Module: Manufacturing Processes 1

Module Specifications.

Current Academic Year 2024 - 2025

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Date posted: September 2024

Module Title	Manufacturing Processes 1
Module Code	MM252 (ITS) / MEC1010 (Banner)
Faculty	Engineering & Computing	School	Mechanical & Manufacturing Eng
Module Co-ordinator	David Kinahan
Module Teachers	Tamas Szecsi
NFQ level	8	Credit Rating	5
Pre-requisite	Not Available
Co-requisite	Not Available
Compatibles	Not Available
Incompatibles	Not Available

Coursework Only

Description

To introduce students to modern manufacturing processes; particularly milling, turning, and 3D printing. The course will address material removal and additive manufacturing processes and their application to produce various parts. The course will also cover basic computer numerical control (CNC) theory and operations and familiarise students with CNC machining operations.

Learning Outcomes

1. Develop a working understanding of advantages and disadvantages of a variety of modern manufacturing processes and acquire the ability to select the appropriate manufacturing method for an appropriate task (PO2, PO3, PO4, P08).
2. Develop the capability to use NC code from a solid design to generate a complex part. (PO2, PO3, PO4)
3. Understand and calculate basic parameters related to material removal processes (cutting force, cutting power, material removal rate, machining time) (PO2, PO3, PO4).
4. Demonstrate the capability to select optimum cutting tool geometry for metal cutting processes, and chose appropriate processes and cutting tools to generate various surfaces. (PO2, PO3, PO4)
5. Solve complex tasks related to manufacturing processes in a group environment. (PO2, PO3, PO4, PO5, PO6, PO7, PO8)
6. Use of presentation skills to convey project outcomes in a clear and technically accurate manner. (PO2, PO3, PO4, PO5, PO6, PO7, PO8)

*Type*	*Hours*	*Description*
Workload	Full-time hours per semester
Lecture	24	No Description
Laboratory	6	No Description
Tutorial	12	No Description
Total Workload: 42

All module information is indicative and subject to change. For further information,students are advised to refer to the University's Marks and Standards and Programme Specific Regulations at: http://www.dcu.ie/registry/examinations/index.shtml

Indicative Content and Learning Activities

Subtractive manufacture / material removal
Orthogonal metal cutting model. Cutting angles, cutting forces and power, cutting temperature, cutting fluids, cutting tool wear, cutting tool materials.

Kinematics of subtractive manufacture / material removal
shaping, turning, milling, drilling, grinding, broaching, sawing. Parameters of basic metal cutting operations: kinematics of chip formation, cutting tool geometry, cutting conditions.

Machining of various shapes
holes, flat surfaces, contoured surfaces, threads, gears.

Additive Manufacture
3D printing technologies, photo-stereolithography, fused deposition modelling, selective laser sintering, robocasting, laminated object manufacture, inkjet printing

Computer Numerical Control (CNC)
CAD/CAM software; G-code; post-processors; co-ordinate systems, precision and accuracy, multi-axis (5-axis) machining

Assessment Breakdown
Continuous Assessment	100%	Examination Weight	0%

Type	Description	% of total	Assessment Date
Course Work Breakdown
Group project	Solving an engineering problem related to manufacturing processes in a group environment (Gear Formation)	20%	Once per semester
Group project	Solving an engineering problem related to manufacturing processes in a group environment (NC Milling)	20%	Once per semester
Group presentation	Group presentation on an assigned manufacturing process (online).	20%	Once per semester
Loop Quiz	Multiple Choice Quiz (4 x 10% each). Last 4 weeks of semester.	40%	As required

Reassessment Requirement Type
Resit arrangements are explained by the following categories: Resit category 1: A resit is available for both* components of the module. Resit category 2: No resit is available for a 100% continuous assessment module. Resit category 3: No resit is available for the continuous assessment component where there is a continuous assessment and examination element.
* ‘Both’ is used in the context of the module having a Continuous Assessment/Examination split; where the module is 100% continuous assessment, there will also be a resit of the assessment
This module is category 1

Indicative Reading List

S. Kalpakjian: 1995, Manufacturing Engineering and Technology, 3,
E.P. DeGarmo: 1988, Materials and Processes in Manufacturing, Prentice Hall,
M.P. Groover: 2002, Fundamentals of Modern Manufacturing, 2, John Wiley & Sons,
JC Horvath: 2014, Mastering 3D printing,
F. Nanfara, D. Murphy, T. Uccello: 1999, The CNC workshop: a multimedia introduction to computer numerical control,

Other Resources

None