Manufacturing Processes II

Code:

L.EM029

Acronym:

PF II

Keywords
Classification	Keyword
OFICIAL	Drawing, Design and Manufacture

Instance: 2024/2025 - 2S

Active?	Yes
Responsible unit:	Metallurgy, Materials and Technological Processes Section
Course/CS Responsible:	Bachelor in Mechanical Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
L.EM	198	Syllabus	3	-	6	52	162

Teaching language

Portuguese

Objectives

This course unit aims at teaching the fundamentals required to understand two groups of complementary and important manufacturing processes for the production of complex parts and/or mass production: conventional machining processes and processes based on metal forming. The course aim is to stimulate students to develop an understanding of the most common and current technological solutions, associated with two groups of manufacturing processes, and at the same time their applications in the production of parts, always using the most efficient routes. This course unit, following the Manufacturing Processes I course unit, will provide students with solid training and a complete theoretical and practical view of the manufacturing processes that dominate the parts manufacturing industry. The knowledge acquired will also form the required background for the future development of new knowledge in the area of advanced manufacturing processes.

Learning outcomes and competences

Knowledge:
- General principles of conventional subtractive manufacturing processes and manufacturing processes based on
metal forming technologies.
- To know the technologies associated with each process (machines, tools, operations, applications).

Skills:
- Select the most efficient manufacturing processes, taking into account the specifications of the products.
- To establish the best sequence of production steps for different products.
- Design and/or selection of tools.

Computing competences:
-Application of CAD / CAM systems in the definition of machining strategies.
-Programming computer-controlled machines (CNC).
-Modelling of tools.

Experimental competences:
-Contact with machining technologies (use of CNC equipment, demonstrations, and machinability tests).
- Characterization of plastic and fracture behaviour of materials by testing.

Transversal competences:
- Teamwork.
- Reporting.
- Oral communication.

Working method

Presencial

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

- Materials Science and Engineering: metallic materials;

- Technical drawing representation and reading and CAD/CAM technologies;

- Background on statics, kinematics, stress and strain states and constitutive laws of materials.

Program

MACHINING MODULE - Principles of Conventional Machining (Cutting). Orthogonal Cutting Model. Geometry of cutting
Tools. Materials for cutting tools. Cutting tools life. Machinability. Economic Conditions of Machining. Cutting Fluids.
Conventional Machining Processes (Turning, Drilling, Reaming, Milling, Grinding); Cutting Parameters, Cutting Tools,
Machine Tools, Machining Sequences. CNC machining: lathes, milling machines and machining centres.


METAL FORMING MODULE - Classification of Metal Forming Processes; Forging, Lamination, Extrusion, Stretching,
Bending, Cutting and Embedding; Applications; Machines for Metal Forming; Parts and Tools design; Plasticity and
Mechanical Characterization Tests.

Mandatory literature

Mikell P. Groover; Fundamentals of modern manufacturing. ISBN: 0-13-312182-8
Rodrigues, J., Martins, P.; Tecnologia Mecânica – Tecnologia da deformação plástica, Escolar Editora, 2005
Abílio Manuel Pinho de Jesus; Fundamentos do corte. ISBN: 978-972-752-245-3

Complementary Bibliography

João Paulo Davim; Princípios da maquinagem. ISBN: 972-40-0878-9
Gerling, H. ; Alrededor de las máquinas-herramienta (3rd ed.). , Reverté Barcelona, 1997
Dias, F., Silva, T., Carvalho, D., Jesus, A.M.P.; Tecnologia da Maquinagem. Torno e Torneamento. , Edições FEUP, 2021
Duarte, J.F., Rocha, A.B., Santos, A.D. ; Corte em ferramenta, INEGI, 2005
Santos, A.D., Duarte, J.F., Rocha, A.B. ; Tecnologia da embutidura, INEGI, 2005

Teaching methods and learning activities

-Weekly load - 1.5h T + 2.5h PL
-Total hours - 52h
-Preparation of practical work (reporting and oral presentations) 38h
- Laboratory work - 12 h (classes of 1,5 hours each)
-Exam preparation - 60 h

- Individual assessment consists of two partial tests (individual weights of 40% each), focused on machining and metal forming, respectively. Group projects focusing on a specific manufacturing process (report), are foreseen with a 20% weight.

