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MANUFACTURING PROCESS

EAT 227

WEEK 0
INTRODUCTIONS

PowerPoint Slides
by Turnad Lenggo Ginta

Last Updated:July 13, 2017 LMS SEGi College 1


Learning outcome

1. Appreciate the diversity of processes involved in successful and


economic materials and component manufacture.
2. To understand the inter-relations between material, process,
design/shape, performance and economics
3. Understand, analyse, and discuss the specific features of processes
associated with the manufacture of metals, ceramics, glasses, polymers
and polymer composite components
4. Establish and interpret the natures and effects of important process
variables
5. Deal with aspects of manufacturing processes in a qualitative manner
6. Appreciate the range of techniques available for the forming and joining
of engineering materials and be able to select process to optimise both
bulk and surface properties.
7. Undertake process selection exercises and understand the underlying
methodology.
8. Select appropriate manufacturing/processing strategies on the basis of
given requirements.

Last Updated:July 13, 2017 LMS SEGi College 2


sylabus
1. Process selection
General review of the nature of manufacturing technologies availables.
General review of the nature and properties of common engineering materials.
Inter-dependence of chosen material, process, design/shape and economics.

2. Manufacturing with metals


Casting: to include as-cast structures, control of grain structures, segregation,
porosity;types of casting processes;heat treatment of casting and fabricated
structures.
Mechanical forming: to include rolling, forging, drawing, extrusion, presswork, etc;
mechanics, work analysis, friction, redundant work;influences on formability/
Cutting, machinability, cutting tools.
Surface treatment: to include cas hardening, nitriding, carbonitriding, plating, nickel
and chromium electroplating, galvanising, painting.

Last Updated:July 13, 2017 LMS SEGi College 3


Sylabus (cont.)
3. Manufacturing with ceramics
Powder technology
Shaping processes
Characteristic and application of
Cold pressing
Casting molding
Extrusion
Injection molding
Hot pressing
Reaction bonding
Vapour processes
Devitrification
Drying and firing processes, sintering mechanisms.

4. Manufacturing with glass


Glass forming materials
Batch and enamels, glaze technology
Melting
Shaping processes for glass components
annealing
Manufacture of common types of glass fibre, including fibre optic materials

Last Updated:July 13, 2017 LMS SEGi College 4


Sylabus (cont.)
5. Manufacturing with polymers
Nature of thermoplastic and thermosetting polymers. Processability of thermoplastics
and thermosets. Physical and chemical changes during processing.
Common thermoplastic forming processes: to include injection moulding, extrusion, blow
moulding, film blowing and thermoforming,
Common thermoset forming processes: to include compression moulding and transfer
moulding.
Effects of mixing and compounding.
Polymer met rheology and its importance in polymer processing.
Quantitative treatment of melt viscosity ( as a function of temperature and shear rates).

6. Manufacturing with polymer composites


Nature of polymer composites: thermoplastic and thermosetting polymer matrix
composites.
nature of unsaturated polyesther resin/glass composite systems
Lay-up techniques: to include contact, vacuum bag, pressure bag and autoclave
moulding
Matched die moulding
Spray-up
Filament winding
Injection moulding

Last Updated:July 13, 2017 LMS SEGi College 5


Assessment:

Lab reports 10%


Mid Term 10%
Assignment 10%

Final Exam 70% (2 hours)

Last Updated:July 13, 2017 LMS SEGi College 6