Programme And Module Handbook
 
Course Details in 2020/21 Session


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Module Title LM Research and Application of Machining Processes (RAMP)
SchoolSchool of Engineering
Department Mechanical Engineering
Module Code 04 33342
Module Lead Dr Richard Hood
Level Masters Level
Credits 20
Semester Semester 2
Pre-requisites
Co-requisites
Restrictions None
Contact Hours Lecture-26 hours
Tutorial-9 hours
Practical Classes and workshops-5 hours
Guided independent study-160 hours
Total: 200 hours
Exclusions
Description Part A: Research and Development:

The aim of part A of the module is to give students an appreciation of recent research developments and acquaint them with the latest manufacturing process/technology results applicable to a range of industries, not least the aerospace sector. In addition to standard lectures, a practical laboratory session is incorporated to demonstrate various workpiece surface integrity evaluation techniques.

SYLLABUS

  • Machining of advanced workpiece materials (tool life, workpiece roughness / integrity, operational features)
  • Advanced titanium and nickel-based superalloys including shape memory alloys
  • Carbon fibre composites and multilayer stacks
  • New machining technologies
  • Point grinding
  • Hybrid machining approaches (electrolytic grinding, ultrasonic assisted processes etc.)
  • ED dressing and ELID
  • Creep feed / VIPER grinding including case studies
  • Micro machining relating to HSM and EDM
  • Minimum damage WEDM
  • Process modelling
  • Cutting processes (2D/3D including associated work on surface integrity modelling)
  • Practical laboratory involving workpiece surface integrity assessment of machined surfaces (e.g. surface roughness, microhardness, microstructure alteration etc.)


Part B: Application:

The aim of Part B of the module is to consider the specific programming strategies, tooling, data acquisition and control technologies to support modern machining systems.

SYLLABUS

  • Design for manufacture
  • Computer aided manufacture (CAM) versus conversational programming
  • Automatic machining algorithms
  • Tool and part probing integration
  • Closed-loop machining versus adaptive control strategies and condition monitoring
  • High-speed machining concepts
  • 3 axes versus 5 axes machining strategies
  • Metrology and geometrical accuracy inspection
  • Statistical process control and six sigma
  • Practical demonstration
Learning Outcomes By the end of the module students should be able to:

  • Demonstrate a comprehenisve knowledge and awareness of recent developments and research in advanced material removal processes and related technology.
  • Understand and crtically evaluate the underlying mechanisms and principles for a wide range of advanced machining processes and their influence on component / surface integrity and functionality.
  • Demonstrate a thorough understanding of the limitations of current industry standard manufacturing operations used for high value aerospace components and the advantages of recently developed process technologies.
  • Demonstrate an extensive knowledge and understanding of the machinability of a range of advanced, difficult to cut materials.
  • Demonstrate an understanding and appreciation of the importance of machined workpiece surface integrity and associated assessment / measurement techniques.
  • Demonstrate a comprehensive knowledge of and critically evaluate the effect of design practice for machined components
  • Demonstrate a comprehensive knowledge and understanding of the generation procedure for machining part programs from basic NC coding through to complex programming using advanced CAM software.
  • Demonstrate a comprehensive knowledge and understanding of automated systems such as on machine probing, tooling, fixturing etc. and adaptive strategies.
  • Demonstrate a comprehensive knowledge of and critically evaluate the use of five axis machining strategies.
  • Demonstrate a comprehensive knowledge and understanding of the use of metrology including surface finish/texture, GD&T and procedures and processes for evaluation
  • Demonstrate knowledge and understanding of the basics of statistical process control for ensuring conformance and monitoring of processes.
Assessment
Assessment Methods & Exceptions Assessment: Part A: One 2 hour formal written unseen examination to be held during the University's main summer examination period (50%). Part B: Continuous assessment, comprising a Manufacturing Report (50%). Part A and Part B carry equal weighting in the overall assessment.

Reassessment: Reassessment will normally only be allowed for students on the following programmes:

9757 MSc Advanced Mechanical Engineering 9758 PG Diploma Advanced Mechanical Engineering 9759 PG Certificate Advanced Mechanical Engineering 222A MSc Advanced Mechanical Engineering (PT)

Reassessment will only apply for the failed component. The mark will be carried forward for the passed component.

One 2-hour formal written examination (50%) to be held during the University's supplementary examination period and/or assessment of coursework (50%), as relevant.
Other
Reading List