Educational guide 2024_25 Escola de Enxeñaría Industrial

Fundamentals of manufacturing systems and technologies

Contents

Topic	Sub-topic
DIDACTIC UNIT 1. INTRODUCTION To THE TECHNOLOGIES And SYSTEMS OF MANUFACTURE.	Lesson 1. INTRODUCTION TO MANUFACTURING ENGINEERING. The production cycle. Classification of industries. Manufacturing technologies.
DIDACTIC UNIT 2. METROTECHNICS.	Lesson 2. PRINCIPLES OF DIMENSIONAL METROLOGY. Introduction. Definitions and concepts. The international system of units. Physical quantities covered by Dimensional Metrology. Elements involved in the measurement. Classifications of measurement methods. Patterns. The traceability chain. Calibration. Uncertainty. Calibration chain and transmission of uncertainty. Relationship between tolerance and uncertainty. Expression of measurement uncertainty in calibration. Lesson 3. MEASUREMENT INSTRUMENTS AND METHODS. Introduction. Patterns. Verification instruments. Interferometric patterns. Principles of interferometry. Direct measurement instruments. Methods and instruments of indirect measurement. Lesson 4. MEASUREMENT BY COORDINATES. IMAGE MEASUREMENT. SURFACE QUALITY. Coordinate measuring machines. Concept. Principles of MMC. Classification of machines. Main components of MMC. Process to follow for the development of a measure. Image measurement systems. Surface Quality. Roughness measurement methods. Roughness parameters.
DIDACTIC UNIT 3. FORMING PROCESSES BY MATERIAL REMOVAL	Lesson 5. INTRODUCTION TO SHAPING BY MATERIAL REMOVAL. Introduction. Movements in the material removal process. Factors to take into account when choosing the tool. Tool geometry. Tool materials. Chip formation mechanism. Types of chips. Power and cutting forces. Tool wear. Tool wear criteria. Determination of tool life. Cutting fluids. Lesson 6. TURNING: OPERATIONS, MACHINES AND TOOLS. Introduction. Main operations around. The machine tool: the lathe. Main parts of the lathe. Assembly or holding of parts. Typical lathe tools. Special lathes. Lesson 7. MILLING: OPERATIONS, MACHINES AND TOOLS. Introduction. Description and classification of milling operations. Parts and main types of milling machines. Types of strawberries. Tool assembly. Piece clamping. Different configurations of milling machines. Special milling machines. Lesson 8. MACHINING OF HOLES AND WITH MAIN RECTILINEAR MOVEMENT: OPERATIONS, MACHINES AND TOOLS. Introduction to hole machining operations. Drilling machines. Boring machines. General characteristics of machining processes with main rectilinear movement. Filer. Mortiser. Planer. Broaching machine. Saws. Lesson 9. SHAPING WITH ABRASIVES: OPERATIONS, MACHINES AND TOOLS. Introduction to hole machining operations. Abrasive wheels. Grinding operation. Types of grinding machines. Honed. Lapped. Polished. Burnish. Super finish Lesson 10. NON-CONVENTIONAL MACHINING PROCESSES. Introduction. Machining by electro-erosion or electro-discharge. Electrochemical machining. Laser machining. Water jet machining. Plasma arc cutting. Ultrasonic machining. Chemical milling.
DIDACTIC UNIT 4. AUTOMATION AND MANAGEMENT OF MANUFACTURING PROCESSES.	Lesson 11. NUMERICAL CONTROL OF MACHINE TOOLS. Introduction. Advantages of the application of NC in machine tools. Information needed to create a NC program. Manual programming of MHCN. Types of CN language. Structure of a program in ISO code. Characters used. Preparatory functions (G__). Auxiliary functions (M__). Interpretation of the main functions. Examples. Automatic programming in numerical control.
