Course Title: Set up manufacturing processes for engineering applications

Part B: Course Detail

Teaching Period: Term2 2012

Course Code: MIET7503

Course Title: Set up manufacturing processes for engineering applications

School: 130T Vocational Engineering

Campus: City Campus

Program: C6069 - Advanced Diploma of Engineering Technology

Course Contact: Program Manager

Course Contact Phone: +61 3 9925 4468

Course Contact Email: engineering-tafe@rmit.edu.au


Name and Contact Details of All Other Relevant Staff

George Zouev
Mechanical Engineering, Level 5, Bldg 57.
Email: george.zouev@rmit.edu.au
Phone: +61 3 9925 4935

Frank (Yanan) Wang
Mechanical Engineering, Level 5, Bldg 57.
Email: yanan.wang@rmit.edu.au
Phone: +61 3 9925 4310

Daniela Achim
Level 5, Bldg 57.
Email: daniela.achim@rmit.edu.au
Phone: +61 3 9925 4523

Nominal Hours: 40

Regardless of the mode of delivery, represent a guide to the relative teaching time and student effort required to successfully achieve a particular competency/module. This may include not only scheduled classes or workplace visits but also the amount of effort required to undertake, evaluate and complete all assessment requirements, including any non-classroom activities.

Pre-requisites and Co-requisites

It is recommended the the learners attempting this unit have the required knowledge and skill as described in:

VBP263: Apply Basic Principles of Material Science to Engineering Applications
VBP264: Apply Advanced Principles of Material Science to Engineering Applications

Course Description

This unit covers the skills and knowledge required to select and set up principal methods of manufacturing in the manufacturing industry, including bulk metal forming operations, fabrication, powder metallurgy, machining, computer numerical control, manufacturing automation, non-traditional manufacturing, lean and sustainable manufacturing.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication. However, practice in this unit is subject to regulations directly related to occupational health and safety and where applicable contracts of training such as apprenticeships and traineeships.

This unit of competency is intended for courses at diploma or higher levels.


National Codes, Titles, Elements and Performance Criteria

National Element Code & Title:

VBP250 Set up manufacturing processes for engineering applications

Element:

1. Identify principal engineering processes within the manufacturing industry

Performance Criteria:

1.1 OH&S and environmental requirements for a given work area are obtained and understood.
1.2 Established OH&S requirements and risk control measures and procedures in preparation for the work area are followed.
1.3 Safety hazards which have not previously been identified are documented and risk control measures devised and implemented in consultation with appropriate personnel.
1.4 The materials testing and evaluation task requirements are determined through documentation, job sheets and through discussion with appropriate personnel.
1.5 Expert advice is sought with respect to the materials science task and according to enterprise procedures where appropriate.
1.6 Appropriate personnel are consulted to ensure the work is co-ordinated effectively with others involved at the work site.
1.7 Resources and equipment needed for the task are obtained in accordance with enterprise procedures and checked for correct operation and safety.

Element:

2. Select engineering processes for specified manufacturing applications

Performance Criteria:

2.1 OH&S requirements for carrying out the work are followed.
2.2 Safety hazards which have not previously been identified are documented and risk control measures devised and implemented in consultation with appropriate personnel.
2.3 The materials testing and evaluation is undertaken according to enterprise procedures.
2.4 The most appropriate materials testing and evaluation methodology is chosen for given task.
2.5 Decisions for dealing with unexpected situations are made from discussions with appropriate personnel, job specifications and enterprise procedures.
2.6 Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

Element:

3. Implement selected engineering processes

Performance Criteria:

3.1 OH&S requirements for completing the work are followed.
3.2 Documentation associated with materials testing and evaluation task is prepared according to enterprise procedures.
3.3 Documentation associated with the materials testing and evaluation task is controlled and correct revision levels are assigned.
3.4 The completion of the materials testing and evaluation task is notified and outcomes are discussed with appropriate personnel.


