Advanced Manufacturing Technologies I

Code:

M.EM054

Acronym:

TAP I

Keywords
Classification	Keyword
OFICIAL	Drawing, Design and Manufacture

Instance: 2021/2022 - 2S

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
M.EM	35	Syllabus	1	-	4,5	39	121,5

Teaching language

English

Objectives

Complement knowledge about casting technologies, with special emphasis on main and complementary equipment, as well as mold design.
Selection of 3D printing technologies and materials.
Empower the student for the project, using computational tools.
Ability to develop metal products using Metal Injection Molding (MIM) technology.
Complement the theoretical knowledge with technical visits to companies.
Computer Skills
Simulation of the process of filling and solidification in the foundry, additive manufacturing and MIM
Experimental Skills
Ability to design and manufacture moulds, mouldings and cores.
Ability to analyse parts defects.
Melting and casting of metal alloys.
Transversal Competencies
Ability to integrate knowledge between curricular units of design, structural calculation, materials, simulation of processes and projects of production tools.

Learning outcomes and competences

The main objective of this unit is to provide students with advanced knowledge of prototypes and components production using casting, additive manufacturing and metal injection technologies.
The topics of the programmatic content are a natural sequence of presentation of the concepts that will allow the students to acquire complementary competences, so as to enhance their capacities of product development.
The theoretical-practical classes are intended to assimilate the theoretical concepts and their consolidation with the application in the project to be developed.
The various study visits to companies that work in the different areas of programmatic content will allow discussing material and production details in order to assist the project in development

Working method

Presencial

Pre-requirements (prior knowledge) and co-requirements (common knowledge)

Foundry knowledge.
Notions about sintering.
Knowledge about additive manufacturing.
Knowledge about metallic, polymeric, ceramic and glass materials.

Program

Foundry Technologies
Advanced casting processes. Die casting, permanent and low pressure casting, and wax casting.
Main and complementary equipment.
Project of mouldings, core boxes and moulds. Materials and methods of non-destructive control.
Design and development of metal products. Computational tools.
Additive Manufacturing
Technologies classification of additive manufacturing processes (AM).
AM processes with plastics, ceramics and composites. Study of materials.
Hybridization of AM with subtractive manufacturing.
Evolution of the market.
Computational tools for the design of prototypes and parts.
Topological optimization and sustainability.
Injection Moulding
Technology for Metallic Materials.
Preparation of powders and their characterization.
Process study.
Design of injected parts. Design of moulds.
Finishing processes. Products and their applications.

Mandatory literature

P. R. Beeley; Foundry technology. ISBN: 0 408 70348 2
Fernando Jorge Lino Alves; Protoclick. ISBN: 972-95376-1-5
Chua, Chee k., Leong, Kah F.; 3D Printing and Additive Manufacturing, World Scie. ISBN: 9-789814-571418

Teaching methods and learning activities

Theoretical exposition using slideshows, complemented with study visits: Injection process: SONAFI. Lost wax process: INEGI and Zollern & Comandita. Low pressure die casting process: CIFIAL. Additive (FA): INEGI and FEUP.
Bibliographic research and project work on specific components, as well as advanced casting processes, and specific
FA processes for plastics and composites, for metals and other materials.

Software

Quickcast/Procast

Evaluation Type

Distributed evaluation with final exam

Assessment Components

Designation	Weight (%)
Teste	50,00
Trabalho prático ou de projeto	50,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Elaboração de relatório/dissertação/tese	49,00
Estudo autónomo	21,50
Frequência das aulas	39,00
Trabalho de campo	12,00
Total:	121,50

Eligibility for exams

Frequency of 75% of practical classes

Calculation formula of final grade

Practical assignments (2 students): 50%
Exam: 50% (minimum classification: 8/20 points)
Calculation formula: 0.5 x Practical Work + 0.5 x Exam

Examinations or Special Assignments

N/A

Internship work/project

N/A

Special assessment (TE, DA, ...)

N/A

Classification improvement

Only the exam part can be improved.
The formula for calculating the final grade for grade improvement remains in relation to that used to calculate the grade the student wants to improve.