PLEASE READ ALL INSTRUCTIONS AND INFORMATION CAREFULLY. This assignment contributes 30% to your final module mark.

THE FOLLOWING LEARNING OUTCOMES WILL BE ASSESSED:

Knowledge an understanding of:

 1. the diversity of processes involved in successful and economic materials and component manufacture.

2. the inter-relations between material, process, design/shape, performance and economics.

3. the range of techniques available for the joining of engineering materials and be able to select processes to optimise both bulk and surface properties.

 Skills and the ability to:

4. establish and interpret the natures and effects of important process variables.

5. deal with aspects of manufacturing processes in a quantitative manner.

 6. analyse and discuss the specific features of processes associated with the manufacture of metals, ceramics, glasses, polymers and polymer composite components.

7. employ process selection software and understand its underlying methodology.

8. select appropriate manufacturing/processing strategies on the basis of given requirements.

IMPORTANT INFORMATION

You are required to submit your work within the bounds of the University Infringement of Assessment Regulations (see your Programme Guide). Plagiarism, paraphrasing and downloading large amounts of information from external sources, will not be tolerated and will be dealt with severely. Although you should make full use of any source material, which would normally be an occasional sentence and/or paragraph (referenced) followed by your own critical analysis/evaluation. You will receive no marks for work that is not your own. Your work may be subject to checks for originality which can include use of an electronic plagiarism detection service.

Where referencing is required, unless otherwise stated, the Harvard referencing system must be used (see your Programme Guide).

 Submission Date and Time 16th Feb 2017

Cambridge Engineering Selector (CES Edupack 2015) Software

1.       Introduction

 CES software is a tool designed to aid in the process of materials and manufacturing process selection. To this end it can be used as:

(i)                  a database of information on materials and processes Covered in Year 1

(ii)                a selection tool for materials and/or processes

 CES is a powerful tool in helping to choose the most appropriate materials and manufacturing processes for engineering components. In this module , we are going to concentrate on process selection. Next year, in the module , we will turn our attention to materials selection.

In terms of materials selection, how do you go about choosing the best material for a given engineering application? What material(s) would be best suited for the manufacture of (say) bicycle forks, flywheels or pressure vessels? Knowing the right questions to ask makes the process easier. So, what sort of questions do we need to ask to make sure we get the correct choice? Such factors include cost, performance (e.g. mechanical, thermal), size, shape etc. CES uses a particularly strong but simple methodology to aid the materials selection process.

In terms of process selection, how do you go about choosing the best manufacturing process for a given component? For instance, how would you select a process to manufacture large steel pressure vessels? How would you manufacture a polyethylene milk carton? To answer such questions you need to know what distinguishes one manufacturing process from another. What questions must be asked to decide which manufacturing process is best?

 The methodologies employed within CES to aid selection of either materials or processes are quite similar. Each relies on knowing the critical questions to ask.

In the task which is described below, you will gather most of your information from CES. However, it is expected that you will add value by sourcing information from outside of CES where appropriate and acknowledge/reference these sources correctly.

2.       The Task

Part 1: Navigation through Processes

1. Open CES software. Choose Aerospace database.

2. In “Browse” mode, select Table: “Process Universe” and Subset: “All Processes”.

3. Choose one process from each of the 3 categories available (Joining, Shaping and Surface Treatment).

4. In your own words, give a summary of each of the 3 processes chosen. For each process, make sure you include information on (i) the nature of the process, (ii) the types of materials which can be processed in this way and (iii) the characteristics of the components which are produced by the process (size, shape, dimensional tolerance etc) and (iv) economics of the process.

Part 2: In-Depth Case Study of Process Selection

1. In , open the “Case Studies – Manufacturing Processes” document. Choose one of the process selection case studies presented. You may choose a case study from elsewhere if you wish.

 2. You are now going to use CES to work through the chosen process selection exercise, generating all selection charts manually.

3. Click “Select” tab.

 4. Choose the appropriate “Process Universe” category (probably “Shaping”) for your chosen process selection case study.

5. Reproduce every selection step (i.e. plot selection charts etc) exactly as described in the case study.

6. Provide your own commentary which shows clearly how you perform each step of the selection exercise and which links them together.

7. Write an overview of your process selection case study methodology in your own words.

Part 3: Environmental Impact of Process Selection

 CES may be used to carry out an Environmental Impact Assessment of both materials and process selections. This is achieved via the Eco-Audit Tool within CES. Write an overview of the Eco-Audit Tool in CES and explain how it may be used in the context of manufacturing process selection. Include relevant examples/data within your answer.

 Hand-In Date: Thurs 16th Feb 2017

 tryfon

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