Learning Outcomes


1. Planning

  • sequencing operations
  • identifying factors influencing process selection
  • materials and process preparation
  • properties and characteristics of materials and consumables
  • identifying and clarifying application requirements
  • identifying specifications and required resources
  • reviewing and revising outcomes against task objectives and requirements
2. Communication
  • researching and interpreting information and specifications
  • categorising manufacturing methods
  • developing enterprise procedures
  • calculations relating to engineering processes within the scope of this unit
  • accessing and using information sources using a variety of methods
  • use of equipment suppliers’ printed data and websites
  • accessing and using alternative information sources
  • documenting of methods, processes & construction techniques and manufacturing requirements
3. Engineering processes
  • applications, features and principles of engineering processes
  • advantages and disadvantages of engineering processes
Processes include:
  • Forming
  • Casting
  • Sand
  • Die
  • Shell
  • Continuous
  • Investment
  • Permanent mould
  • Forging
  • Drop
  • Press
  • Rolling
  • Drawing
  • Extrusion
  • Direct
  • Indirect
  • Impact
  • Pressworking
  • Basic types of presser
  • Blanking
  • Piercing
  • Bending
  • Deep drawing
  • Powder Metallurgy
  • Powders
  • Forming methods
  • Sintering
  • Hot pressing
  • Finishing
  • Economics
  • Automatic Lathes
  • Copying
  • Single spindle turret
  • Multi-spindle
  • Sliding head (Swiss)
  • Plugboard
  • Economics
  • Grinding
  • Surface
  • Horizontal and vertical spindle
  • Reciprocating and rotating table
  • Cylindrical
  • Centreless
  • External
  • Internal
  • CNC
  • Principles of control
  • Machines and axes
  • Turning machines
  • Machining centres
  • Applications to manufacturing cells and FMS
4. Engineering process selection
  • scientific principles relevant to engineering processes
  • applying scientific principles in the choice of methods, processes & construction techniques
  • the provision for particular materials properties in the choice of methods, processes & construction techniques
  • factors affecting process selection
  • the suitability of application to particular continuous, mass, batch, jobbing shop, sequential or cellular manufacture and assembly
  • identifying and considering materials properties in the choice of methods, processes & construction techniques
  • regulations, standard procedures and MSDS specifications
  • manufacturing requirements
5. Manufacturing processes
  • selecting methods, processes and construction techniques suitable for continuous, mass, batch or jobbing shop production, work cell or sequential manufacture and assembly
  • applications suitable for a range of materials handling techniques
  • principles of TQM, JIT and Competitive (lean manufacturing)
  • requirements of TQM, JIT and Competitive (lean manufacturing) environments
  • calculations and assumptions for processes & construction techniques choices
  • materials handling processes and procedures


Details of Learning Activities

Students will participate in a variety of learning methods including: lectures, tutorials,practicals, class discussion, group/individual work on projects, and interaction with individuals and groups as required.


Teaching Schedule

Please note: while your teacher will cover all the materials in the schedule, the weekly teaching and assessment order is subject to change depending on class needs and availability of resources.Students are required to self study the learning materials for the hours not scheduled in teaching schedule.
Week Topic Content Delivery Including Learning activities Performance Criteria Assessment task
 

Week 1 Introduction to Manufacturing

 

  • Definition of Manufacturing
  • Materials and Processes used in Manufacturing
  • Development of Manufacturing

Class activity: Introduction to Manufacturing. Discussion on the manufacturing cycle from concept to output.
Video: Introduction to Manufacturing
Elements: 1, 2, 3
Assignment scheduled for session 6
Engineering Materials Used in Manufacturing

  • Metals

Plain Carbon Steel
Alloy Carbon Steel
HSLA Steel
Stainless Steels
Cast Irons
Titanium
Aluminium Alloys
Copper Alloys
Powdered Metals
Nickel Alloys
Super Alloys

  • Non-metals
  • Engineering Plastics
  • Elastomers
  • Advanced Composites
  • Ceramics

Class activity: Discussion focusing on the primary materials utilised in mainstream manufacturing.
Tutorial chapter 2 questions,
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Elements: 1,2,3 Assignment scheduled for session 6

Week 2-3 Forming Technologies

  • Casting

Sand
Die
Shell
Continuous
Investment
Permanent Mould

  • Forging

Drop
Press
Upset

  • Rolling
  • Drawing

Deep
Wire

  • Extrusion

Direct
Indirect
Impact

  • Press-working

Blanking
Piercing
Bending
Deep Drawing

  • Explosive forming
  • Spinning
  • Powder metallurgy

Class activity: Discussion on Wrought Forming Technologies.
Distinguishing hot and cold working attributes and limitations. Preparation of metals.
Grain structure, formation, growth, refinement and recrystallisation
Videos:
Casting
Rolling
Extrusion
Drawing
Forging
Press working
Explosive forming
Powder metallurgy
Case studies.
Tutorial chapter 3 questions and
Tutorial chapter 4 questions:
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Visit to RMIT TAFE Engineering workshop 57-01-01
Elements: 1, 2, 3
Assignment scheduled for session 6

Week 4 Surface Texture as Applied to Manufacturing Processes

  • Drawing Symbols
  • Surface Roughness Applications

Class activity: Discussion on surface texture as developed by manufacturing process.
Case studies.
Elements: 1, 2, 3
Mid semester test scheduled for session 6

4 Orthogonal Machining

  • Introduction
  • Fundamentals
  • Turning
  • Boring
  • Facing
  • Parting
  • Drilling
  • Reaming
  • Knurling
  • Lathe Design and Terminology
  • Automatics Lathes
  • Drilling machine and tooling
  • Milling Machines and tooling

