ENEM13018 - Materials and Manufacturing
Term 2 - 2017


All details in this unit profile for ENEM13018 have been officially approved by CQUniversity and represent a learning partnership between the University and you (our student). The information will not be changed unless absolutely necessary and any change will be clearly indicated by an approved correction included in the profile.

Overview

This unit offers extended information on material behaviours and manufacturing properties, principles of manufacturing processes and technologies. The unit aims to deepen the understanding of material selection process and enable you to identify appropriate manufacturing processes for a particular product design and development. You will study a wide variety of manufacturing processes such as bulk deformation processes, material removal processes, finishing and joining processes, micro/nano scale manufacturing and other modern manufacturing techniques and learn product design, quality management and manufacturing in a competitive environment. You will apply information literacy skills to obtain relevant engineering information and identify appropriate standards and practices. Students enrolled in distance mode can opt to attend a Residential School.

Details

Career Level Undergraduate
Unit Level Level 3
Credit Points 6
Student Contribution Band 2
Fraction of Full-Time Student Load 0.125

Pre-requisites or Co-requisites

Prerequisites: (ENEG11008 Materials for Engineers or ENEG12005 Materials Science & Engineering) AND MATH11218 Applied Mathematics or MATH11219 Engineering Mathematics

Residential Schools

This unit has a Optional Residential School for distance mode students and the details are:
Click here to see your Residential School Timetable.

Attendance Requirements

All on-campus students are expected to attend scheduled classes – in some units, these classes are identified as a mandatory (pass/fail) component and attendance is compulsory. International students, on a student visa, must maintain a full time study load and meet both attendance and academic progress requirements in each study period (satisfactory attendance for International students is defined as maintaining at least an 80% attendance record).

Offerings

Term 2 - 2017
  • Bundaberg
  • Distance
  • Gladstone
  • Mackay
  • Rockhampton

Website

This unit has a website, within the Moodle system, which is available two weeks before the start of term. It is important that you visit your Moodle site throughout the term. Go to Moodle

Recommended Student Time Commitment

Each 6-credit Undergraduate unit at CQUniversity requires an overall time commitment of an average of 12.5 hours of study per week, making a total of 150 hours for the unit.

Class Timetable

Assessment Overview

Assessment Task Weighting
1. Practical and Written Assessment 20%
2. Written Assessment 20%
3. Written Assessment 20%
4. Examination 40%

This is a graded unit: your overall grade will be calculated from the marks or grades for each assessment task, based on the relative weightings shown in the table above. You must obtain an overall mark for the unit of at least 50%, or an overall grade of ‘pass’ in order to pass the unit. If any ‘pass/fail’ tasks are shown in the table above they must also be completed successfully (‘pass’ grade). You must also meet any minimum mark requirements specified for a particular assessment task, as detailed in the ‘assessment task’ section (note that in some instances, the minimum mark for a task may be greater than 50%). Consult the University’s Grades and Results Procedures for more details of interim results and final grades.

All University policies are available on the IMPortal.

You may wish to view these policies:

  • Grades and Results Procedure
  • Assessment Policy and Procedure (Higher Education Coursework)
  • Review of Grade Procedure
  • Academic Misconduct Procedure
  • Monitoring Academic Progress (MAP) Policy and Procedure – Domestic Students
  • Monitoring Academic Progress (MAP) Policy and Procedure – International Students
  • Refund and Excess Payments (Credit Balances) Policy and Procedure
  • Student Feedback – Compliments and Complaints Policy and Procedure
  • Acceptable Use of Information and Communications Technology Facilities and Devices Policy and Procedure

This list is not an exhaustive list of all University policies. The full list of University policies are available on the IMPortal.

On successful completion of this unit, you will be able to:
  1. Clearly establish the relationships between the microstructural of materials and their mechanical and manufacturing properties
  2. Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials; and the machine tools that are used to carry out these operations
  3. Calculate numerically the forces, torques and power requirements for various processing different materials for bulk deformation
  4. Mathematically analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics
  5. Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products
  6. Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices
  7. Work, learn and communicate in an ethical, professional manner, both individually and in teams

Learning outcomes are linked to Engineers Stage 1 Competencies and also discipline capabilities. You can find the mapping for this on the Engineering Undergraduate Course website.

