Coursecode: wb5181
Coursename: Manufacturing 1

DUT creditpoints: 2,5
ECTS creditpoints: 4
Faculty of Mechanical Engineering and Marine Technology
Lecturer(s): Buiting-Csikós, ir. Cs., Luttervelt, ir. C.A. van

Tel.: 015-2783300
Catalog data:
Casting, Forming, Cutting, Quality assurance, Machine-tools & Automation, Process planning, Cost calculation, Design for Manufacturing.

Courseyear: IO1
Semester: 0/0/0/4/0/0
Hours p/w: 4
Other hours: 3 (exercise)
Assessment: Written
Assessm.period(s): 4,5
(see academic calendar)
Prerequisites: ide100, ide140, ide141, mk65
Follow up: ide242
Detailed description of topics:
  • Introduction: survey of manufacturing processes, economics, environmental aspects.
  • Casting: mold making in sand, design aspects.
  • Forming: manufacturing properties of materials, massive deformation (rolling, forging, extrusion, drawing), dies/tools & machines.
  • Cutting: fundamentals, tools & tool materials, processes (turning, hole making, milling, grinding, finishing).
  • Quality: metrology, quality assurance.
  • Machine-tools, mechanization and flexible automation.
  • Process planning: macro/micro process planning, fixturing, process selection and sequencing.
  • Cost calculation.
  • Design for Manufacturing.
Course material:
  • H.J.J. Kals, C.A. van Luttervelt, K.A. Moulijn, Industriële produktie (Industrial Production), 1996, Middelburg, De Vey Mestdagh, ISBN 90 6376 0582.
References from literature:
  • Kalpakjian, S., Manufacturing Engineering and Technology, Addison-Wesley, ISBN 0-201-53846-6, 1995.
  • Reijers, L.N., De Haas, H.J.L.M., Flexibele Produktie Automatisering (Flexible Production Automation), De Vey Mestdagh, part 1: ISBN 90-6376-037x, 1991, part 2: ISBN 90-6376-0329, 1990, part 3: ISBN 90-6376-0264, 1989.
Final terms:
This course, focussed on manufacturing processes, is given in the first year of the study industrial design engineering.
It gives an overview of various basic manufacturing processes (sand casting, forming, cutting) with their possibilities and limitations. Attention is paid to the engineering of manufacturing processes regarding quality assurance, dies & tools, machine-tools, process planning and cost calculation. The course ends with aspects of design for manufacturing (DFM).
With all this knowledge over process and material parameters a design engineer should be able to make a first, rough decision about his design approach, whether to cast, to form or to cut out of a block. He would be aware of the influence of the material properties, the product shape and batch size on the selection of the manufacturing process.
There are follow up courses in the second and the third year with more information about the processes and the industrial production.
As a goal can be stated that a design engineer would be able to communicate with production engineers in order to obtain designs which can be realised without too high manufacturing costs.

Remarks (specific information about assesment, entry requirements, etc.):

  • There are three instructions in small groups, focussed on 1. Sand casting, 2. Cutting, 3. Process planning.
  • There is an additional lecture a few days before the examination where students can ask questions.
Goals:
Knowledge of the various manufacturing processes and the corresponding terminology. Knowledge of process planning and solution of simple process planning problems.
Insight into process and material parameters, constraints to the design. Awareness of the influence of material properties, product shape and batch size on the selection of manufacturing processes. Relation between design and manufacturing.
Computer use:

The course is supported by computer aided learning: there are computer exercises available to learn to solve process planning problems.
Laboratory project(s): -
Design content:

The course provides basic manufacturing knowledge to obtain designs which can be realised without too high manufacturing costs.
Percentage of design: 50%