Class activity: Discussion on Machining and cutting tools.
Video: Machining principles, cutting tools
Case studies
Visit to RMIT TAFE Engineering workshop 57-01-01
Tutorial chapter 7 questions:
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Elements: 1, 2, 3
Assignment scheduled for session 6

Week 5 Abrasive Machining

  • Processes
  • Principles
  • Abrasives
  • Grain size and Geometry
  • Wheel Structure and Grade
  • Bond Strength
  • Dressing
  • Geometry
  • Cutting Fluids
  • Grinding Machines
  • Surface

Horizontal and Vertical Spindle
Reciprocating and Rotating Table

  • Cylindrical
  • Centreless

Internal
External

  • Mounted Wheels
  • Coated Abrasives
  • Honing
  • Lapping
  • Super Finishing

Class activity: Discussion on Abrasive machining processes and tools.
Video: Abrasive machining processes
Case studies
Visit to RMIT TAFE Engineering workshop 57-01-01
Tutorial chapter 8 questions:
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Elements: 1, 2, 3
Assignment scheduled for session 6

Week 5-6 Manufacturing Automation

  • Introduction
  • Levels of Automation
  • Feedback and control
  • Computer Numerical Control
  • CNC Applications to Manufacturing Cells and Flexible
  • Manufacturing Systems
  • Robotics

Configurations
Applications


Class activity: Discussion on Manufacturing Automation, FMS and Robotics.
Video: CNC and FMS systems
Case studies.
Tutorial chapter 9 questions:
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Elements: 1, 2, 3
Assignment scheduled for session 6

6 Assignment Elements: 1, 2, 3 Assignment for weeks 1-4

Week 7 Non-Traditional Manufacturing

Rapid Prototyping
Lean Manufacturing (TQM, JIT)

  • Non-traditional machining
  • Chemical machining processes
  • Photochemical machining
  • Design factors
  • Mechanical non-traditional processes Ultrasonic

Waterjet
Abrasive waterjet cutting
Abrasive waterjet machining
Abrasive flow machining

  • Thermal Non-Traditional Machining processes

Electrical Discharge machining
Wirecut EDM
Particle Beam Machining
Laser Beam Machining
Plasma beam cutting

  • Rapid Prototyping
  • Lean Manufacturing

Principles of Total Quality Management
Just in Time
Six Sigma

Class activity: Discussion on Non-traditional manufacturing: Chemical, Electrochemical, Mechanical and Thermal systems.
Video: Non-traditional Machining
Case studies.
Tutorial chapter 10 questions:
Set Up Manufacturing Processes for Engineering Applications, RMIT Press
Elements: 1, 2, 3
End semester test scheduled for session 10

Week 8 Planning and Communication

  • Process selection and suitability of process for applications in manufacturing
  • Sequencing operations
  • Documentation, researching and identifying specifications for manufacturing requirements

Class activity: Discussion on planning and communication of manufacturing processes.
Case studies.
Tutorial: Process selection, sequencing
Elements: 1, 2, 3
End semester test scheduled for session 10

Week 9 OH&S Requirements

  • Legislation
  • Protective equipment
  • Material safety management systems
  • Hazardous substances and dangerous goods code
  • Local safe operation procedures

Class activity: Discussion and Video on OH&S considerations as part of the selection process.
Case studies.
Tutorial: OH&S implementation.
Elements: 1, 2, 3
End semester test scheduled for session 10

Week 10 Unit Competency Test

Elements: 1, 2, 3
This is an closed book test

 


Learning Resources

Prescribed Texts

MIET7503 (VBP250) Set Up Manufacturing Processes for Engineering Applications, RMIT Press, available from RMIT Bookshop


References

Fundamentals of Modern Manufacturing, M. P. Groover, John and Wiley & Sons
Manufacturing Engineering and Technology, Kalpakjian, Steven R Schmid, Prentice Hall,
Exploring Advanced Manufacturing Technologies, Steve Krar, Arthur Gill, Industrial Press
Manufacturing processes Reference Guide, Robert H Todd, Dell K, Industrial Press Inc
Machinery’s Handbook, Industrial Press Inc
Materials and Processes in Manufacturing, DeGarmo et al, Wiley
Engineering Drawing, Boundy, McGraw-Hill
Materials Science and Engineering, an Introduction; 7th Edition. William D. Callister, Jr. John Wiley & Sons – Publisher,


Other Resources

Student resource S drive and Blackboard:
S:\Mechanical & Manufacturing Students\MIET7503 (VBP250) Set Up Manufacturing Processes for Engineering Applications


Overview of Assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit:

  • demonstrate essential knowledge and skills as described in this unit;
  • demonstrate a representative body of performance criteria within a timeframe typically expected of the discipline, work function and industrial environment;
  • demonstrate the ability to select and set up principal methods of manufacturing in the manufacturing industry on more than one occasion and in different contexts.
This includes identifying and discussing engineering methods, processes and construction techniques suitable for continuous, mass, batch or jobbing shop production, work cell or sequential manufacture and assembly;
and selecting and implement engineering processes for specified manufacturing applications based on functional specifications and other factors affecting the selection decision.

