Engineering

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ECM3154 - Manufacturing (2019)

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MODULE TITLEManufacturing CREDIT VALUE15
MODULE CODEECM3154 MODULE CONVENERProf Christopher Smith (Coordinator)
DURATION: TERM 1 2 3
DURATION: WEEKS 11 weeks 0 0
Number of Students Taking Module (anticipated) 28
DESCRIPTION - summary of the module content

Fabrication of advanced materials and robotics are elements of the manufacture of the technology we use in our daily lives, such as aeroplanes and cars, so understanding these processes is vital to a mechanical or material engineers' training.
 

This module offers an advanced investigation of materials, applications and high-tech manufacturing systems; focussing mainly on composite laminates and robotics. You will learn to design a composite; using, for example, carbon fibres, to get the required properties. Furthermore, you will analyse aspects of robotics, from how this technology functions, to use of robots for industrial purposes.


Completing this module enables you to explain in detail how manufacturers create many advanced technology products, and how advanced manufacturing systems work. Finally, the module provides ideal preparation for pursuing a career in manufacturing or materials processing.


Prerequisite module: ECM2103 or equivalent


Corequisite module: ECM3160 or equivalent
 

AIMS - intentions of the module

This module is designed to give you examples of current practice in advanced manufacturing, concentrating on the technical issues and applications of the technologies. It is also intended to provide you with experience in considering the interrelationship between materials, applications, sustainability and the environment, and manufacturing technologies, and in the theoretical analysis of manufacturing processes. This is relevant to you if you are aiming for a manufacturing industrially related project and if you wish to pursue a career in manufacturing or materials processing.

 

INTENDED LEARNING OUTCOMES (ILOs) (see assessment section below for how ILOs will be assessed)

This is a constituent module of one or more degree programmes which are accredited by a professional engineering institution under licence from the Engineering Council. The learning outcomes for this module have been mapped to the output standards required for an accredited programme, as listed in the current version of the Engineering Council’s ‘Accreditation of Higher Education Programmes’ document (AHEP-V3).

 

This module contributes to learning outcomes: SM3p, SM3m, SM4m, SM6m, EA1p, EA1m, EA5m, D2p-D5p, D2m-D5m, ET2p, ET2m, ET4p, ET4m, EP2p, EP2m, EP4p, EP4m, EP8p, EP8m, G1p, G1m

 

A full list of the referenced outcomes is provided online: http://intranet.exeter.ac.uk/emps/subjects/engineering/accreditation/

 

The AHEP document can be viewed in full on the Engineering Council’s website, at http://www.engc.org.uk/

 

On successful completion of this module, you should be able to:

 

Module Specific Skills and Knowledge:
1 understand the uses of rapid prototyping(RP), robotics, lasers, and HERF, EDM, and water jet technologies in an industrial context;
2 select an appropriate RP solution for a given manufacturing application, manipulate matrices and perform complex coordinate transformations in robotics;
3 calculate fundamental laser power requirements for welding and cutting, and calculate water jet operating parameters;
4 comprehend the basics of composite manufacturing technologies;
5 apply classical laminate theories;
6 utilise fundamental mathematical tools and theories implicit in the application of robots, lasers, HERF technologies, water jet machining, and composites in manufacturing;
7 appreciate how new manufacturing processes and materials affect the environment.
 

Discipline Specific Skills and Knowledge:
8 demonstrate, given a typically limited background knowledge, enhanced ability to analyse manufacturing processes;
9 show, by studying examples and case studies, an increased awareness of manufacturing technological requirements;
10 exhibit a significant ability in determining the theoretical operating parameter values for a range of technologies;
11 reveal enhanced awareness of the impact of manufacturing technologies on the environment.
 

Personal and Key Transferable/ Employment Skills and  Knowledge:
12 illustrate a significant advance in your ability to seek out information and to learn independently;
13 exemplify an increased awareness of manufacturing technological requirements;
14 evidence a significant ability in determining the theoretical operating parameter values for a range of technologies.

