Overview
This unit offers extended information on material behaviours and manufacturing properties, principles of manufacturing processes and technologies. The unit aims to deepen the understanding of the material selection process and enables you to identify appropriate manufacturing processes for a particular product design and development. You will study a wide variety of manufacturing processes such as bulk deformation processes, material removal processes, finishing and joining processes, micro/nano scale manufacturing, and other modern manufacturing techniques and learn product design, quality management, and manufacturing in a competitive environment. You will apply information literacy skills to obtain relevant engineering information and identify appropriate standards and practices.
Details
Pre-requisites or Co-requisites
Prerequisites: (ENEG11008 Materials for Engineers or ENEG12005 Materials Science & Engineering) and MATH11218 Applied Mathematics or MATH11219 Engineering Mathematics
Important note: Students enrolled in a subsequent unit who failed their pre-requisite unit, should drop the subsequent unit before the census date or within 10 working days of Fail grade notification. Students who do not drop the unit in this timeframe cannot later drop the unit without academic and financial liability. See details in the Assessment Policy and Procedure (Higher Education Coursework).
Offerings For Term 2 - 2021
Attendance Requirements
All on-campus students are expected to attend scheduled classes – in some units, these classes are identified as a mandatory (pass/fail) component and attendance is compulsory. International students, on a student visa, must maintain a full time study load and meet both attendance and academic progress requirements in each study period (satisfactory attendance for International students is defined as maintaining at least an 80% attendance record).
Recommended Student Time Commitment
Each 6-credit Undergraduate unit at CQUniversity requires an overall time commitment of an average of 12.5 hours of study per week, making a total of 150 hours for the unit.
Class Timetable
Assessment Overview
Assessment Grading
This is a graded unit: your overall grade will be calculated from the marks or grades for each assessment task, based on the relative weightings shown in the table above. You must obtain an overall mark for the unit of at least 50%, or an overall grade of 'pass' in order to pass the unit. If any 'pass/fail' tasks are shown in the table above they must also be completed successfully ('pass' grade). You must also meet any minimum mark requirements specified for a particular assessment task, as detailed in the 'assessment task' section (note that in some instances, the minimum mark for a task may be greater than 50%). Consult the University's Grades and Results Policy for more details of interim results and final grades.
All University policies are available on the CQUniversity Policy site.
You may wish to view these policies:
- Grades and Results Policy
- Assessment Policy and Procedure (Higher Education Coursework)
- Review of Grade Procedure
- Student Academic Integrity Policy and Procedure
- Monitoring Academic Progress (MAP) Policy and Procedure - Domestic Students
- Monitoring Academic Progress (MAP) Policy and Procedure - International Students
- Student Refund and Credit Balance Policy and Procedure
- Student Feedback - Compliments and Complaints Policy and Procedure
- Information and Communications Technology Acceptable Use Policy and Procedure
This list is not an exhaustive list of all University policies. The full list of University policies are available on the CQUniversity Policy site.
Feedback, Recommendations and Responses
Every unit is reviewed for enhancement each year. At the most recent review, the following staff and student feedback items were identified and recommendations were made.
Feedback from Have your say source; UC and Lecturer
Major manufacturing processes would be good to learn in more depth.
On top of in-class learning, planned manufacturing industry visit, starting from Term 2, 2021, for students of all campuses will help students to learn a wider spectrum of machine manufacturing practices.
Feedback from Have your say
Feedback was informative but could be improved
Keep providing comprehensive written feedback in the assignment document indicating the errors and mistakes, amendments and sources where this can be learned more.
Feedback from Have your say source
More concise lecture and more videos on processes.
Provide industry-based short videos. 1 hr lecture, 1 hr tutorial, and 1 hr drop-in session.
- Establish the relationships between the microstructures of materials and their mechanical and manufacturing properties
- Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools that are used to carry out these operations
- Calculate the forces, torques and power requirements for various processing of different materials for bulk deformation
- Analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics
- Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products
- Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices
- Work, learn and communicate in an ethical, professional manner, both individually and in teams.
