Please note - Swinburne University of Technology

~ ~ 6 0 Design 5 for Manufacture
No. of hours per week: four hours
Assessment: assignments, project work and
examination
Subject aims and description
The subject forms the second part of Design for Manufacture
aims to prepare students with further knowledge of the
design of tooling, machinery and systems for quality
production.
Tooling design for metalworking: economy and batch
quantity, relationship. Tool design for cold and hot forging,
and diecasting.
Quality and reliability: concept of quality, cost of quality.
Responsibility for quality. Statistical quality control, charting by
variables and attributes and sampling. Reliability - principles
and applications.
Computer aided design: CAD Systems, processing and
techniques. NC programming, kinematics and robotics.
References
American Society for Metals, Metals Handbook, Vol. 1. Properties and
Selection of Metals, Vol. 4, Forming 8th and 9th edn, Metals Park,
Ohio, The Society, 1969, 1978
Society of Manufacturing Engineers, Tool and Manufacturing
Engineers Handbook. 4th edn, Dearborn, Mich., Society of
Manufacturing Engineers, 1983-1 992
Donaldson, C. et al. Tool Design. 3rd edn, New York, McGraw-Hill,
1973
Smith, D.A. (ed.) Die Design Handbook. 3rd edn, Dearborn, Mich.,
S.M.E., 1990
Thomas, L.F. The Controlof Quality. London, Thames and Hudson,
1965
Wilson, F.W. and Harvey, P.D. Manufacturing Planning and Estimating
Handbook. New York, McGraw-Hill, 1963
~ ~ 6 0 Manufacturing 6
Technology
No. of hours per week: five hours
Assessment: assignments and tests
Subject aims and description
Sheetmetal work: presses; classification, drive systems and
mechanisms, evaluation of different types, operation,
applications, selection. Press feed mechanisms; types,
advantages and disadvantages, applications. Die cushions.
Bending of sheetmetal; analysis of die types, forces, recoil,
springback, blank development. Deep drawing; planning, force
reauirements, variables, effects of clearance, cutting with
shear, stripping force. Materials selection for press forming;
general requirements, mechanical tests, tensile test, analysis of
stress-strain curves and parameters, rand n values, tests to
simulate processes, stretch forming tests, deep-drawing tests,
bending tests, forming-limit diagrams, applications. Function
and terminology for die components; blanking dies,
commercially available die sets, punches and accessories.
Numerical control; introduction to NC machine tools,
comparison with conventional, hardware configurations,
software implementation, control systems, machine control
unit, feedback, sensitivity. NC system components; comparison
of actuation systems, electric, hydraulic, pneumatic. Design
considerations for NC machine tools; design differences
between conventional and NC machines, mechanical design
considerations, control system design considerations. System
inputloutput; types of input media, symbolic codes, tape input
format, communication with MCU. NC programming;
programming methods, computer assisted NC programming
[processors, post; processors], part programming languages -
APT. Com~uter Numerical Control (CNC). Direct Numerical
Control (DNC); comparison, manageme;;t implications.
Plastics and rubbers; overview of processes. Melt forming,
rheology, mathematical analysis of pseudoplastic, dilatent,
newtonian flow, time dependant flow, thixotropy, viscosity,
tractional viscosity. Extrusion defects; causes and prevention.
Extrusion die design. Single and multiple screw extrusion;
hardware and product characteristics. lnjection moulding;
mould design, basics of the moldflow philosophy, cooling
systems. Thermoforming die design. Elastomers; C black,
other additives, compounding. Compression and injection
moulding.
Textbooks
Crawford, R.J. Plastics Engineering. 2nd edn, Oxford, Pergamon Press,
1987
Groover, M.P. Automation, Production Systems and Computer
Integrated Manufacturing. 2nd edn, Englewood Cliffs, N.J., Prentice
Hall, 1987
References
Harris, J.N. Mechanical Working of Metals: Theory and Practice.
Oxford, Pergamon, 1983
Kalpakjian, S. Manufacturing Processes for Engineering Materials. 2nd
edn, Reading, Mass., Addison-Wesley, 1991
~ ~ 6 0 Manufacturing 7
Technology
No. of hours per week: five hours
Assessment: assignments and tests
Subject alms and description
Mathematical analysis of forming: equilibrium analysis of
common working processes, e.g. wire drawinglstrip drawing/
extrusion/tube drawing/forging. - - - Redundant work, friction and
lubrication.
Deformation mechanics: slip line field applied to forming
problems - metal flow.
Polymeric materials- blow moulding - parison production
including parison programming. Closing, blowing and ejection.
Cooling systems including economic analysis of specialised
cooling. Stretch blowing moulding -effects on the materials
and products and production economics in particular. lnjection
moulding. Introduction to moldflow. Rubber compounding and
vulcanisation.
Vibration and noise: revision of theory of vibration for multidegree
of freedom systems including viscous and hysteretic
damping. Vibration isolation, transmission and measurement.
Equivalent systems. Chatter and stability. Sound transmission,
power, intensity sound absorption. Insulation, resonance, noise
rating. Noise control and measurement.
Textbooks
Crawford, R.J. Plastics Engineering. 2nd edn, Oxford, Pergamon Press,
1987
Roe, G. Elements of Metalworking Theory. London, Edward Arnold,
1979