Mechanical manufacturing.

Teacher(s)

Delannay Laurent; Simar Aude;

Language

French

Main themes

• Molding of metals
• Machining processes
• Extrusion and molding of polymers
• Polymer-based composite materials
• Powder metallurgy
• Metal forming
  - extrusion and drawing (incl. wire drawing) 
  - rolling, bending, stamping  and deep drawing
  - forging
• Hardening and surface treatments
• Assembly processes (incl. welding and pasting)

Learning outcomes

At the end of this learning unit, the student is able to :
1	Regarding the common AA references of the program "Masters degree in Mechanical Engineering", this course contributes to the development, the acquisition and the evaluation of the following learning outcomes: AA1.1, AA1.2, AA1.3 AA2.1, AA2.2, AA2.3, AA2.4 AA3.1 AA5.4 AA6.1, AA6.2, AA6.3 More precisely, at the end of the course, students will be able to: identify and justify the choice of a manufacturing process that is best suited to produce a commonly used object. explain, based on the knowledge of the underlying physical phenomena, the influence of a manufacturing process on the mechanical properties of the final product. explain the main challenges of each manufacturing process as well as the existing technological solutions. At the end of the course, students will have a first experience of machining of metal parts in a mechanical manufacturing workshop, experimental techniques used to characterize stiffness, hardening, hardness and toughness in a mechanical testing laboratory.

Content

Basics of solid mechanics
- Physics underlying deformation
- Mathematical description of stresses and strains
- Mechanical constitutive laws
- Failure processes
Physical basis of the mechanical strength of materials
- Cristalline structure of metals
- Defects of the cristal lattice
- Grain size, texture, recovery and recristallization
- Strengthening of alloys
Molding of metals
- Underlying physics
- Practical questions raised
- Technological solutions
Machining processes
- Mechanics of the cut
- Cutting conditions
- classification of the processes and machining machines
Metallic joining
- Welding
- Adhesion
Metal forming
- Forging
- Extrusion and drawing of long products
- Rolling of flat products
- Secondary sheet metal forming
Surface treatments and coatings
- Mechanical surface treatments
- Hot dipping
- Surface coating
- Electrodeposition
- Conversion treatment
- Vapor deposition
- Diffusion treatment
Manufacturing of polymers
- Physics of polymers
- Extrusion of thermoplastics and elastomers
- Molding of thermosets
- Polymer-based composites
Sintering and additive manufacturing
- Powder metallurgy
- Production of ceramic pieces by powder metallurgy
- Additive manufacturing

Teaching methods

The whole course is taught in French.
Face-to-face teaching is priviledged but some activities may be organized in distant mode.

• lectures (introduced with practical problems),
• lecture notes written in French by the teachers (English reference book available),
• solution of exercises in smaller groups,
• laboratories in groups of 3 or 6 students,
• videos showing processes that are not presented in the lab sessions.

Evaluation methods

The written exam assessing the learning outcomes will represent about 80% of the total grade. The remainder of the evaluation will be determined as function of the student participation to laboratories as well as homeworks (~20%). However, this second part of the evaluation will contribute to raise the student grade only if the mark obtained at the exam is higher than 9/20.
If the written exam is organized is distant mode, the professors may complete the evaluation of some students based on an individual oral exam.

Online resources

http://moodleucl.uclouvain.be/enrol/index.php?id=8095

Bibliography

Syllabus écrit en français par les enseignants.
Deux références utiles (pas obligatoires):

• M.P. Groover. Fundamentals of Modern Manufacturing, Materials, Processes, and Systems, 3rd edition. Wiley, 2007, USA.
• S. Kalpakjian, S.R. Schmid. Manufacturing Engineering and Technology, 6th edition. Pearson, 2010, Singapour.

Teaching materials

• Syllabus rédigé par les enseignants (disponible au SICI et sur moodle)

Faculty or entity

MECA