Alignment of Assessment Tasks to Learning Outcomes

Assessment Tasks Learning Outcomes
1 2 3 4 5 6 7
1 - Practical and Written Assessment      
2 - Written Assessment    
3 - Written Assessment      
4 - Examination    

Alignment of Graduate Attributes to Learning Outcomes

  • Introductory Level
  • Intermediate Level
  • Graduate Level
Graduate Attributes Learning Outcomes
1 2 3 4 5 6 7
1. Communication          
2. Problem Solving      
3. Critical Thinking    
4. Information Literacy  
5. Team Work        
6. Information Technology Competence        
7. Cross Cultural Competence            
8. Ethical practice            

Alignment of Assessment Tasks to Graduate Attributes

  • Introductory Level
  • Intermediate Level
  • Graduate Level
Assessment Tasks Graduate Attributes
1 2 3 4 5 6 7 8
1 - Practical and Written Assessment        
2 - Written Assessment        
3 - Written Assessment        
4 - Examination        

Corrections

Date Updated Information
15-Jun-2017 12:42

The recommended textbook has now been changed to:

Kilpakjian, S., and Schmid, S.R. Manufacturing Engineering and Technology, SI Edition (7e), Pearson Singapore. ISBN 9789810694067

15-Jun-2017 08:55

The recommended textbook has now been changed to:

Kalpakjian, S., and Schmid, S.R. (2014) Manufacturing Engienering & Technology, SI Edition (7e), Pearson Singapore. ISBN 9789810694067

Prescribed Textbooks

Principles of Modern Manufacturing, SI Version
Author/s: Groover, Mikell, P. Year: 2015
Edition: 5th Publisher: John Wiley
City: New York State: New York
Country: USA
View textbooks at the CQUniversity Bookshop
Note:

An ebook access will be provided to students closer to the commencement of the term.

IT Resources

You will need access to the following IT resources:
  • CQUniversity Student Email
  • Internet
  • Unit Website (Moodle)
All submissions for this unit must use the Harvard (author-date) referencing style (details can be obtained here). For further information, see the Assessment Tasks below.
Unit CoordinatorPrasad Gudimetla (p.gudimetla@cqu.edu.au)
Note: Check the Term-Specific section for any additional contact information provided by the teaching team
Week Begin Date Module/Topic Chapter Events and Submissions
Week 1 10-07-2017

Lecture 1a: Introduction to the Unit

Lecture 1b: Introduction to Manufacturing

Lecture 1c: Microstructural Aspects & Manufacturing Properties of Engineering Materials

Lecture Notes

Reading: Part I - Kalpakjian

  1. Discussion on assignments
  2. Machine Shop Practice
  3. Forming teams
Week 2 17-07-2017

Lecture 2a: Synthesis of Materials - Solidification Processes, Principles of Metal Casting

Lecture 2b: Metal Casting Processes, Cast Design, Materials & Economics

Lecture Notes

Reading: Part II - Kalpakjian

Tutorial 1

Week 3 24-07-2017

Lecture 3a: Fundamentals of Metal Forming - Material behaviour, bulk deformation properties (yield strength, plasticity, strain, strain rate, strain-rate sensitivity, flow stress, ductility)

Lecture 3b: Influence of Temperature, Friction and Lubriation on Metal Forming

Lecture Notes

Tutorial 2

Monday, 24th July 2017 - Machine Shop Session at Rockhampton TAFE

27th July 2017 - Machine Shop Session at Mackay TAFE. Refer to unit Moodle site for more details.

Week 4 31-07-2017

Lecture 4a: Bulk Deformation Processes - Rolling, Forging, Extrusion, Deep Drawing: Operations, process control, parameters

Lecture 4b: Sheet Metal Working - Operations, process control, parameters

Lecture Notes

Reading: Part III - Kalpakjian, Chapters 13 - 16

Tutorial 3

Week 5 07-08-2017 Lecture 5: Forming & Shaping of Plastics

Lecture Notes

Reading: Part III - Kalpakjian, Chapter 19

Tutorial 4

Practical and Written Assessment Due Friday (11 Aug 17) 11:45 PM AEST
Vacation Week 14-08-2017
Week 6 21-08-2017

Lecture 6a: Mechanics of Metal Cutting - materials properties governing metal cutting, theory of chip formation, force, power and energy relationships, cutting parameters

Lecture 6b: Cutting Tool Technology - Tool life, Tool Materials, Geometry, Cutting Fluids

