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.
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
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.
Supplementary/Reassessment: 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.
