Module Code - Title:
MF4024
-
MANUFACTURING PROCESSES 4
Year Last Offered:
2025/6
Hours Per Week:
Grading Type:
N
Prerequisite Modules:
Rationale and Purpose of the Module:
To give an in-depth examination of manufacturing processes currently used in Ireland and globally. This will introduce students to current state-of-the-art manufacturing technology applicable to a wide range of manufacturing environments, through a combination of lectures, and workshop component manufacture. This knowledge is necessary pre-coop and to underpin key themes such as automation and operations.
Syllabus:
CNC control: code generation, CAD/CAM software integration, quality control and inspection, in contexts such as machining and fabrication.
Manufacturing processes: These can include, but are not limited to injection moulding, pressing and forming, 3-D printing, EDM, grinding, knowledge of industry-specific processes, e.g. dairy, pharma, bio-pharma, printed circuit board production, IC fabrication, medical devices. Choice of appropriate materials with respect to cost, reliability, repeatability, availability, and environmental factors.
Tool wear and life: cutting tools / machining, mechanics of cutting, tool/chip temperature, tool wear and failure, cutting tool materials, ISO codes for inserts and holders, cutting fluids. Tool economics, tool life for optimal production output, quality and cost.
Learning Outcomes:
Cognitive (Knowledge, Understanding, Application, Analysis, Evaluation, Synthesis)
On successful completion of this module students will be able to:
1. Describe the operating principles of CNC control, an indicative range of manufacturing processes, and tool life issues including materials and cost/sustainability.
2. Write and generate working part programmes.
3. Design and illustrate mould cavity layouts that will minimise product defects.
4. Describe the operating principles of presses and press tools including progressive die design
5. Derive and calculate the critical operating parameters inherent in the operation of a typical process.
6. Justify choice of alternative manufacturing processes for some simple designs by value analysis.
7. Working in a small team design, build and test a small process to manufacture a chosen component.
Affective (Attitudes and Values)
N/A
Psychomotor (Physical Skills)
On successful completion of this module students will be able to:
1. Working in a small team design, build and test an indicative process component such as a small injection mould to manufacture a chosen component.
2. To write a working part programme to manufacture a component on a CNC milling machine or lathe or similar.
How the Module will be Taught and what will be the Learning Experiences of the Students:
This area of knowledge and practice aligns with CONFIRM (SFI funded) and IBUS (EU funded) research in the School of Engineering.
The team work dimension challenges students to be collaborative and creative. accounting for their work develops their ability to articulate their logic. They also need to master the basic knowledge of manufacturing processes through lectures and practicals. The topics are essential underpinning for coop, for automation modules, and for advanced manufacturing in the final semester, as well as for final-year project work.
Research Findings Incorporated in to the Syllabus (If Relevant):
Prime Texts:
Mikell P. Groover
(2015)
Fundamentals of Modern Manufacturing
,
, Wiley
Black JT & Kohser RA (2017)
Degarmo's Materials and Processes in Manufacturing
, Wiley
Ghosh, A., and Mallik, A.K. (2010)
Manufacturing Science
, Affiliated East-West Press
Other Relevant Texts:
Programme(s) in which this Module is Offered:
BEDEMAUFA - DESIGN AND MANUFACTURE
Semester(s) Module is Offered:
Spring
Module Leader:
peter.tiernan@ul.ie