The subject "Manufacturing Technologies" is taught in 3rd Course and is the only subject corresponding to the mechanical manufacturing processes in the Degree of Engineering in Industrial Organization in the Faculty of Engineering of Bilbao.



The objective of this subject is to provide students with a basic knowledge related to the world of mechanical manufacturing, with the primary aim of describing the main processes of mechanical component manufacturing as well as the tools and necessary equipment. Students should also be taught on the capabilities of each machine and tools when the accuracy, good finishing (roughness) are looking for. The limit batch size to be produced under certain conditions will also be analyzed.

Manufacturing Technologies subject introduces students to the capabilities of key manufacturing processes, including machining processes (ie, chip removal), manufacturing processes by metal plastic deformation and molding processes by casting, amongst others. In addition, dimensional metrology is also a chapter related to manufacturing and different instruments and equipment will be studied.



The classes of the course will be of three types:



- Theoretical classes in the classroom where the teacher will explain the main concepts of matter using transparencies, copies of which are available to students in the Publications Service School.



- Video classes. Because of the largely descriptive nature of the subject, video classes are a very suitable complement to theoretical explanations. In these various industrial aspects of implementation of the processes described in class they are shown in detail.



- Practices. These classes will take place in the classroom where theory is taught in a specific classroom practices and the Workshop of the Mechanical Engineering Department. In them, students can analyze manufacturing processes of different pieces and parts and observe real machines. The contents of these practices are a necessary complement to theoretical classes in order to establish the differences between different manufacturing processes and observe them real applications of industrial components. Given the importance of these practices, its contents are proper matter of consideration, like the contents of the video and theory classes.



As for the relationship with other subjects previously studied in degree, it should be noted that there are subjects directly related manufacturing technologies, such as technical drawing , Materials Science and Mechanics, which help understanding the basic concepts necessary for the understanding of the subject are given. Thus, students will be given an overview of most manufacturing processes from the most basic concepts. In fact, the importance of this subject is given because in the context and industrial environment in which students of this degree are located is essential to the general understanding of the processes most common manufacturing or greater impact on our society.



It is noteworthy that historically has been an important relationship of this subject with the Final Project of the Degree. Many of the projects that possibly will develop a graduate in Industrial Organization involve the manufacture of components or managing their lay-out. This requires knowledge of manufacturing processes of projected equipment, especially if it is to establish a budget and a realistic implementation plan. Moreover, it is obvious the importance of knowledge of the techniques to design projects and properly document a new lay-out or management of a plant and its flows and establish the prerequisites that must be met.

The competences of this subject are defined taking into account the manufacturing technologies most widely used in the industry of our environment. These skills are:



1 Be able to justify why manufacturing processes could be used for the production of a mechanical certain part, that is, a solid body of material and well defined geometric features, and in a certain production conditions (batch size in particular).



2nd Be able to describe the equipment and most important parameters of a particular process of manufacturing parts, and propose reasoned, an order of magnitude of the parameters.



3rd Be able to describe, in general, the drive systems and control of the machines used in the manufacture of parts, and the most important for the geometric verification methods and equipment manufactured parts.



M02R9 specific competence: Basic knowledge of production systems and manufacturing

MODULE I. DIMENSIONAL METROLOGY

1. Introduction to Dimensional Metrology

2. Operational and instruments

3. Metrology surface finish



MODULE II. FOUNDRY

4. Sand Casting

5. Development of sand casting

6. Permanent mold casting



MODULE III. PLASTIC FORMING

7. General

8. Forging process

9. Rolling

10. Sheet forming

11. Semi-continuous processes



MODULE IV. MACHINING

12. Turning

13. Milling

14. Drilling

15. Cutting Tools

16. Grinding

17. Numerical Control



MODULE V. OTHER TECHNOLOGIES

18. Flexible manufacturing systems

19. Sintering

The teaching activity is organized into: theoretical classes (T) practices in classroom (GA), practices at the workshop (TI) and personalized tutorials.