Lecture Notes

Reading: Part IV - Kalpakjian, Chapters 21, 22

Tutorial 5

Week 7 28-08-2017

Lecture 7a: Machining Operations and Machine Tools- Turning, Milling, Drilling, Boring, Shaping, Planing, Broaching

Lecture 7b:Machining Economics

Lecture Notes

Reading: Part IV - Kalpakjian, Chapters 23 - 25

Tutorial 6
Week 8 04-09-2017

Lecture 8a: Abrasive Machining - Grinding Technology & Processes

Lecture 8b: Surface Processing Operations

Lecture Notes

Reading: Part IV - Kalpakjian, Chapters 26, 34

Tutorial 7

Written Assessment Due Friday (08 Sep 17) 11:45 PM AEST
Week 9 11-09-2017

Lecture 9a: Advanced Manufacturing Processes - waterjet, abrasive waterjet, laser, ECM, EDM, Plasma

Lecture 9b: Additive Manufacturing - 3D printing, VAT Photopolymerisation, Material Jetting, Binder Jetting, Material Extrusion, Powder Bed Fusion, Sheet Lamination, Directed Energy Deposition

Lecture Notes

Reading: Part IV - Kalpakjian, Chapter 27

Tutorial 8

Week 10 18-09-2017

Lecture 10: Advanced Materials - Composites, Shape Memory Alloys & Polymers, Biocomposites

Lecture Notes

Reading: Part II - Kalpakjian, Chapters 9, 19

Tutorial 9

Written Assessment Due Friday (22 Sep 17) 11:45 PM AEST
Week 11 25-09-2017 Lecture 11: Powder Metal Processes

Lecture Notes

Reading: Part III- Kalpakjian, Chapter 17

Tutorial 10

Week 12 02-10-2017

Lecture 12a: Joining Processes - Welding Technology

Lecture 12b: Joining Processes - Soldering, Adhesive Bonding

Lecture Notes

Reading: Part VI - Kalpakjian

Review/Exam Week 09-10-2017
Exam Week 16-10-2017

The Machine shop sessions will run in Week 3 at the TAFE campuses in Mackay and Rockhampton. Students from all other campuses are required to travel to either of these campuses on the scheduled dates below. Distance students may elect to travel to a campus nearest to them.

Rockhampton - 24th July 2017 8 a.m. to 2 p.m.

Mackay - 27th July 2017 8 a.m. to 2 p.m.

Please see the detailed run sheet on the unit Moodle site.

1 Practical and Written Assessment

Assessment Title Practical and Written Assessment
Task Description

The goal of this assessment is to test your observational skills and ability to relate theory to practice. You will participate in a 4-hour interactive show-and-tell session in one of the TAFE machine shops. Following this, you will answer a set of questions provided to you in the hand out. You will also access the Qld Workplace Health & Safety Act (WHS 2011) and research into the legislation related to various safety aspects in design and manufacture, and provide a 500 word essay on how you think they were followed during your visit to the TAFE machine shop.

Assessment Due Date Week 5 Friday (11-Aug-2017) 11:45 PM AEST
Submission via link on the unit Moodle site
Return Date to Students Week 7 Friday (01-Sep-2017)
Via link on the unit Moodle site
Weighting 20%
Assessment Criteria

The following criteria shall apply to this assessment:

  1. Your report will provide clear answers with appropriate sketches where applicable and will be duly referenced with in-text citations in Harvard Style
  2. Your WHS essay will draw up on several examples and relate them to appropriate sections of the WHS Act as evidence
Conditions Minimum mark or grade - 50%
Referencing Style Harvard (author-date)
Submission Online

Submit a PDF document via the assessment link provided on the unit Moodle site.

Learning Outcomes Assessed
This section can be expanded to view the assessed learning outcomes

2. Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials; and the machine tools that are used to carry out these operations

3. Calculate numerically the forces, torques and power requirements for various processing different materials for bulk deformation

6. Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices

7. Work, learn and communicate in an ethical, professional manner, both individually and in teams

Graduate Attributes
This section can be expanded to view the assessed graduate attributes

1. Communication

2. Problem Solving

5. Team Work

8. Ethical practice



2 Written Assessment

Assessment Title Written Assessment
Task Description

The goal of this assessment is to test your ability to retrieive information about a manufacturing process of your choice and capture its state-of-the-art and future directions. You will access various databases, scientific journals, textbooks and web resources and gather relevant information and compile a professional report with a word limit ranging between 2500 and 3000 words at 1.5 line spacing using a suitable 11 or 12 point font. The final report shall be a properly structured document along with a set of good references and in-text citations in Harvard Style.