The Learning Outcomes for this unit are linked with the Engineers Australia Stage 1 Competency Standards for Professional Engineers in the areas of 1. Knowledge and Skill Base, 2. Engineering Application Ability and 3. Professional and Personal Attributes at the following levels:
Intermediate
Advanced
Refer to the Engineering Undergraduate Course Moodle site for further information on the Engineers Australia's Stage 1 Competency Standard for Professional Engineers and course level mapping information
Alignment of Assessment Tasks to Learning Outcomes
Assessment Tasks | Learning Outcomes | ||||||
---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | |
1 - Written Assessment - 20% | |||||||
2 - Written Assessment - 20% | |||||||
3 - Written Assessment - 20% | |||||||
4 - Online Test - 40% |
Alignment of Graduate Attributes to Learning Outcomes
Graduate Attributes | Learning Outcomes | ||||||
---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | |
1 - Communication | |||||||
2 - Problem Solving | |||||||
3 - Critical Thinking | |||||||
4 - Information Literacy | |||||||
5 - Team Work | |||||||
6 - Information Technology Competence | |||||||
7 - Cross Cultural Competence | |||||||
8 - Ethical practice | |||||||
9 - Social Innovation | |||||||
10 - Aboriginal and Torres Strait Islander Cultures |
Alignment of Assessment Tasks to Graduate Attributes
Assessment Tasks | Graduate Attributes | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | |
1 - Written Assessment - 20% | ||||||||||
2 - Written Assessment - 20% | ||||||||||
3 - Written Assessment - 20% | ||||||||||
4 - Online Test - 40% |
Textbooks
Manufacturing Engineering and Technology
Edition: 7 (2014)
Authors: Serope Kalpakjian, Steven Schmid
Pearson Higher Ed
ISBN: 9780133128741
Binding: Paperback
Materials and Processes in Manufacturing
Authors: E. Paul DeGarmo, J. T. Black, R. A. Kosher
Wiley
Binding: Paperback
Additional Textbook Information
Both paper and eBook versions can be purchased at the CQUni Bookshop here: http://bookshop.cqu.edu.au (search on the Unit code).
IT Resources
- CQUniversity Student Email
- Internet
- Unit Website (Moodle)
All submissions for this unit must use the referencing style: Harvard (author-date)
For further information, see the Assessment Tasks.
a.mazid@cqu.edu.au
Module/Topic
One hour lecture:
Introduction to Manufacturing Processes; Mechanics of metal cutting: Merchants theory, Chips formation, Cutting forces.
Chapter
Textbook Chapter 20
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom. .
Module/Topic
One hour lecture:
Cutting tools: classification, materials, geometry; Cutting fluids.
Chapter
21
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom. .
Module/Topic
One hour lecture:
Turning and boring processes. Tools and turning parameters.
Chapter
22
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Drilling, boring, reaming, and relevant processes.
Chapter
22
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Milling processes for various shapes.
Chapter
23
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Problem solving on manufacturing processes Due: Week 5 Friday (13 Aug 2021) 12:00 am AEST
Module/Topic
Study break - work on assignments
Chapter
20 - 23
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Grinding and relevant processes. Grinding wheels and fluid.
Chapter
25
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Gear cutting and forming processes.
Chapter
23
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Machining centres: Numerical control (NC) and computer numerical control (CNC) machine tools; Computer integrated manufacturing (CIM).
Chapter
Lecture notes and Chapter 24
Events and Submissions/Topic
Industry site visit.(TBA)
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Forming processes: Cold and hot forming processes, Micro-structure and anisotropy;
Chapter
13
Events and Submissions/Topic
Industry site visit.(TBA)
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Production processes development Due: Week 9 Friday (17 Sept 2021) 12:00 am AEST
Module/Topic
One hour lecture:
Welding processes: Oxyfuel gas welding, Arc welding, TIG and MIG welding.
Micro-structure and quality of weld.