• Continuous Assessment System
• Final Assessment System
• Tools and qualification percentages:
  • Written test to be taken (%): 80
  • Exhibition of works, readings ... (%): 20

General considerations:

- All the topics lectured during the theoretical and practical lessons are subject to evaluation.

- The minimum pass mark in the subject will be obtained with a grade equal to or greater than 5 in the corresponding call. Evaluations out of the official dates will not be done in any case.

- Only those students who are officially enrolled in the subject can receive the final mark of the subject.



The evaluation process consists in qualifying the final level of competences and skills that students have acquired. The evaluation of the subject is focused on a continuous method and consists of the following parts: written exams (80%) and Oral Presentation of a related work (20%)



WRITTEN EXAMINATIONS (TO BE DEVELOPED AND TEST)

The theoretical and practical part of the subject will be evaluated by written examination. To pass the lesson, a grade of 5 or more must be obtained in the written exam section. If at least 5 notes are not obtained in the written examination, the note of the subject will be that obtained in the written examination. The system of evaluation of written examinations is detailed below.



PARTIAL EXAM

Partial liberatory examination corresponding to the first three modules of the subject: Metrology, Foundry and Plastic Forming. It's an optional exam, weighing 35% on the ordinary exam of the subject. The qualification required for the release of this part is 5, and will be released only in the first official (ordinary) call.



ORDINARY EXAM

Official examination of the ordinary call, consisting of four parts:

1. Written exam of the last two modules of the lesson: machining and other technologies. The weight on the final exam of the subject is 30%.

2. The numerical exercise of module IV. The weight on the final exam of the subject is 25%.

3. Written exam of the PTIs. The weight on the final exam of the subject is 10%.

4. Written exam of the first three modules of the subject: metrology, casting, and plastic forming. The weight on the final exam of the subject is 35%. This part shall not be mandatory if the partial examination has been passed.



ORAL EXPOSITION AND DISCUSSION OF A RELATED TOPIC

The students must present a related topic by an oral presentation in groups of 3 students. The topic is free and can be choose from any related area of the course.

The presentation is limited to 15 minutes in total with additional 10 minutes for discussion. The weight of this activity is 20% of the total mark of the subject, which is distributed according to the following:

1) Technical content of the presentation 65%

2) Content of audiovisual media 15%

3) Faculty questions phase 20%

This teamwork is optional. Students performing group work shall inform the teaching team of the subject during the first two weeks of school.



For students who don't do group work, the weight of the written exam will be 100%.

It's the official exam for the extraordinary call, and it's divided into four parts:

1. Written exam of the first three modules of the subject: metrology, casting, and plastic forming. The weight on the final exam of the subject is 35%.

2. Written exam of the last two modules of the lesson: machining and other technologies. The weight on the final exam of the subject is 30%.

2. The numerical exercise of module IV. The weight on the final exam of the subject is 25%.

3. Written examination of the PTIs. The weight on the final exam of the subject is 10%.



To pass the extraordinary examination, the average must be 5 or more. If the minimum grade of 5 is not obtained in the written examination, the grade of the subject will be that obtained in the written examination.

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

I MODULE - FOUNDRY



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

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



II MODULE - PLASTIC FORMING



•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



III MODULE - MACHINING



• Davim, J. Paulo (Ed.); MachiningFundamentals 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.



IV MODULE - METROLOGY



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

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



V MODULE - OTHER PROCESSES



• American Welding Society, Welding handbook, varios volúmenes.

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

In-depth bibliography

Manufacturing Engineering & Technology, 6/E
Serope Kalpakjian, Illinois Institute of Technology
Steven Schmid, The University of Notre Dame
ISBN-10: 0136081681
ISBN-13: 9780136081685
Publisher: Prentice Hall
Copyright: 2010

Metals Handbook. Vols. 14A, 14B, 15, 16 y 17
ASM International
1989

Journals

IMHE Información de máquinas-herramienta, equipos y accesorios
Bilbao: Ediciones Técnicas Izaro

Manufacturing engineering
Dearborn, Michigan: Society of Manufacturing Engineers

CIRP Annals - Manufacturing Technology
(http://www.sciencedirect.com/science/journal/00078506)

Web addresses

www.cirp.net