Introduction to Manufacturing Processes and Product Development

Code:

EM0007

Acronym:

IPFDP

Keywords
Classification	Keyword
OFICIAL	Materials

Instance: 2011/2012 - 1S

Active?	Yes
Responsible unit:	Materials and Technological Processes Group
Course/CS Responsible:	Master in Mechanical Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
MIEM	178	Syllabus since 2006/2007	1	-	5	56	133

Teaching language

Portuguese

Objectives

1- BACKGROUND
Mechanical Engineering played a fundamental role in the Industrial Revolution, thus contributing to the changes, the world has since witnessed on economy, society and politics. Nowadays, this branch of engineering is a broad and multidisciplinary activity. In 2004 ASME (American Society of Mechanical Engineers) expressed its Vision accordingly: "To meet the demands of the 'Biotech Century,' mechanical engineering must adopt a synergistic, broad-scope approach in which mechanical engineering methodology is part of multi-discipline industrial and research environments.”


Also, ASME President in 2008 following his report: "2028 VISION FOR MECHANICAL ENGINEERING", considers that: 

“Mechanical engineers must provide solutions to the drivers of change (…)

We are inspired by a vision that calls us to: 

■ Develop sustainably through new technologies and techniques, and respond to the global environmental pressures brought about by economic growth;

■ Be at the forefront of implementing a system design approach across large and small-scale systems;

■ Engage in international collaboration around our critical knowledge and competencies;

■ Work in the emerging Bio-Nano technologies to provide solutions in such diverse fields as healthcare, energy, water management, the environment and agriculture management, and

■ Create engineering solutions for the other 90 percent that live on less than two dollars a day.“

"Introduction to Manufacturing Processes and Product Development" is the first introductory discipline on Mechanical Engineering.
Students shall be aware of Mechanical Engineering history and current role, shall open their mind about current main issues, thus developing their skills in order to identify problems and find solutions. These solutions must include design for all, i.e., the potential user should be also poor, elderly and disabled people.


2- SPECIFIC AIMS
To develop the knowledge and understanding about how the world works and identify the main global problems of the society, environment, sustainability and economy.
To provide information regarding the main technological processes to design and produce parts in Mechanical Engineering.
To promote the insight of new perspectives related with restraining factors for product manufacturing and its interaction with users (e.g. design for all), environmental problems and sustainability.
To see reality and open their minds, by visiting manufacturing companies and other institutions as well as attending to conferences.
To develop their communication and team work skills.

3- PREVIOUS KNOWLEDGE
Students come to University with low level of Mechanical Engineering and Technology. They learned the basis of physics and chemistry and became aware about environment. Their knowledge about economical and political history of XX century is very low thus being difficult for them to understand completely our world and have some vision into the future.

4-PERCENT DISTRIBUTION
Estimated percent distribution for the scientific and technological contents:
- Scientific: 20 %.
- Cultural: 40%
- Technological: 40 %.

5- LEARNING OUTCOMES
It is expected at end of this module, the students will have:
1. developed their knowledge and understanding of today’s world, main current issues and the importance of mechanical engineering;
2. the basis of fundamental issues like society problems, environment and sustainability, as well as ethics;
3. developed the knowledge on the possibilities of product development technologies and mechanical manufacturing technologies;
4. developed their capabilities to critically analyze the reality, to identify problems , study and propose solutions.
5. developed their reporting skills and self-critiquing capabilities.

Program

1. Current and future trends in mechanical engineering practice;
2. Ecodesign and Design for All;
3. Technologies to support product development: Rapid Prototyping and Rapid Manufacturing technologies.
4. Environment and sustainability; global warming;
5. First and Second Industrial Revolutions and role of Engineering
6. Informatics Revolution and Education: on the way to a society of knowledge?
7. Company models for the XXI century
8. Introduction to Manufacturing Processes:
Casting Technology, molding processes and materials, metals used in foundry. Design of castings.
Shearing and blanking technologies (CNC Punching, Laser, Plasma and Waterjet).
Machine tools and machining technology. Turning, Drilling, Milling, Grinding, EDM.
Welding Technology and Processes: Stick welding, MIG/MAG, TIG, Submerged Arc welding, resistance welding.
Metal Forming Technologies, Bulk Forming: Forging, Rolling, Extrusion. Sheet Metal Forming.