Chapter
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Casting metals and plastics: Conventional and die casting processes; plastic moulding, cast quality;
Chapter
11
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Module/Topic
One hour lecture:
Additive and advanced manufacturing processes (Selected processes only)
Chapter
H El-Hofy - Advanced machining processes (McGraw-Hill) and lecture notes
Events and Submissions/Topic
One hour Tutorial via Zoom..
One hour interactive drop-in session via Zoom.
Research Report Due: Week 12 Friday (8 Oct 2021) 12:00 am AEST
Module/Topic
Final assessment
Chapter
Events and Submissions/Topic
QUIZ (3 hr duration) at 3 PM 17 Aug.
Module/Topic
Chapter
Events and Submissions/Topic
1 Written Assessment
This assessment item involves design analysis and numerical problem solving based on theories and mechanics of metal machining, machine tools and tooling. This will instill your theoretical knowledge gained in areas of turning, milling, drilling and other machining processes with reflection on real life scenario of manufacturing processes. A set of relevant problems will be provided at the beginning of the Term.
Week 5 Friday (13 Aug 2021) 12:00 am AEST
Week 7 Friday (3 Sept 2021)
Each problem-solving answer will be assessed considering the following factors:
- Correct approach and schematic of the problem demonstrating clear understanding of it (20% marks);
- Selection and appropriate use of right theory/equations and procedures (20% marks);
- Appropriate solving methodology using the right theory/equations and procedures (50% marks);
- Neat and cleanliness, and orderly work-flow (10% marks).
- Problem Solving
- Critical Thinking
- Information Literacy
- Information Technology Competence
- Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools that are used to carry out these operations
- Calculate the forces, torques and power requirements for various processing of different materials for bulk deformation
- Analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics
- Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products
- Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices
2 Written Assessment
This assessment item involves selecting one machine part and developing complete manufacturing processes routed from machine to machine for individual operation in an economic way considering the part handling and operation time. The designed well-routed processes will transform a work-piece into a finished product. Initially students are supposed to prepare manufacturing drawing/s of selected part/s in 2D form (follow ISO or AS1100) showing geometric dimensions with tolerances and surface finish grades (where necessary). Considering the created part design students will design, step by step, the machining processes using all or some of the processes like turning, milling, drilling, grinding, etc. For each of the processes chosen you need to choose cutting tool/s and using the data you need to calculate/estimate/select operational parameters like cutting speed, feed rate and depth of cut considering the accepted dimensional tolerances and surface roughness. Each step of operations must be appropriately documented for helping the machine operator for production. At the end you may wish to calculate the production cost of the part using your designed processes and routing.
Week 9 Friday (17 Sept 2021) 12:00 am AEST
Week 11 Friday (1 Oct 2021)
Marking criteria for this creative assignment are:
- Production of ISO standard (AS1100) part drawing in 2D showing all necessary dimensions with tolerances and surface finish grades (20% marks);
- Creation of appropriate documentation of economic operation routing and machining operation instruction demonstrating the operation in drawing, selecting/estimating values of operation parameters (v, f,d), cutting tool, job clamping methods and engineering metrology procedures. This document must help machine operators in machine setting, tool selection and cutting regime (v, f, d) setting without any physical presence or help of engineers. (60% marks);
- Production cost calculation of your part (10% marks);
- Appropriate presentation of all process documentation for easy and friendly uses and neatness (10%).
- Problem Solving
- Critical Thinking
- Information Literacy
- Information Technology Competence
- Establish the relationships between the microstructures of materials and their mechanical and manufacturing properties
- Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools that are used to carry out these operations
- Analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics
- Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices
3 Written Assessment
During the Term all students of all campuses will attend an industry site visit in a manufacturing or relevant production engineering industry. On-line students working themselves in engineering company may be exempted from site visit; anyone interested to join the visit should directly talk to the UC. This assignment is dedicated to write a technical research report on the processes visited in the host industry. On-line students may select a work-related topic in consultation with the UC.
