Programme And Module Handbook
Course Details in 2022/23 Session

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Module Title LM Advanced Manufacturing
SchoolSchool of Engineering
Department Mechanical Engineering
Module Code 04 33330
Module Lead Dr Khamis Essa
Level Masters Level
Credits 20
Semester Semester 1
Restrictions None
Contact Hours Lecture-16 hours
Seminar-2 hours
Tutorial-14 hours
Project supervision-6 hours
Demonstration-6 hours
Guided independent study-156 hours
Total: 200 hours
Description The aim of the module is to expose students to the modelling of manufacturing processes and also to introduce them to laser-based manufacturing technologies. The first part will cover the generic aspects in modelling a wide range of advanced manufacturing processes while the second part will mainly focus on enhancing the students’ knowledge and understanding in the field of laser material processing and its integration into application specific manufacturing platforms/machines. A good programming knowledge (e.g. Matlab or any other coding software) is an essential pre-requisite for the study of this module.


The first part of the module will cover the differences between the different numerical techniques available (FEM, FVM, FDM etc.). 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 modelling aspects of advaced manufacturing technologies that will be covered include metal removal (machining), powder metallugy (hot isostatic pressing), sheet forming (rolling, deep drawing), bulk forming (closed die forging and bi-metallic forming) and casting (investment casting).

The second part of module will provide the necessary ability to design and implement laser-based manufacturing solutions by applying theoretical, modelling and practical knowledge about the fundamentals of laser-material interactions, process monitoring, component technologies/systems of laser-based manufacturing platforms and application specific implementations of different machine configurations and beam delivery systems. The practical skills covered includes: laser-based manufacturing fundamentals (laser phenomena and principals, classification of laser sources and factors affecting laser-material interactions; process design, monitoring and modelling; classification of laser-based manufacturing processes; component technologies/systems for laser-material processing); laser-based additive manufacturing platforms (classification, manufacturing workflow, data preparation, layer-based processing of liquid polymers, discrete particles and sheets, machine design and implementation, process optimisation issues, applications); laser-based subtractive manufacturing platforms (classification, machine configurations, beam delivery systems, process design, monitoring and optimisation, CAD/CAM solutions, machining strategies, applications).
Learning Outcomes By the end of the module students 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 and heat transfer.
  • Demonstrate awareness and understanding in modelling and implementing manufacturing technologies.
  • Extract and critically analyse data pertinent to an unfamiliar process modelling problem, and apply its solution using computer based engineering tools when appropriate.
  • Develop a numerical model for an actual manufacturing technology related to mechanical engineering.
  • Demonstrate a comprehensive knowledge and understanding of developing laser-based manufacturing solutions related to mechanical engineering.
  • Use fundamental knowledge to study, investigate and critically evaluate laser-based manufacturing solutions/platforms.
  • Generate an innovative design of a laser-based manufacturing system to fulfil new needs and products’ technical requirements.
  • Demonstrate a thorough understanding of current practice and critically evaluate its limitations in laser material processing and identify new practices.
Assessment 33330-01 : Module Mark : Mixed (100%)
Assessment Methods & Exceptions Assessment:
(40%) A case study, end of module assessment
(35%) A process modelling group presentation (recorded group presentation), end of semester 1
(25%) Online test on laser processing fundamentals

Reassessment to match the main assessment method with due consideration made to any restrictions imposed at the time of reassessment. Students can carry forward passed assessment components from main assessment.
Reading List