Mandatory literature

A. Barbedo de Magalhães; Apontamentos da disciplina e acetatos
Alves, Fernando Jorge Lino 070; Protoclick. ISBN: 972-95376-1-5
A. Dias dos Santos, J. Ferreira Duarte, A. Barata da Rocha; Tecnologia da embutidura. ISBN: 972-8826-03-06
J. Ferreira Duarte, A. Barata da Rocha, A. Dias dos Santos; Corte em ferramenta. ISBN: 972-8826-00-1
A. Barata Rocha, A. Dias dos Santos, J. Ferreira Duarte; Puncionadoras CNC. ISBN: 972-8826-01-X
Henrich Gerling; À volta da máquina-ferramenta
Jorge Rodrigues, Paulo Martins; Tecnologia mecânica. ISBN: 972-592-184-4 (vol. 1)
John A. Schey; Introduction to manufacturing processes. ISBN: 0-07-031136-6

Complementary Bibliography

Jordan, Wendy A.; Universal Design for the Home, Quarry Books, 2008. ISBN: 13:978-1-59253-381-7
William Engdahl; A century of war. ISBN: 978-0-7453-2309-1
H.Peter Gray; The Exhaustation of the Dollar, Palgrave, 2006
Marsden, John P.; Humanistic Design of Assisted Living, The Johns Hopkins University Press, 2005. ISBN: 0-8018-8031-9
Collier, Paul; The Bottom Billion: why the Poorest Countries are Failing and What Can be Done About it, OUP Oxford, 2008. ISBN: 978-0195374636
Parra, Francisco; Oil Politics - a modern history of petroleum, I.B. Tauris, 2004. ISBN: 1860649777
McWilliams, Wayne C.; Piotrowski, Harry; The World Since 1945: A History of International Relations, Lynne Rienner Publishers, 2005. ISBN: 1588263479
Meredith, Martin; The State of Africa: A History of Fifty Years of Independence, Free Press, 2006. ISBN: 0743232224
Chang, Ha-Joon; Bad Samaritans: The Guilty Secrets of Rich Nations and the Threat to Global Prosperity, Random House Business Books , 2008. ISBN: 978-1905211371
Pilger, John; The New Rulers of the World , Verso Books, 2003. ISBN: 185984412X
Chomsky, Noam; Failed States: The Abuse of Power and the Assault on Democracy, Penguin, 2007. ISBN: 0141023031

Teaching methods and learning activities

Theoretical-practical classes: presentation of the Main product development techniques. Presentation and debate of the main issues include in the program.
Practical classes: problem solving; case studies; presentation of technological videos; visit to industrial companies and other institutions.
Team work, writing of reports, their presentation, peer review (by other work teams) and debate.

Evaluation Type

Distributed evaluation without final exam

Assessment Components

Description	Type	Time (hours)	Weight (%)	End date
Attendance (estimated)	Participação presencial	68,00
Team work topic and a report of a visit to a company or Institute	Trabalho escrito	37,00		2012-01-06
Two examinations	Exame	3,00		2012-01-23
	Total:	-	0,00

Amount of time allocated to each course unit

Description	Type	Time (hours)	End date
Study	Estudo autónomo	27	2012-01-27
	Total:	27,00

Eligibility for exams

According to Faculty rules.

Calculation formula of final grade

Teamwork, its presentation and discussion correspond to 35%; Peer review of one team work by another team, its presentation and discussion corresponds to 10%;
Reports on the visits, their presentation and discussion corresponds to 10%
Each of two examination tests corresponds to 20%
Student participation in the classes correspond to 5%.

Notes:
1.- Each student participation in the presentation of reports corresponds to 50% of the corresponding evaluation. So, if a student does not actively participate in any apresentation will have zero in that evaluation component. The corresponding evaluation will be 50% of the classification he woul have for his participation in the production in the written report.
2.- The evaluation calculation rule reported in note 1 will be adapted to special cases, namely for working students, missing classe for health reasons and similar special cases.
3.- Students may apply to do recourse of their examination tests.

Special assessment (TE, DA, ...)

According to Faculty rules.