This assignment is designed to develop your skills and understanding of workpiece/part manufacturing using any of the processes like casting, forming, hot- and cold rolling, welding, powder metallurgy, or any other production systems you visited in the site visit. At the end you will produce a technical report in a fruitful and constructive manner for assessment. Students will select a topic in consultation with UC/Lecturer/Tutor. Students are supposed accomplish enhanced research within their selected topic area and produce review output of the selected processes. You may need to visit several databases exploring technical journals and conferences, textbooks, and industry websites to gather information. Structure of the report to be submitted may contain title page, aim and objectives, introduction and background, full process description and explanation including illustrations, schematics, images etc., applications and economic aspects, as necessary.
Week 12 Friday (8 Oct 2021) 12:00 am AEST
Exam Week Friday (22 Oct 2021)
The technical report assessment will be guided by the following factors:
- Topic of Report relevance to visited industry.
- Minimum 10 resources (published articles, company websites, videos, and promotional presentations, etc.) to be visited and studied. Out of these at least 05 well reputed published articles and very related resources will be appreciated. Complying all of these in perfection may carry 20% marks.
- Demonstration of skills of narration including methods, procedures and materials involved in the processes, economic and environmental aspects of the processes, and critical comments, appreciation, and criticism will carry 50% marks.
- Demonstration of enough evidences like graphs, labelled images, figures with perfect explanations and any other necessary data/information on economic impact and relevant government policies referencing in relevant to the technology in the report will carry 30% marks.
- Communication
- Problem Solving
- Team Work
- Ethical practice
- Work, learn and communicate in an ethical, professional manner, both individually and in teams.
4 Online Test
On-line test/quiz may contain short and/or long questions, manufacturing processes design based questions, analysis and numerical problem solving spreading over the study materials of all 12 weeks.
Exam Week Wednesday (20 Oct 2021) 3:00 pm AEST
Marks selection will be indicated for each of the question or for each portion of the questions providing enough factors of assessment.
- Communication
- Problem Solving
- Critical Thinking
- Ethical practice
- Establish the relationships between the microstructures of materials and their mechanical and manufacturing properties
- Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools that are used to carry out these operations
- Calculate the forces, torques and power requirements for various processing of different materials for bulk deformation
- Analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics
- Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products
- Work, learn and communicate in an ethical, professional manner, both individually and in teams.
As a CQUniversity student you are expected to act honestly in all aspects of your academic work.
Any assessable work undertaken or submitted for review or assessment must be your own work. Assessable work is any type of work you do to meet the assessment requirements in the unit, including draft work submitted for review and feedback and final work to be assessed.
When you use the ideas, words or data of others in your assessment, you must thoroughly and clearly acknowledge the source of this information by using the correct referencing style for your unit. Using others’ work without proper acknowledgement may be considered a form of intellectual dishonesty.
Participating honestly, respectfully, responsibly, and fairly in your university study ensures the CQUniversity qualification you earn will be valued as a true indication of your individual academic achievement and will continue to receive the respect and recognition it deserves.
As a student, you are responsible for reading and following CQUniversity’s policies, including the Student Academic Integrity Policy and Procedure. This policy sets out CQUniversity’s expectations of you to act with integrity, examples of academic integrity breaches to avoid, the processes used to address alleged breaches of academic integrity, and potential penalties.
What is a breach of academic integrity?
A breach of academic integrity includes but is not limited to plagiarism, self-plagiarism, collusion, cheating, contract cheating, and academic misconduct. The Student Academic Integrity Policy and Procedure defines what these terms mean and gives examples.
Why is academic integrity important?
A breach of academic integrity may result in one or more penalties, including suspension or even expulsion from the University. It can also have negative implications for student visas and future enrolment at CQUniversity or elsewhere. Students who engage in contract cheating also risk being blackmailed by contract cheating services.
Where can I get assistance?
For academic advice and guidance, the Academic Learning Centre (ALC) can support you in becoming confident in completing assessments with integrity and of high standard.