Unit 10: Manufacturing Process


 

Unit 10:

Manufacturing Process


Unit code:
H/601/1487

QCF level:
4


Credit value:
15






Aim

This unit will develop learners’ knowledge of manufacturing processes and techniques that can be applied to a range of materials for a variety of manufacturing applications.

Unit abstract

It is essential that engineering technicians involved in the planning, operation and management of manufacturing systems should have a broad underpinning knowledge of conventional production processes. Computer-aided processes are now the norm in medium- to large-scale manufacturing companies and are also to be found with small-scale specialist producers. The full potential of computer-aided systems cannot however be fully appreciated without knowledge of the conventional processes from which they are derived.

This unit provides learners with this knowledge of manufacturing processes and techniques. The first outcome gives an appreciation of conventional machining techniques together with associated tooling and work holding methods. The second outcome gives an appreciation of the basic moulding and shaping processes used with metals, plastics and ceramics. The final outcome covers non-conventional machining techniques that include electro-discharge machining, ultrasonic machining, etching of electronic printed circuit boards, laser-beam machining and plasma-jet machining.

Learning outcomes

On successful completion of this unit a learner will:

1       Understand the use of conventional machining processes and techniques for generating geometrical forms for a given component specification

2       Understand the use of moulding and shaping processes for a given component specification

3       Understand the use of less conventional machining techniques for a given component specification.
  

Unit content



1      Understand the use of conventional machining processes and techniques for generating geometrical forms for a given component specification

Component manufacture: specify components for manufacture eg criteria-tolerances, types of material, machining technique, surface texture, material removal rates, speeds and feeds, cutting times, cutter offsets, table angles

Machining techniques: production of flat and cylindrical geometry eg milling, surface grinding, lapping, planing, turning, cylindrical grinding, centreless grinding, honing, super-finishing, thread milling techniques, jig boring, horizontal boring, vertical boring, transfer machines

Tooling requirements: multi-tooth cutting eg milling, grinding, hobbing, drilling, reaming, and broaching; single-point cutting eg turning, planing and slotting; appropriate cutting angles for given materials; types, advantages and disadvantages of coolants and cutting fluids used for various materials and processes eg advantages – prolonging tool life, increased material removal rate, improved surface finish; disadvantages – fumes and possible irritations to operators

Work-holding techniques: selection of appropriate work-holding devices eg three and four jaw chucks, vices, jigs, fixtures, clamping arrangements, vee blocks, angle plates and magnetic chucks; health and safety issues and limitations of devices


2      Understand the use of moulding and shaping processes for a given component specification

Component manufacture: specify components for moulding and shaping eg criteria-tolerances, type of moulding/shaping technique to be used, limitations of size, shape and production volume, properties of materials being moulded/shaped, surface texture, cost factors, post-moulding operations required (machining, clipping, welding, finishing)

Moulding processes: casting eg sand, die, investment and continuous casting; powder metallurgy; sintering

Shaping processes: extrusion eg direct, indirect and impact; forging eg drop, pressure and upset; rolling; hot and cold presswork eg forming, bending and deep drawing; metal spinning Metallic materials: range applicable to component eg ferrous, non-ferrous, alloys

Ceramic materials: range applicable to component eg metallic carbides, nitrides and oxides

Material properties: changes to the molecular structure and hence the material properties that may arise from a moulding or shaping operation eg grain growth, work hardening, cracking, orientation of grain flow

Tooling requirements: appropriate tooling and equipment required to produce given components by moulding and shaping techniques eg re-usable moulds and non-permanent moulds, suitable casting materials for a particular casting process; press tools, punches, dies, press capacity and calculations in terms of tonnage



3      Understand the use of less conventional machining techniques for a given component specification

Component manufacture: principle of operation of the less-conventional machining techniques eg electro-discharge machining (EDM), wire erosion, ultrasonic machining, etching of electronic printed circuit boards (PCBs), laser-beam machining, plasma-jet machining; specification of components for less-conventional machining techniques eg criteria-tolerances, types of material, suitable technique, surface texture, material removal rate, cost factors

Tooling requirements: tooling and ancillary equipment needed to perform less-conventional machining techniques; work-holding techniques; health and safety issues


Learning outcomes and assessment criteria




Learning outcomes
Assessment criteria for pass


On successful completion of
The learner can:


this unit a learner will:










LO1 Understand the use of

1.1
select suitable data and processes for component


conventional machining


manufacture using a range of conventional machining


processes and techniques


techniques


for generating geometrical

1.2
assess tooling requirements and work-holding


forms for a given component





techniques for a given component using a range of


specification






conventional machining techniques













LO2 Understand the use of

2.1
select suitable data and processes for component


moulding and shaping


manufacture using moulding and shaping techniques for


processes for a given


metals and ceramics


component specification

2.2
explain changes to material properties due to the









moulding and shaping processes




2.3
explain the tooling requirements for producing a given





component by moulding and shaping







LO3 Understand the use of less-

3.1
select suitable data and processes for component


conventional machining


manufacture using a less-conventional machining


techniques for a given


process


component specification

3.2
explain the tooling and ancillary equipment









requirements to manufacture a given component by a





less-conventional machining process.









Guidance



Links

This unit can be linked with Unit 15: Design for Manufacture and Unit 21: Materials Engineering.


Essential requirements

There are no essential resources for this unit.


Employer engagement and vocational contexts


The learning outcomes and indicative content of this module lend themselves to be based on a real engineering environment. This approach would make the delivery more relevant through the use of detailed and realistic case study material. Equally, where learners have access to work-based traditional machining environments, including shaping and moulding, and less-traditional machining environments then they should be encouraged to use the real-life information available to them from this source wherever possible.

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