Assessment may incorporate a variety of methods including written/oral activities and demonstration of practical skills to the relevant industry standards. Participants are advised that they are likely to be asked to personally demonstrate their assessment acitvities to their teacher/assessor. Feedback will be provided throughout this course. Evidence of the student’s competance can be gathered through a variety of methods, including:
  • observation of processes and procedures
  • oral and/or written questioning on required knowledge and skills
  • testomony from supervisors, clients and/or other appropriate personnel
  • inspection of the final product or outcome
  • a portfolio of documentary evidence
Graded assessment out of 100 marks will be based on practical activities, asssignments, reports, tests and/or written/oral examinations

Candidates must gain a pass in all the components of the assessment/s in order to pass this competency.


Assessment Tasks

Assessment 1 – Assignment

This assessment will focus on your ability to: 1. Identify principal engineering processes within the manufacturing industries, 2. Select engineering processes for specified manufacturing applications, and 3. Implement selected engineering processes
It will require you utilise the underpinning skills and knowledge that has been demonstrated in the previous 4 sessions in your classroom and visit. You will be required to identify appropriate manufacturing processes for engineering applications, describe the classification of processes, compare and prioritise the processes suitable for manufacturing and describe the factors that influence those choices to adequately demonstrate this competency’s elements.
The assignment consists of multiple choice and short answer questions and you will be required to select and identify the most appropriate manufacturing process applicable to an engineering design.
This assignment will have a weighting of 40% of the final overall assessment mark and will be based on the first four weeks of this course as indicated in the teaching schedule.
 

Assessment 2 – End of Term Test (closed book)

This assessment will focus on your ability to: 1. Identify principal engineering processes within the manufacturing industries, 2. Select engineering processes for specified manufacturing applications, and 3. Implement selected engineering processes
It will require you utilise the underpinning skills and knowledge that has been demonstrated in the previous 4 sessions in your classroom and visit following the mid term test. You will be required to identify appropriate manufacturing processes for engineering applications, describe the classification of processes, compare and prioritise the processes suitable for manufacturing and describe the factors that influence those choices to adequately demonstrate this competency’s elements.
The test consists of multiple choice and short answer questions and you will be required to select and identify the most appropriate manufacturing process applicable to an engineering design.
This test will have a weighting of 60% of the final overall assessment mark and will be based on the second period of four weeks of this course as indicated in the teaching schedule. This test does not reassess any of the course material previously assessed in Assessment 1.

 


Assessment Matrix

Competency / ModuleAssessment 1 40%Assessment 2 60%
Performance Element 1YESYES
Performance Element 2YESYES
Performance Element 3YESYES

Other Information

Please note: while your teacher will cover all the material in the above schedule, the weekly teaching and assessment order is subject to change depending on class needs and availability of resources.

Study and learning Support:

Study and Learning Centre (SLC) provides free learning and academic development advice to you.
Services offered by SLC to support your numeracy and literacy skills are:

assignment writing, thesis writing and study skills advice
maths and science developmental support and advice
English language development

Please Refer http://www.rmit.edu.au/studyandlearningcentre to find more information about Study and learning Support

Disability Liaison Unit:

If you are suffering from long-term medical condition or disability, you should contact Disability Liaison Unit to seek advice and support to complete your studies.

Please Refer http://www.rmit.edu.au/disability to find more information about services offered by Disability Liaison Unit

Late submission:

If you require an Extension of Submittable Work (assignments, reports or project work etc.) for 7 calendar days or less (from the original due date) and have valid reasons, you must complete and lodge an Application for Extension of Submittable Work (7 Calendar Days or less) form and lodge it with the Senior Educator/ Program Manager.

The application must be lodged no later than one working day before the official due date. You will be notified within no more than 2 working days of the date of lodgement as to whether the extension has been granted.

If you seek an Extension of Submittable Work for more than 7 calendar days (from the original due date) must lodge an Application for Special Consideration form under the provisions of the Special Consideration Policy, preferably prior to, but no later than 2 working days after the official due date.

Submittable Work (assignments, reports or project work etc.) submitted late without approval of an extension will not be accepted or marked.


Special consideration:

Please Refer http://www.rmit.edu.au/browse;ID=riderwtscifm (unresolved) to find more information about special consideration

Plagiarism:

Plagiarism is a form of cheating and it is very serious academic offence that may lead to expulsion from the University.

Please Refer: www.rmit.edu.au/academicintegrity  to find more information about plagiarism.

Other Information:

All email communications will be sent to your RMIT email address and you must regularly check your RMIT emails.

 

Course Overview: Access Course Overview