 

SYLLABUS PLAN - summary of the structure and academic content of the module

- robotics: applications, types, consideration of working envelopes, performance: speed, accuracy and repeatability;

- structural design considerations, transmissions systems, encoding and encoders: moire fringe theory , Fresnel diffraction, scale/index grating gap calculation; 

- co-ordinate transformations, rotational matrices and translational movement combined, derivation of forward kinematics; 

- end effectors and tooling; 

- determination of gripper forces; 

- rapid prototyping: systems and applications, CAD and building systems, stereo lithography and Beer-Lambert's law, performance considerations, topical developments, sustainability; 

- lasers: applications in manufacturing with particular emphasis on welding, cutting and alignment;

- power calculation for spot welding, continuous welding, and cutting;

- laser gauging and size determination; 

- determination of power requirements;

- advanced composites: laminate design, classical laminate theory, large size composite manufacture, mould design and effects in properties, resin transfer moulding, hybrid composites, adhesives; 

- economic and sustainability drivers for composite use; 

- composites in manufacturing - a case study;

- powder technology: description of powder processing methods and comparison with alternative manufacturing processes. 

LEARNING AND TEACHING
LEARNING ACTIVITIES AND TEACHING METHODS (given in hours of study time)
Scheduled Learning & Teaching Activities 25.00 Guided Independent Study 125.00 Placement / Study Abroad 0.00
DETAILS OF LEARNING ACTIVITIES AND TEACHING METHODS
Category Hours of study time Description
Scheduled learning and teaching activities 20 Lectures
Scheduled learning and teaching activities 5 Tutorials
Guided independent study 125 Guided independent study

 

ASSESSMENT
FORMATIVE ASSESSMENT - for feedback and development purposes; does not count towards module grade
Form of Assessment Size of Assessment (e.g. duration/length) ILOs Assessed Feedback Method
       
       
       
       
       

 

SUMMATIVE ASSESSMENT (% of credit)
Coursework 30 Written Exams 70 Practical Exams
DETAILS OF SUMMATIVE ASSESSMENT
Form of Assessment % of Credit Size of Assessment (e.g. duration/length) ILOs Assessed Feedback Method
Written exam – closed book 70 2 hours - January Exam All None
Coursework – test 1 15 Maximum 1hour All Written
Coursework – test 2 15 Maximum 1 hour All Written
         

 

DETAILS OF RE-ASSESSMENT (where required by referral or deferral)
Original Form of Assessment Form of Re-assessment ILOs Re-assessed Time Scale for Re-reassessment
All above Written exam (100%) All August Ref/Def period
       
       

 

RE-ASSESSMENT NOTES

If a module is normally assessed entirely by coursework, all referred/deferred assessments will normally be by assignment.

If a module is normally assessed by examination or examination plus coursework, referred and deferred assessment will normally be by examination. For referrals, only the examination will count, a mark of 40% being awarded if the examination is passed. For deferrals, candidates will be awarded the higher of the deferred examination mark or the deferred examination mark combined with the original coursework mark.

RESOURCES
INDICATIVE LEARNING RESOURCES - The following list is offered as an indication of the type & level of
information that you are expected to consult. Further guidance will be provided by the Module Convener

ELE – http://vle.exeter.ac.uk

Reading list for this module:

Type Author Title Edition Publisher Year ISBN Search
Set Kalpakjian S Manufacturing Engineering and Technology 5th Addison-Wesley 2006 0131976397 [Library]
Set Callister, WD Materials Science and Engineering: an introduction 8th John Wiley & Sons 2007 978-0470505861 [Library]
Set Hull, Derek An introduction to composite materials 2nd CUP 1996 0521388554 [Library]
Set Halpin, John C. Primer on composite materials analysis 2nd Technomic 1992 0877627541 [Library]
Set Gay, D., Hoa, S.V.,Tsai, S.W. Composite Materials: Design and Applications CRC press 2007 9781420045192 [Library]
CREDIT VALUE 15 ECTS VALUE 7.5
PRE-REQUISITE MODULES ECM2103
CO-REQUISITE MODULES ECM3160
NQF LEVEL (FHEQ) 3 (NQF level 6) AVAILABLE AS DISTANCE LEARNING No
ORIGIN DATE Tuesday 10 July 2018 LAST REVISION DATE Tuesday 10 July 2018
KEY WORDS SEARCH Composite; laminate; classical laminate theory; powder metallurgy; manufacturing; sustainability; design; composite materials.