Course Details in 2022/23 Session
|Module Title ||LM Research and Application of Machining Processes (RAMP)|
|School||School of Engineering|
|Department || Mechanical Engineering|
|Module Code || 04 33342 |
|Module Lead ||Dr Richard Hood|
|Level || Masters Level |
|Credits || 20 |
|Semester|| Semester 2|
|Restrictions || None |
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.
- 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
- Hybrid machining approaches (electrolytic grinding, ultrasonic assisted processes etc.)
- Creep feed / VIPER grinding including case studies
- Micro machining relating to HSM and EDM
- 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.
- 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
|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.
33342-01 : Module Mark : Mixed (100%)
|Assessment Methods & Exceptions || Assessments:|
(50%) Part A: 2-hour closed book centrally timetabled exam in May/June assessment period (replaced by online assessment if closed book exam not possible).
(50%) Part B: Continuous assessment, comprising a Manufacturing Report.
Part A and Part B carry equal weighting in the overall assessment.
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.
Reassessment will only apply for the failed component. The mark will be carried forward for the passed component.
|Other || |