MANUFACTURING TECHNOLOGY subject is taught in 4th Course Degree in Industrial Technology and is the introduction to advanced subjects dealing with manufacturing processes at the Faculty of Engineering of Bilbao.

The course introduces students to the capabilities of key manufacturing processes (machining, forging, casting ...) and machine tools and equipment necessary to perform them. In addition, given its link with manufacturing, special attention is given to measurement technologies (Dimensional Metrology). Within this context, the course aims to address the need for students to be able to justify what manufacturing processes could be used for the production of a certain component.

On the other hand, it is intended that students can describe the equipment and calculate the most important parameters of a particular manufacturing process, and propose, under clear reasons, orders of magnitude of the fundamental parameters.

Finally, it is also intended that students can describe the drive systems and control of the machines used in the manufacture of parts. All this taking as general context the importance of the industry and machine tool accessories in the Basque Country and surroundings.

M02R9 specific competence: Basic knowledge of production systems and manufacturing.



From these competences the following learning outcomes are derived:

-To be able to integrate the design requirements of a component in the productive means available in a particular manufacturing plant.

-To be able to design components and sets of machine tools, as well as to address the modifications in them to extract the maximum productive yield of them.

-To be able to integrate the techniques of metrology and quality control in the production chain.

-To be able to optimize the machining, casting and plastic deformation processes.

-To be able to select and design the tools and equipment needed to manufacture a specific component.

-To be able to obtain the maximum added value for a given component through the selection of the most suitable process.

-To be able to understand the consequences of the material -manufacturing process interaction, valuing the modification of functional and service properties that can suffer a certain component after the forming operations.

MODULE I. DIMENSIONAL METROLOGY

Lesson 1. Introduction to Dimensional Metrology

Lesson 2. Operational and instruments

Lesson 3. Metrology surface finish



MODULE II. FOUNDRY

Lesson 4. Sand Casting

Lesson 5. Development of sand casting

Lesson 6. Permanent mold casting



MODULE III. PLASTIC FORMING

Lesson 7. General

Lesson 8. The forging process

Lesson 9. Rolling

Lesson 10. Forming sheet

Lesson 11. Semi-continuous processes



MODULE IV. MACHINING

Lesson 12. Turning

Lesson 13. Milling

Lesson 14. Drilling

Lesson 15. Cutting Tools

Lesson 16. Grinding

Lesson 17. Numerical Control



MODULE V. OTHER TECHNOLOGIES

Lesson 18. Introduction to welding processes

Lesson 19. Additive Manufacturing

Lesson 20. Sintering

The teaching of the subject is articulated through the following instruments:



- Theoretical and practical classes (M and GA) taught in the classroom, where the teacher will explain the main concepts.



- Industrial workshop practices (TI): Students will be able to analyze the manufacturing processes of different workpieces, perform calculations corresponding to real problems and use instruments and machines similar to those that can be found in an industrial manufacturing workshop.



- Seminars (S): Students will be able to carry out calculations corresponding to machining problems to strengthen the knowledge acquired in the magistral lessons related to the machining module.



The contents of both the industrial workshop practices and the seminars are a necessary complement to the magistral lessons in order to establish the differences between different manufacturing processes and to observe real applications of these to industrial components. Given the importance of both, their content is a subject of examination, as well as the contents of magistral lessons (M) and classroom practices (GA). The industrial workshop practices and the seminars will be carried out by groups in the official schedules of the subject.

• Final Assessment System
• Tools and qualification percentages:
  • Written test to be taken (%): 100

General features:

- All concepts taught in both theoretical and practical classes are subject to evaluation.

- The pass in the subject will be obtained with a grade equal to or greater than 5 in the corresponding call. In no case will evaluations be carried out outside the official published dates.

- Only those students who are officially enrolled in the subject may receive the evaluation of the subject.



The evaluation process consists of quantifying to what extent the students have assimilated the fundamental concepts of the subject. The evaluation of the subject is continuous and is made up of a set of written exams.



WRITTEN EXAMS (development and test)



The evaluation of the theoretical-practical part is carried out through a set of written exams. The evaluation system for the written exams is detailed below.



MIDTERM EXAM

Partial exam corresponding to the first three modules of the subject: Dimensional Metrology, Casting and Plastic Forming. It is an optional exam, whose weight on the ordinary call of the subject is 35%. The qualification required in order not to repeat it in the regular exam is 5.



