The subject ‘Manufacturing Processes in Automotive Technology’ aims to introduce students to the most relevant metal-mechanical manufacturing processes in the automotive sector and to familiarise them with the most significant elements and characteristics of each of them.



The main objectives are:



1.- To provide a general overview and basic information related to the Metal-Mechanical Manufacturing Industry.



2.- To introduce the characteristics and capabilities of the main M-M manufacturing processes (welding, moulding, plastic forming and material removal).



3.- To establish the fundamentals and criteria to know how to choose the appropriate manufacturing process for a specific type of part.



4.- To know the basic procedures for the measurement and verification of parts.

Starting from product design and knowledge of materials, the subject Manufacturing Processes in Automotive Technology establishes the fundamentals of knowledge and the application of metal-mechanical forming processes in a logical sequence according to their location in the production context. Hence the multidisciplinary character of the subject, and the large number of interrelationships with other fields or areas of knowledge.

This discipline is responsible for the identification and characterisation of the different factors involved in the mechanical transformation processes undergone by a material (mainly metals and their alloys), from when it has been produced in its raw state until it is transformed into a finished product, as well as the parameterisation of these factors and the establishment of the limits for their control.



The aim is to develop the basic knowledge and skills for the selection, design and control of metal-mechanical manufacturing processes, from the production of unitary parts to the production of large series, paying special attention to the criteria of flexibility and production costs and to the relations with other fields of knowledge in Engineering.

METROTECHNICS



Introduction to Metrology. Characteristics of measurements. Measuring instruments and standards. Tolerances. Measurement uncertainty. Acceptance tolerances. Analysis of a measurement system. Statistical control of manufacturing processes.



JOINING OF METALLIC ELEMENTS. WELDING



Basic welding concepts. Weldability of metals. Contribution energy. Cooling and solidification. Metallurgy of welding. Homogeneous electric arc welding (fundamentals and most characteristic processes). Homogeneous electric resistance welding Heterogeneous welding



SHAPING BY MOULDING



Sand moulding. Fundamentals and classification. Elements of the mould. Process design. Introduction to automated processes. Shell moulding. Investment casting. Permanent mould casting. Gravity, Low pressure, Injection.



PLASTIC METAL FORMING

Introduction to the theory of plastic deformation. Processes and products. Types of processes. Hot deformation processes. Forging. Continuous and semi-continuous processes. Rolling, extrusion, drawing and drawing. Cold deformation processes. Sheet metal forming. Types of machines.



MACHINING BY CHIP REMOVAL



Introduction to machining processes. Classification. Machinability. Forces in machining. Fundamentals of cutting tools. Processes: Turning and milling. Types of machines. Introduction to Numerical Control - CNC. Economics of machining.

The lectures will serve to explain the theoretical foundations of manufacturing processes and those subjects that are closely linked to their development and control, trying to describe the multiple existing relationships with other disciplines and with the application of the knowledge that will be acquired in other engineering specialities. In the same way, the conceptual bases are established for the workshop and laboratory practicals and for the resolution of practical exercises of medium complexity.



In the workshop and laboratory practicals, some of the knowledge acquired in the lectures will be put into practice through the use of the software, instruments and machinery available in each case.



The workshop and laboratory practicals will be carried out in groups composed of a maximum of 25 students who will be organised into teams of two, maximum three students (depending on the practical), who will develop the practical by integrating skills and knowledge. In those cases in which, for reasons of space, safety or capacity of the available equipment, the number of participants must be limited, the practical group will be subdivided into two subgroups of twelve or thirteen members each.

• Continuous Assessment System
• Final Assessment System
• Tools and qualification percentages:
  • Written test to be taken (%): 30
  • Realization of Practical Work (exercises, cases or problems) (%): 20
  • Team projects (problem solving, project design)) (%): 30
  • Exhibition of works, readings ... (%): 10
  • CORRECCIÓN DE PROYECTOS (%): 10

The assessment of the ordinary exam will be carried out according to the following criteria:



1) Assessment of the workshop or laboratory practicals: up to a maximum of 20% of the joint grade.



2) Assessment of mastery and/or knowledge of the contents of the lectures and the corresponding application exercises: up to a maximum of 40% of the overall grade.



3) Assessment of PBL project-based learning: up to a maximum of 20% of the overall grade.



4) The previous evaluations will be complementary and their respective grades will add up to a maximum of 100% of the final joint grade, having to pass both independently to pass the subject as a whole. The first practical class of the term will be introductory and students will be informed about the details of the process of both evaluations and the minimums to be reached in each case.



5) Unexcused absence from two or more practical sessions will mean the automatic loss of 20% of the maximum grade achievable in the evaluation as a whole for workshop or laboratory practices.



100% of the grade may be obtained by means of the written theoretical-practical exam in the case that the student chooses the ‘Final Evaluation System’ for which he/she will have to communicate it in writing to the teacher of the master classes of his/her group within nine weeks from the beginning of the course.





In other cases, the weighted sum of the marks obtained in the evaluation of the lecture contents and application exercises and the evaluation of the workshop and laboratory practicals shall be applied, and the condition expressed in points 3 and 4 shall be fulfilled in all cases.

In the extraordinary call, there will be a single test or final exam (written test) in which all the contents developed during the course will be covered.



If the student does not take the exam in the ORDINARY or the EXTRAORDINARY exam, he/she will get a ‘No-show’ regardless of his/her participation in the workshop or laboratory practicals.

Documentation and information provided by the teaching staff of the subject.

Basic bibliography

The bibliography is specific to each topic, although there are two books that cover most of the topics in a consistent manner.



Tecnología Mecánica y Metrotécnia Coca Rebollero, Pedro and Rosique Jiménez, Juan

Publisher: Pirámide



Manufactura. Engineering and Technology Kalpakjian, Serope and Schmid, Steven R.

Publisher: Pearson Educación



The aim of these texts is educational and not informative. For this reason, in the writing of each chapter, the process is analysed rather than described so that the reader, at each stage, can assess the influence of the parameters involved. Thus, when studying rolling, for example, the analysis of the thermal-mechanical process of the passage of the material between the rolls is more in-depth, and the lengthy (to be read) description of the rolling mills is dealt with very succinctly, as it does not change the essence of the process, whether the roll is more or less. The same can be said of casting technology, welding methods, etc.