Introductory description

Fundamentals of Manufacturing.
This module provides a broad overview of the most widespread manufacturing processes that most engineering students are expected to know, covering the necessary process theory and complemented with practical elements going from process demonstrations to simulations.

Module aims

Outline syllabus

This is an indicative module outline only to give an indication of the sort of topics that may be covered. Actual sessions held may differ.

This is an indicative module outline. Actual sessions held may differ.

• Introduction to Assembly Modes: Tolerances, Limits & Fits. Topics covered: Design limits and their specifications; tolerances, tolerance representations, International Tolerance Classes (IT Ranges); interacting components & fit; types of fit (clearance, interference and transitional).
• Introduction to Primary Manufacturing Processes. Casting processes (lost wax / lost foam, moulding, investment casting, die casting, and others); Metal forming processes (forging, wire drawing, rolling, extrusion, swaging, hot & cold working); Powder metallurgy, sintering.
• Fundamentals of Machining . Machining and its processes (turning, milling, drilling, grinding, and others); machining concepts & definitions; geometry of the cutting tool and ancillary cutting parameters; tool wear.
• Non-conventional machining processes. (EDM cutting, abrasive water-jet cutting, etching, electrochemical cutting, etc.).
• Sheet metal working: cutting, forming and Joining. Design for sheet metal, profiles, and cutting technologies.
• Introduction to polymer processing. Injection moulding essentials: part design, mould elements and considerations. Process simulations. Other processes: thermoforming, compression moulding and blow moulding.

Learning outcomes

By the end of the module, students should be able to:

• Develop knowledge and understanding of key manufacturing processes, including their operation fundamentals, machinery and equipment, capacity, as well as their implications in terms of shape, tolerances and accuracy. [C2, C12, M12]
• To understand the material selection implications for different manufacturing routes, considering aspects of surface finish, accuracy, productivity, structural stability and sustainability. [C13, M13]
• Use of computational tools to aid in decision-making for process analysis and identify which process parameters influence variation in final product characteristics. [C3]
• Develop expertise in manufacturing principles supported by up-to-date literature, trends and findings regarding design innovation. [C4,M4 C17, M17]
• To promote an appreciation for the additional implications of manufacturing technology, including health and safety, operational requirements, materials datasheets, process standardisation and regulations. [C5, C9, C10,M10]

Indicative reading list

• Fundamentals of modern manufacturing: materials, processes, and systems, Groover, Mikell P 2021
  *Handbook of manufacturing engineering and technology, Andrew Y. C. Nee 2015
• Manufacturing processes for engineering materials; Kalpakjian, Serope; Schmid, Steven R, 2023
• Manufacturing engineering and technology by Kalpakjian, Serope; Schmid, Steven R; Sekar, K. S. Vijay, 2014

Interdisciplinary

Although aimed at Mechanical Engineering stream students, it can include any other related engineering discipline.

International

The module is a viable route for exchange students wanting to choose a technical/practical course whilst at Warwick.

Subject specific skills

*Ability to conceive, make and realise a component, product, system or process
*The use of technical literature, datasheets, and other information sources including industry standards in the design and selection of manufacturing routes.
*Development of Design for X skills which are process-specific.

• Apply knowledge of CAD/CAM tools and technologies to propose strategies to enhance engineering design and manufacture of familiar products.
• Apply design and manufacturing methods to solve engineering problems.

Transferable skills

• Apply problem-solving skills, information retrieval, and the effective use of general IT facilities
• Plan self-learning and improve performance, as the foundation for lifelong learning.
• Exercise initiative and personal responsibility, including time management, which may be as a team member or leader.
• Appreciation of the broad implications of manufacturing routes, including their impact on sustainability.
• Professional outlook, team working capacity and leadership skills in a technical environment.
• Effective communication and the exercise of responsibility for technical decisions.
• Commit to personal learning and professional development.