course home page.

Be on time for your scheduled lab occasions (lab 1 and 3). If late you might have to take the lab at another occasion if available.

 

Course home page

Handouts from lectures, latest version of this document, news about lectures as well as literature can be found on the course Canvas homepage. Also registration for labs as well as hand-in of reports is made here.

 

Literature

For each lecture or topic there will be literature on the course home page on Canvas in a specific folder. Written theory is mixed with scientific articles to get both the basics and the ongoing development of the different manufacturing methods. Most literature come in the form of pdf-files but there are also links to specific E-books or on-line articles. Note that you typically might need to be logged in to the library or work on a Chalmers computer to access E-books.

 

A reading instruction will be found on the course home page. Most of the material is intended as reading for the examination, but not all and some is considered more important etc.

 

 

Examination

The course is assessed through a written exam which determines the course grade.

 

The labs together with the group assignments are reported separately (gives 1,5 hec).

Here is required:

• Attendance at laboratory exercises (1 and 3).
• Approval of all four group assignment reports.

 

For final course approval the exam as well as the labs+assignments are required.
Schedule

Study week	Date	Time	Topic	Room	Teacher
1	Tue 3/9	9.00-9.45	Introduction	KA	GH
		10.00-11.45	Repetition, Basics in  manufacturing technology	KA	GH
	Wed 4/9	8.00-9.45	Principles of Manufacturing	HC2	PK
	Fri 6/9	10.00-11.45	Waterjet cutting	HA3	GH
2	Tue 10/9	10.00-11.45	Process and metalworking fluids	KA	PK
	Wed 11/9	8.00-9.45	-	HC2	-
	Fri 13/9	10.00-11.45	Laser & Electrical Discharge Machining	HA3	GH
3	Tue 17/9	8.00-9.45	Metal Cutting Machines	KA	PK
		10.00-11.45	Abrasive fine-finishing	KA	PK
	Wed 18/9	8.00-9.45	Process selection and Sustainability	HC2	GH
	Fri 20/9	10.00-11.45	Machining methods and cutting data optimization	HA3	SH
4	Tue 24/9	10.00-11.45	Grinding	HC2	JB
	Wed 25/9	8.00-9.45	Metal Cutting – Difficult-to-machine materials	HC2	AM
	Fri 27/9	10.00-11.45	Process capability, Measurement System Analysis	HA3	PH
5	Tue 1/10	9.00-9.45	Sum-up and study-tips	HC2	GH
		10.00-11.45	Sheet metal forming - Introduction	HC2	GH
	Wed 2/10	8.00-9.45	Sheet metal forming - advanced methods	HC2	GH
	Fri 4/10	10.00-11.45	Forming of Advanced High Strength Steels	HA3	GH
6	Tue 8/10	10.00-11.45	Joining – Introduction, soldering, adhesives	HC2	GH
	Wed 9/10	8.00-9.45	Introduction to JMP (software for data analysis)	HC2	PH
	Fri 11/10	10.00-11.45	Re – exam (other courses) or own time	-	-
7	Tue 15/10	10.00-11.45	Joining – Soldering cont., Thin sheet metal joining	HC2	GH
	Wed 16/10	8.00-9.45	MSA lab, occasion 1	FL51	PH
			MSA lab, occasion 2	FL51	PH
	Fri 18/10	10.00-11.45	Functional Surfaces, surface topography	HA2	GH
8	Tue 22/10	10.00-11.45	Course Summary	HC2	GH

 

• Changes will be notified by email to all registered students.
• In addition to these scheduled hours, lab hours for lab 1 will be available to choose from (see course home page).
• Wednesday 16/10: lab 4 (MSA) is scheduled in class rooms FL51 (see above). You must (later) register for one of the occasions through the home page.