Assessment Due Date Week 8 Friday (08-Sep-2017) 11:45 PM AEST
Return Date to Students Week 10 Friday (22-Sep-2017)
Weighting 20%
Assessment Criteria

The following criteria shall apply to this assessment:

  1. The report will not exceed the set word limit and conform to the other format specifications
  2. The report will include all the elements as outlined the assessment handout
  3. You include a section highlighting your own veiws on the manufacturing process and its impact on the manufacturing sector in the Australian vis-a-vis global contexts
  4. You will include at least 20 references with at least 60% of them being reputed journal articles
  5. The report will be well referenced in Harvard Style
Conditions Minimum mark or grade - 50%
Referencing Style Harvard (author-date)
Submission Online

Submit a PDF document via the assessment link provided on the unit Moodle site.

Learning Outcomes Assessed
This section can be expanded to view the assessed learning outcomes

2. Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials; and the machine tools that are used to carry out these operations

3. Calculate numerically the forces, torques and power requirements for various processing different materials for bulk deformation

4. Mathematically analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics

5. Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products

6. Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices

Graduate Attributes
This section can be expanded to view the assessed graduate attributes

2. Problem Solving

3. Critical Thinking

4. Information Literacy

6. Information Technology Competence



3 Written Assessment

Assessment Title Written Assessment
Task Description

This assessment will comprise a set of questions which demand short descriptive answers and numerical solutions. They are modelled around the various examples and tutorial problems you will solve during the term. The problems will span across various chapters and you will solve them progressively and submit this assessment in the later part of the term.

Assessment Due Date Week 10 Friday (22-Sep-2017) 11:45 PM AEST
Return Date to Students Week 12 Friday (06-Oct-2017)
Weighting 20%
Assessment Criteria

The following assessment criteria shall apply to this assessment:

  1. Short answer questions - You will provide succinct answers with neatly labelled diagrams where applicable, with proper referencing (Harvard Style)
  2. Numerical questions - You will present your solutions in a logical structure by providing free body diagrams where applicable, implementing the correct formulas and using the correct system of units to express your final answers. You will make appropriate and valid comments on your final results.
Conditions Minimum mark or grade - 50%
Referencing Style Harvard (author-date)
Submission Online

Submit a PDF document via the assessment link provided on the unit Moodle site.

Learning Outcomes Assessed
This section can be expanded to view the assessed learning outcomes

1. Clearly establish the relationships between the microstructural of materials and their mechanical and manufacturing properties

2. Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials; and the machine tools that are used to carry out these operations

3. Calculate numerically the forces, torques and power requirements for various processing different materials for bulk deformation

6. Apply information literacy skills, obtain relevant engineering information and identify appropriate standards and practices

Graduate Attributes
This section can be expanded to view the assessed graduate attributes

2. Problem Solving

3. Critical Thinking

4. Information Literacy

6. Information Technology Competence



Examination

Outline Complete an examination
Date During the University examination period
Weighting 40%
Condition Minimum percentage of examination marks required to pass course - 50%
Length 120 minutes
Details Dictionary - non-electronic, concise, direct translation only (dictionary must not contain any notes or comments).
Calculator - all non-communicable calculators, including scientific, programmable and graphics calculators are authorised.
Restricted
Recommended textbook - Groover, Mikell, P., Fundamentals of Modern Manufacturing, John Wiley, 6th Ed. Hardcopy and binder versions permitted Lecture notes
Learning Outcomes Assessed
This section can be expanded to view the assessed learning outcomes

1. Clearly establish the relationships between the microstructural of materials and their mechanical and manufacturing properties

2. Explain various bulk deformation and material removal processes as applicable to ductile and brittle materials; and the machine tools that are used to carry out these operations

3. Calculate numerically the forces, torques and power requirements for various processing different materials for bulk deformation

4. Mathematically analyse the mechanics of metal cutting and the control of various process parameters to achieve optimum material removal and machining economics

5. Apply the knowledge of engineering metrology, instrumentation and quality assurance of manufacturing of products

Graduate Attributes
This section can be expanded to view the assessed graduate attributes

1. Communication

2. Problem Solving

3. Critical Thinking

8. Ethical practice


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