This course is intended to teach types and characteristics of manufacturing methods to undergraduate students with the aim of understanding fundamentals of manufacturing processes. First, an overview of the basic various manufacturing methods used in the production of industrial products, including mechanical components, electric and electronic parts, will be taught, followed by the introduction of manufacturing process of the products. In particular, manufacturing methods of the components are focused, and students are allowed to understand fundamental characteristics and application of manufacturing processes, based on gaining the knowledge on the principle of manufacturing method in connection with the characteristics of materials. These knowledge are essential to perform functional and structural design of the products. Furthermore, students are allowed to learn how to select appropriate manufacturing method in accordance with the product.
1. Deformation processes (casting, plastic deformation processes, etc.)
2. Material-removal processes (cutting, grinding, etc.)
3. Joining processes (welding etc.)
4. Materials (microstructure, mechanical properties, etc.)
By the end of this course, students will be able to:
1. Understand the fundamentals of manufacturing process, and advantages and drawbacks of each process as follows.
casting, forming of plastics, welding and joining processes, rolling, extrusion, drawing, sheet-metal forming processes, forging, cutting, metal die manufacturing and CAE, grinding, polishing, electrical processes, laser-beam machining, surface treatment, coating, additive manufacturing, micromachining
2. Gain the knowledge on the relationship between materials' microstructure/properties and processings.
3. Select appropriate materials processing method applied for individual industrial component.
|✔ Applicable||How instructors' work experience benefits the course|
|A lecturer who has experience working at a company will educate them so that they can learn a wide range of practical knowledge on the importance of the fundamentals of manufacturing engineering and its applications, including experience in the company.|
Manufacturing processes, monotsukuri, materials processing, selection of materials processing method
|✔ Specialist skills||Intercultural skills||Communication skills||Critical thinking skills||Practical and/or problem-solving skills|
1) Towards the end of class, students are given exercise problems related to what is taught on that day to solve.
2) Before coming to class, students should read the course schedule and check what topics will be covered. Required learning should be completed outside of the classroom for preparation and review purposes.
3) Students must familiarize themselves with topics described in the required learning section before coming to class.
|Course schedule||Required learning|
|Class 1||What is manufacturing engineering? Materials and Processing||Do you understand the outline of Monotsukuri? Do you understand that the manufacturing processes depend on material?|
|Class 2||Casting, Processing of polymer materials||Do you understand casting, and crystal growth and defects in cast products? Do you understand the fundamentals of injection molding?|
|Class 3||Welding and joining||Do you understand types and characteristics of welding, and heat affected zone (HAZ)? Do you understand brazing, solid state welding and adhesion?|
|Class 4||Plastic forming (Milling, Extrusion, Drawing)||Do you understand the machining characteristics of milling, extrusion and drawing?|
|Class 5||Plastic forming (Sheet metal forming, Forging)||Do you understand sheet metal forming and forging process?|
|Class 6||Cutting||Do you understand the theory and practice of cutting?|
|Class 7||Die forming and computer aided engineering||Do you understand die and die forming? Do you understand application of CAE to die forming?|
|Class 8||Grinding||Do you understand the theory and practice of grinding?|
|Class 9||Polishing||Do you understand the theory and practice of polishing?|
|Class 10||Electronical machining and laser processing||Do you understand the theory and practice of electronical machining and laser processing?|
|Class 11||Surface treatment and coating||Do you understand surface treatment process and characteristics of coatings?|
|Class 12||Additive manufacturing||Do you understand the trend of additive manufacturing?|
|Class 13||Micro processing||Do you understand the types of micro-machining, and micro fabrication process?|
|Class 14||Selection of materials processing methods||Do you explain how to select materials processing methods?|
To enhance effective learning, students are encouraged to spend approximately 100 minutes preparing for class and another 100 minutes reviewing class content afterwards (including assignments) for each class.
They should do so by referring to textbooks and other course material.
Obikawa, Toshiyuki. Fundamentals of Manufacturing and production 1&2，Tokyo, Kodansha; ISBN 978-4-06-156550-0, 978-4-06-156556-2 (in Japanese)
Yamaguchi, Katsuhiko and Okimoto, Kuniaki. Materials Processing, Tokyo Kyoritsu shuppan; ISBN 978-4320081314 (in Japanese)
Tani, Yasuhiro and Murata, Junji. Introduction of Manufacturing and Production. Suurikougaku-sha; ISBN 978-4864810128 (in Japanese)
To be evaluated based on the results of the on-site final exam (80%) and the exercise problems related to what is taught on that day (20%), or the results of quizzes and assignments given during each session and after the end of the course (100%).
You have to completed ’Mechanical Materials', or have equivalent knowledge.