Course Details in

Module Title	Process Modelling
School	School of Engineering
Department	Mechanical Engineering
Module Code	04 23818
Module Lead	Dr. Khamis Essa
Level	Masters Level
Credits	10
Semester	Semester 1
Pre-requisites
Co-requisites
Restrictions	None
Contact Hours	Lecture-8 hours Seminar-2 hours Tutorial-10 hours Guided independent study-80 hours Total: 100 hours
Exclusions
Description	The aim of the module is to analyse the theoretical and practical aspects of process modelling using proprietary software for the modelling of a wide range of manufacturing processes. The module will cover the differences between the different numerical techniques available (FEM, FVM, FDM etc.) as well as knowledge based systems. Other topics covered will include: the influence of geometry and meshing, the relationship between the physics of processes and process parameters and defect predictions and the influences of boundary conditions, thermo-physical and other property data. The processes presented will include casting (e.g. investment) orthogonal cutting, hot isostatic pressing and metal forming processes (e.g. forging, slab rolling, deep drawing, spinning and incremental forming). Practical experience will be given on at least two software programs and the student will be expected to complete an assignment which will involve process and / or geometry design changes to improve a product taking into consideration cost implications Differentiate between FE and FV/FD techniques Understand the role of process modelling Understand that there are limitations to process modelling. Understand the influence of process control on process modelling Use commercial FE software to model and simulate a manufacturing process Understand the importance of thermophysical data Understand the problems of length scale in process modelling.
Learning Outcomes	By the end of the module the student should be able to: Demonstrate a comprehensive knowledge and understanding of mathematical and computer models relevant to process modelling for a wide range of manufacturing processes. Demonstrate a comprehensive awareness of developing technologies related to process modelling for a wide range of manufacturing processes. Extract and critically analyse data pertinent to an unfamiliar process modelling problem, and apply its solution using computer based engineering tools when appropriate. Apply mathematical and computer-based models for solving problems in manufacturing processes and assess the limitations of particular cases. Develop a numerical model for an actual manufacturing technology related to mechanical engineering. Demonstrate a comprehensive knowledge and understanding of the theoretical and practical aspects of process modelling using proprietary software for the modelling of a wide range of manufacturing processes.
Assessment	23818-01 : Presentation : Presentation (30%) 23818-02 : Case Study Report : Coursework (70%)
Assessment Methods & Exceptions	Assessment: 100% continuous assessment, comprising: Case Study report (70%) and Presentation (30%) Reassessment: Written assessment (100%) to be submitted during the University’s supplementary examination period.
Other	None
Reading List	Zienkiewicz, O.C. and Taylor, R.L. ¿The Finite Element Method¿, 5th Edition, Vols 1,2 and 3, Butterworth-Heinemann, Oxford, 2000; Sahm, P. R. - Numerical simulation and modelling of casting and solidification processes Zurich : International Committee of Foundry Technical Associations, 1984; Holman, J. P., Jack Philip, 1934-. - Heat transfer / J.P. Holman. - 7th ed. - New York; London :McGraw-Hill, 1990; Fox, Robert W. (Robert William), 1934-. - Introduction to fluid mechanics / Robert W. Fox, Alan T. McDonald. - 4th ed. - New York; Chichester : John Wiley, 1994;