Simulation of Technological Processes

Code:

M.EMAT011

Acronym:

SPT

Keywords
Classification	Keyword
OFICIAL	Science and Technology of Materials

Instance: 2025/2026 - 2S

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

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
M.EMAT	22	Syllabus	1	-	4,5	39	121,5

Teaching language

English

Objectives

At the end of this course, students are expected to acquire knowledge of simulation applications to accelerate product development and manufacturing processes.
Students should be able to use simulation to optimize 3D component geometry and make the correct selection of materials. They should also be able to use simulation tools to avoid problems during manufacturing processes.
As secondary objectives, it is intended that students are able to understand the working principle of simulation software, as well as understand the limitations of these technologies.

Learning outcomes and competences

By conducting tutorials on the different simulation applications covered, representative of the various CAE technologies commonly used in the industry, students have an introductory background with a broad spectrum of applications, thus being able to use either technology in a future engineering career.
The very practical, real-world approach allows students to quickly learn how to derive concrete results from CAE tools.
Theoretical accompaniment aims to transmit to students the knowledge necessary to interconnect the results obtained in the simulation with the concepts acquired in other curricular units, in order to be able to interpret these same results and make the appropriate decisions.
They also get to know the main problems and limitations of the CAE tools, thanks to the proposed tutorials and exercises.
The consolidation of the subject is achieved through the challenges proposed in each step of the course, where students have to be able to overcome deficiencies or errors in the component, its tool or its manufacturing process.

Working method

Presencial

Program

1. Topological optimization
• Using CAE software
2. Machining simulation
• Using of CAE software
• Machining of components 
3. Additive manufacturing simulation with nTopology
4. Casting process simulation with QuikCAST
• Sand casting
• Injection casting
• Lost wax casting
5. Forming process simulation with DEFORM
• Forging
6. Welding process simulation with SYSWELD
7. Plastic injection simulation with MoldFlow/Moldex3D8
8. Phase transformation simulation in steels with JMatPro

Mandatory literature

K. W. Morton; Numerical solutions of partial differential equations. ISBN: 0-521-41855-0
David V. Hutton; Fundamentals of Finite Element Analysis, McGraw Hill, 2004. ISBN: 0-07-239536-2

Complementary Bibliography

Autodesk; Autodesk® Nastran® 2016 , 2016
Jay Shoemaker; Moldflow Design Guide, Moldflow Corporation
Several; Others softwares Users Guides

Teaching methods and learning activities

Each module will present simulation tools using a practical approach with real-life examples, enabling students to use CAE tools and understand how to obtain concrete results. Students will be organised into groups of two to three members and will develop a project proposed by the teacher to consolidate the presented concepts. These projects will be presented in the form of a report and evaluated.

Software

ESI DEFORM
nTopology
ESI SYSWELD
Autuodesk PowerMILL
Autodesk Moldflow
JMatPro
ProCAST/QuikCAST
Moldex3D

Evaluation Type

Distributed evaluation with final exam

Assessment Components

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

Amount of time allocated to each course unit

Designation	Time (hours)
Elaboração de projeto	39,00
Estudo autónomo	43,50
Frequência das aulas	39,00
Total:	121,50

Eligibility for exams

FEUP absence regulation will be applied.

Calculation formula of final grade

Final Classification = Examination Classification * 0.7 + Distributed Evaluation * 0.3

Final Grade = 100% (distributed assessment grade)
The distributed assessment grade is calculated as follows:
19% - assessment of report 1 (module 1);
19% - assessment of report 2 (module 2);
19% - assessment of report 3 (module 3);
28% - assessment of report 6 (module 6);
5% - assessment of report 7 (module 7);
10% - assessment of report 8 (module 8);

Special assessment (TE, DA, ...)

For the special assessment a project will be proposed for the first and fourth module. In addition, students will have to take an exam that covers all four modules.

Classification improvement

The improvement of the final grade may be improved through an exam appeal.