Manufacturing Processes I

Objectives

Enable the understanding of the general plasticity, friction, wear and lubrication applied to manufacturing processes.
Acquire a general knowledge of metal forming, shearing/blanking and metal cutting.
Develop the ability to select a manufacturing process, suggest possible changes in a product design considering its requirements, to select the most suitable raw materials and tool materials.

Program

1. General introduction to the manufacturing processes, bulk and sheet forming, shearing/blanking and machining. Selection of mechanical processing technologies based on specifications related to materials, geometries, tolerances, surfaces, batch size and production costs. Environmental topics.
2. Phenomenological topics in the mechanical behaviour of materials. Temperature and strain-rate sensitivity. Stress-strain/strain-rate relationships. Mechanical and formability testing of materials.
3. Plasticity and viscoplasticity. Friction testing of materials and lubricants. Analysis based on the ideal work, slab and slip line fieldmethods.
4. Mechanical processing of materials. Fundamentals of bulk metal forming: Forging. Fundamentals of sheet metal forming. Fundamentals of shearing/blanking. Fundamentals of metal cutting: orthogonal metal cutting.

Teaching Methodologies

The teaching methodology aims to encourage learning based on problem solving and projects, reinforcing the practical component, active learning, autonomous work and student accountability. The evaluation model incorporates a group work in which student sanalyze the manufacturing sequence of a metallic component (40%) and questions from the laboratories (10%). The final exam willhave a weight of 50%.

Bibliography

"Tecnologia Mecânica – Tecnologia da Deformação Plástica" Vol I, Jorge Rodrigues e Paulo Martins, , 2005, Escolar Editora;"Tecnologia Mecânica – Tecnologia da Deformação Plástica" Vol II, Jorge Rodrigues e Paulo Martins, 2005, Escolar Editora;"Tecnologia Mecânica – Tecnologia da Deformação Plástica" Vol III, Bárbara Gouveia, Jorge Rodrigues e Paulo Martins, 2011,Escolar Editora; "Introduction to manufacturing processes", Schey J. A. , 1987, McGraw Hill; "Manufacturing processes forengineering materials", Kalpakjian S. , 1984, Addison-Wesley