ES3A8 Design for Manufacture

Module Leader: Dr J. Wallbank

Co-lecturer: Dr K. Neailey

Module Information

Scope

This 15 CATS module is one of the third year modules for:

Core:	Optional:
Automotive Engineering Manufacturing and Mechanical Engineering	Engineering Engineering Business Management

Aims

To establish the detailed links between design, material, behaviour and process limitations with a view to ensuring design is carried out with manufacturing being considered.

Learning Outcomes

By the end of the module the student should be able to...

Understand the differences between die/mould geometry and component geometry.
Understand the effect of material behaviour on mould/die fill and contraction.
Understand the geometry requirements for heat-treatment and assembly.
Create designs with the above as compromises.

Syllabus

This course selects a number of common manufacturing processes and covers the basic understanding of the behaviour of materials in these processes and thus the design considerations associated with the process limitations. Six groups of processes are considered.

Casting: Die casting, sand casting and Investment casting will be assumed. The modulus technique for feeding a casting will be described along with the gating considerations. Tooling requirements for producing holes by coring, stripping from the mould/die and location of die pieces will also be discussed.

Forging: Only closed die forging will be considered. Metal flow in the cold and hot conditions will be considered along with annealing cycles. Folds, laps, etc. will be explained. Detail of forging plant and the relation to component geometry and type of operation will be covered.

Machining: This will cover the process of grinding, milling, drilling and single point cutting on the lathe. Use of standard tools will be a major feature. Problems associated with surface finish and surface integrity will be dealt with in detail.

Heat Treatment: This will cover both the heating plant and quenching cycles to avoid cracks, decarburisation and distortion. The processes featured will be Induction hardening, Salt bath and vacuum furnaces and controlled atmospheric furnaces.

Injection Moulding: This will be concerned with the flow of material resulting in air entrapment, residual stress and distortion, polymer and filament alignment, weld lines and sink marks.

Joining: The processes of Welding, Brazing and soldering and adhesive joining will be covered. The joint design, joint preparation and quality of the final bond will be featured. Some examples of non destructive testing will also form part of this section.

Assembly: This will cover the DFA techniques developed by Boothroyd and Dewhurst.

At the end of this course, students should have an appreciation, in some depth, of the design considerations needed for manufacture using the above processes and an ability to question other process limitations not covered here.