REGULAR EXAM

It is an official exam. It consists of 4 parts:

1. Written exam corresponding to the last two modules of the subject: Machining by Chip Removal and Other Technologies. The weight on the final exam of the subject is 30%.

2. Numerical problem associated with module IV. The weight on the final exam of the subject is 25%.

3. Written exam corresponding to the Industrial Workshop Practices (PTI). The weight on the final exam of the subject is 10%.

4. Written exam corresponding to the first three modules of the subject: Dimensional Metrology, Casting and Plastic Forming. The weight on the final exam of the subject is 35%. This part will not be compulsory if the midterm exam has been passed.



If this call is failed, the complete exam should be taken in the extraordinary call.

It is an official exam which consists of 4 parts:

1. Written exam corresponding to the first three modules of the subject: Dimensional Metrology, Casting and Plastic Forming. The weight on the final exam of the subject is 35%.

2. Written exam corresponding to the last two modules of the subject: Machining by Chip Removal and Other Technologies. The weight on the final exam of the subject is 30%.

2. Numerical problem associated with module IV. The weight on the final exam of the subject is 25%.

3. Written exam corresponding to the PTI. The weight on the final exam of the subject is 10%.



The student has to take all the parts in order to pass the exam.

Teaching Guide available for free on the platform of Virtual Teaching at the UPV / EHU Student Guide, Course notes, Sheets practices and general information.

Basic bibliography

•American Society for Metals; Casting Design Handbook; American Society for Metals (ASM), 1962

•Beeley, P.R.; Foundry Technology; Butterworth-Heinemann, 2001

•American Society for Metals; Powder Metal Technologies and Applications ASM Handbook, Vol. 7, 1998

•Byrer, T.G., Semiatin, S.L., Vollmer, D.C.; Forging Handbook; Forging Industry Association/American Society for Metals, 1985

•Wick, C., Benedict, J.T., Veilleux, R.F.; Tool and Manufacturing Engineers Handbook. Vol 2. Forming; SME, 1984

•American Welding Society, Welding handbook, varios volúmenes.

•Jeffus, L., Welding. Principles and applications, Delmar Publishers, Inc., 1993.

•Davim, J. Paulo (Ed.); Machining Fundamentals and Recent Advances; Springer 2008.

•Metals Handbook. 9th Ed. Vol 16 Machining; ASM International, 1989

•Boothroyd, G., Knight, W.A.; Fundamentals of Machining and Machine tools, 2nd edition; Marcel Dekker, 1989.

•Arnone, M.; Mecanizado de alta velocidad y gran precisión. El Mercado técnico SL, 2000.

•Dotson C. L.; Fundamentals of Dimensional Metrology; Delmar Cengage Learning, 2006

•Farago, F.T.; Handbook of Dimensional Measurement. Industrial Press, 1982

In-depth bibliography

•Lopez de Lacalle, L.N.; Lamikiz, A. (Eds.); Machine Tools for High Performance; Springer 2009.
•Bucher J. L.; The Metrology Handbook; ASQ Quality Press, 2012.
•Casting Design Handbook; American Society for Metals (ASM).
•Campbell, J.; Castings; Butterworths-Heinemann, 1991.
•Byrer, T.G., Semiatin, S.L., Vollmer, D.C.; Forging Handbook; American Society for Metals (ASM).
•Pearce, R.; Sheet Metal Forming. Adam Hilger, 1991.
•Metals Handbook, 9th edition, vol. 14. Forming and forging. ASM International.
•López de Lacalle, L.N., Sánchez, J.A., Lamikiz, A.; Mecanizado de alto rendimiento: Procesos de arranque. Ediciones Técnicas Izaro, 2004
•Kieff, H.B. Manual de CNC. Gran Duc. 1998
•Galyer J.F.W., Shotbolt, C.R.; Metrology for engineers. Cassell Publishers Limited, 1990.

Journals

Scientific journals with articles directly related to the subject content and accessible from the library of the University of the Basque Country UPV/EHU.

* Advanced Materials and Processes.
* Annals of the International Institution for Production Engineering Research (CIRP).
* IMHE (Información de Máquinas-Herramienta, Equipos y Accesorios).
* International Journal of Machine Tool and Manufacture
* Journal of Engineering Materials & Technology.
* Journal of Material & Processing Technology.
* International Journal on Production Research.

Web addresses

www.ehu.es/manufacturing
www.engineershandbook.com
www.moderncasting.com/
www.forjas.org
www.euroforge.org/
www.afm.es
www.coromant.sandvik.com/es
www.cem.es