DIDACTIC UNIT 5. PROCESSES FOR SHAPING MATERIALS IN LIQUID AND GRANULAR STATES.	Lesson 12. GENERAL ASPECTS OF METAL CASTING FORMING. Introduction. Stages in casting forming. Nomenclature of the main parts of the mold. Materials used in casting. Fluid flow in the feeding system. Solidification of metals. Contraction of metals. The suck. Calculation procedure for the casting distribution system. Considerations on design and defects in cast parts. Lesson 13. FOUNDRY MANUFACTURING PROCESSES. Classification of foundry processes. Sand molding. Shell molding. Plaster molding. Ceramic molding. CO2 molding. Lost wax molding Full mold casting. Merccast molding. Molding in permanent mold. Injected casting. Centrifugal casting. Furnaces used in foundry. Lesson 14. POWDER METALLURGY (POWDER METALLURGY). Introduction. Manufacturing of metal powders. Characteristics and properties of metal powders. Dosing and mixing of metal powders. Compaction. Sintered. Sintering furnaces. Disruptive discharge sintering. Presintered. Subsequent operations. Design considerations. Products obtainable by sintering. Lesson 15. SHAPING OF PLASTICS. Introduction. Classification of polymeric materials. Physical properties of polymers. Classification of processes. Extrusion molding. Injection molding. Compression molding. Transfer molding. Rotational molding. Thermoforming.
DIDACTIC UNIT 6. UNION SHAPING PROCESSES.	Lesson 16. WELDING PROCESSES. Introduction to welding processes. Electric arc welding. Resistance welding. Welding with oxygen and fuel gas. Welding with the melting temperature of the filler metal lower than that of the metals to be joined. Lesson 17. JOINNING AND ASSEMBLY PROCESSES WITHOUT WELDING. Bonding processes using adhesives. Adhesion resistance. Conditions for gluing. Joint design Types of adhesives according to origin and composition. Mechanical joining processes. Removable and permanent mechanical joints.
DIDACTIC UNIT 7. FORMING PROCESSES BY PLASTIC DEFORMATION OF METALS.	Lesson 18. GENERAL ASPECTS OF FORMING BY PLASTIC DEFORMATION. Introduction. Stress-strain curves. Expressions of deformation. Volume constancy. Approximate models of the real stress-natural deformation curve. Plane strain state. Primary and secondary processes. Hot and cold work processes. Conditions and process control. Lesson 19. LAMINATION AND FORGING PROCESSES. Lamination: basics; lamination temperature; hot rolling equipment; characteristics, quality and tolerances of hot rolled products; cold rolling. Forging: free; in printing matrix; in press; by stressing; cold heading; by lamination; in cold. Lesson 20. EXTRUSION, DRAWING AND RELATED. Extrusion. Stretching of bars and tubes. Wire drawing. Section reduction. Embossing. Embossed around. Pieces made by embossing: design considerations. Stretch forming. Forming with rubber pads and pressurized liquid. High power shaping. Lesson 21. SHEET METAL SHAPING. Curving or bending of sheets. Curved with rollers. Formed with rollers. Straightened. Snapped. Sheet metal cutting operations.
PRACTICE PROGRAM	Practice 1.- Use of conventional metrology devices. Measurement of pieces using a normal caliper, depth gauge, exterior and interior micrometer. Use of dial gauge. Checking flat surfaces. Use of go/no go gauges, rules, squares and pattern cleats. Measuring and checking threads. Making metric measurements and in English units. Practice 2.-Indirect measurements. Checking a cone using rollers and a caliper, measuring a dovetail using rollers, measuring the angles of a double dovetail and measuring using a sine ruler. Direct measurements with goniometer. Checking threads. Practice 3.- Coordinate measurement machine. Coordinate system selection. Checking part measurements, using a coordinate measuring machine. Verification of tolerances, shape and position. Practice 4.- Manufacturing with conventional machine tools. Manufacture of a part using the conventional lathe, milling machine and drill, defining the basic operations and carrying them out on the machine. Manufacturing process planning. Preparation of process sheets. Practice 5, 6 and 7.- Introduction to numerical control applied to the lathe and milling machine. Realization of a CNC program using a simulator, with the main and simplest commands. Programming and machining of parts on both the lathe and the milling machine in the workshop classroom. Practice 8.- Welding. Knowledge of different electric welding equipment. Welding of different materials using coated electrode, TIG and MIG techniques. Practice 9.- Scoring practical test on numerical control.