Students acquire fundamental properties of various materials that constitute machines and learn the basic processes, principles, theories on manufacturing technologies that produce shaped parts from the materials.
Students learn the fundamental properties of various materials that constitute machines and the basic processes, principles, theories on manufacturing technologies that produce shaped parts from the materials.
This course covers various manufacturing processes for industrial products such as machines. The knowledge on manufacturing processes are crucial for design. Since manufacturing processes are based on the laws of mathematics, physics and chemistry, students will acquire the fundamentals to understand phenomena of the processes from the scientific viewpoint. In particular, mechanisms of manufacturing processes are organized in terms of the structure and properties of materials.
At the end of this course, students will be able to:
1) Explain various manufacturing processes by categorizing them as removal process, joining process and forming process.
2) Design products with consideration of manufacturing processes
3) Explain the relationship between processing mechanism and fundamental materials properties.
production, processing, material, machine, forging, casting, powder metallurgy, injection molding, cutting, grinding, polishing, welding, joining, electrical discharge machining, electrochemical machining, chemical machining, laser processing, electron beam processing, ion processing, surface treatment, micromachining
|✔ Specialist skills||Intercultural skills||Communication skills||Critical thinking skills||✔ Practical and/or problem-solving skills|
Each class has a specific topic, and the fundamentals concerning properties of materials, forming processes, removal processes, joining processes and modern processes are outlined in turn. Review questions are given for each unit of topics.
|Course schedule||Required learning|
|Class 1||Introduction of manufacturing processes||Explain the procedure of the production of machinery.|
|Class 2||Types and structure of materials used for machinery||Explain what types of materials are used for production of machines. In addition, list and explain each of the major three types of the crystal structure of metals and the defects.|
|Class 3||Mechanical properties of materials||Define tensile strength, elongation, toughness and hardness.|
|Class 4||Casting||Explain the process of casting.|
|Class 5||Plastic deformation processes (rolling, extrusion, drawing)||Explain the process of hot rolling with showing the behavior of metallic materials.|
|Class 6||Plastic deformation processes (sheet metal forming, forging)||Explain why the products made by forging are mechanically strong.|
|Class 7||Powder metallurgy Forming and shaping of plastics||Explain the ways of manufacturing that use particle or powder materials.|
|Class 8||Cutting||Explain the types of cutting with showing the tools used.|
|Class 9||Grinding||What do you examine to obtain desirable grinding surface?|
|Class 10||Surface finishing (polishing)||Explain why surface finishing is required. In addition, list and outline three common surface finishing processes.|
|Class 11||Surface treatment||What types of process that coat substrate with different materials are there in surface treatment? Explain the processes with their principles.|
|Class 12||Joining processes||What types of joining processes are there? Explain the processes with their principles.|
|Class 13||Electrical and chemical processes||List the practical processes that use electrical, chemical and electrochemical energies, and explain the way of each process.|
|Class 14||High-energy beam processing||What types of beam are applied to high energy beam processing? Summarize the processes in terms of energy used.|
|Class 15||Micromaching||Give an outline of the production process of semiconductor devices.|
Toshiyuki Obikawa and Hiroyuki Sasahara ed., A 1st Course in Manufacturing Processes 1, Kodansha, ISBN 978-4-06-156550-0 (Japanese)
Toshiyuki Obikawa and Hiroyuki Sasahara ed., A 1st Course in Manufacturing Processes 2, Kodansha, ISBN 978-4-06-156556-2 (Japanese)
Katsushiko Yamaguchi and Kunio Okimoto, Materials Processing Processes, Kyoritsu Publication Co., ISBN4-320-08131-5 (Japanese)
Masataka Inagi and Takeshi Yoneyama, Fundamental Knowledge of Processing Required for Designers, Nikkan Kogyo Shinbun Ltd., ISBN4-526-04396-6
Students’ course scores are based on final exams (70%) and review quizzes (30%).
Double registration with "MEC.G311 ： Introduction to Manufacturing Engineering" is not allowed.