-Students having a minimum weighted average rating of 10 points and a minimum grade of 7.0 points at each of the evaluation tests will be approved for the course unit.

-Students:

• not getting the minimum average of 10 points;


• having the minimum average of 10 points but not meeting all requirements for approval;


• missing at least one of the tests;

may access the global Resource Exam (80% weight) or the partial Resource Exam (same topics as the partial tests, weight of 40%).

-Approved students may access the Resource Exam to make grade improvements.

Two groups of manufacturing processes are presented in two complementary modules, where the fundamental knowledge required to understand the processes is taught, and contact with the associated manufacturing technologies is provided to the students.

Regarding the machining module, lectures will address transversal topics of conventional machining, which is essential for understanding the different technological processes. The reference to the mechanics of metal cut is fundamental to introducing the knowledge required for the selection of cutting tools and the definition of the machining parameters. References are also made to the geometry of cutting tools, cutting tool materials, economical machining conditions and cutting fluids. The laboratory classes introduce the different conventional machining technologies (turning, drilling, milling, grinding) and their applications. Students will be conducted in the elaboration of machining sequences, the definition of cutting parameters and the selection of tools. These classes culminate with the validation of the machining sequences in the laboratory.

Regarding the modulus of metal forming, fundamental and cross-cutting themes of metal forming technology will be addressed in the lectures. It will be essential to introduce the concepts of formability and explain phenomena associated with this behaviour, such as hardening and anisotropy. Reference is also made to the various plastic forming processes, with emphasis on the different technological parameters and the design of tools and components to be produced. Information on these processes is complemented by the characterization of representative materials for the various manufacturing processes and information about the machines and technology used. The laboratory classes cover different technologies and their application in producing parts. These classes will include the experimental characterization of some materials, with the involvement of students who can later use the results to analyse the formability of different materials.

Students will also be requested to carry out a project to consolidate and integrate knowledge. This practical exercise will focus on a manufacturing process studied. This academic year, machining will be the priority where the production of a part by integrating the CAD/CAM/CNC systems, tool selection, cutting parameters, optimization of the machining sequences, execution and quality control will be envisaged. The classes culminate with a discussion of the projects that resulted from this activity.

Evaluation Type

Distributed evaluation without final exam

Assessment Components

Designation	Weight (%)
Exame	80,00
Trabalho laboratorial	20,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Estudo autónomo	60,00
Frequência das aulas	52,00
Trabalho laboratorial	50,00
Total:	162,00

Eligibility for exams

Attendance of at least 75% of the PL classes (classes of 2,5 hours duration).

Successful completion of the practical group assignment (score of at least 10 points/20).

Calculation formula of final grade

FM = A*0.80 + B*0.20

FM: Final Mark
A: Average grade on the two quizzes;
B: Group assignment grade;

Each quiz covers the topics of each course part with the same weight: Machining (1st quiz) and Metal Forming (2nd quiz).

The group assignment will be mandatory and includes a written report. 

There is a possibility to perform a final exam (appeal exam), which may cover the topics of each part of the course (partial exam) or all topics of the course (global exam). The final mark (FM) will be based on the highest grades on the quizzes or the final exam.

Note 1: Minimum grade in each quiz of 7.0 points (over 20).

Special assessment (TE, DA, ...)

An exam based on all the topics that have been taught.

A practical work (assignment) including a written report and an oral presentation about a topic proposed by the professors.

FM= A*0.8 + B*0.20

FM: Final Mark

• Grade of the global exam
• Grade of the assignment

For students with a positive mark in the group assignment, in the present or in the last academic year, this mark will be used for B, with no need for new assignments.

Classification improvement

An exam based on the topics that have been taught is foreseen.
Group assignments are not allowed to be improved in the exam period.