ENN435 Advanced Manufacturing

Unit Outline: Semester 2 2024, Gardens Point, Internal

Overview

Modern industries use innovative Advanced Manufacturing technologies in their process and design to enhance productivity and maximise manufacturing and process operations. This unit focuses on advanced manufacturing technique including both additive and subtractive manufacturing processes. The unit will provide you with practical experience in the design for, and use of, 3D printing and various CNC machining techniques such as turning, milling, shaping, drilling and grinding and various other super finishing techniques. In addition, you will develop knowledge on mechanics of metal cutting (orthogonal), tooling considerations and economics of tooling. This unit introduces various non-traditional manufacturing processes such as Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM) and Laser Cutting.  In a broad sense this unit will provide you the necessary knowledge about manufacturing a product/assembly/machine including process capability and sequencing.

Learning Outcomes

On successful completion of this unit you will be able to:

1. Discuss the basic principles of 3D printing for polymers and bio-process materials
2. Describe the physics of the mechanics of metal cutting involved in material removal
3. Compare different material removal processes and relate the relative advantages and disadvantages in process selection based on material properties
4. Explain the different subtractive advanced manufacturing techniques and various manufacturing processes for bio-manufacturing and bio-fabrication
5. Design a component or product in a team and present to engineering peers

Content

Learning Approaches

In this unit you can expect to experience the following timetabled activities:

• Formal interactive lectures from experienced professional engineers and scientist cover the main concepts with real world applications and examples to give you insight into basic engineering knowledge, skills and attributes.    
• Tutorials in a flexible learning space will provide hands-on experience and insight into the principles of advanced manufacturing to support the topics covering in the lecture and the project.
• You will participate in a group project to design and fabricate a component or product in laboratory space. Gaining teamwork and information retrieval skills will be a significant part of your time in the project as well as applying the theoretical principles to practice. There will be machining demonstration that will take you through a show-and-tell information session in a workshop or industrial site where you will see different kinds of machining systems in action, their various features and operational conditions.

To complement the timetabled activities and complete your learning in this unit, you will be provided online resources and activities the unit's Canvas website:

• Informative recap videos as extra problem-solving resources to enhance your problem-solving approach, skills and knowledge.
• Basic materials such as notes, handouts, and Echo360 recordings.

You are expected to:

• Engage with timetabled activities on campus and ask questions. You should follow the weekly guide and announcements from Canvas on the online materials that should be completed prior to attending timetabled activities on campus.
• Engage with the online materials for developing your understanding of fundamental concepts. These will be available on the unit Canvas site. You will receive regular email announcements regarding release of these resources.
• Manage your time to engage with online resources outside of timetabled activities. 
• Engage with your peers during the interactive tutorials and the teamwork project tasks. 

Complete assessment tasks by working consistently across the semester and meeting the due dates that are published via the unit Canvas site.

Feedback on Learning and Assessment

You will receive informal verbal feedback on your progress in this unit during tutorials and discussions throughout the semester. Written feedback will be provided with each summative assessment throughout the semester.

Assessment

Overview

Assessment in this unit has been designed to give you the opportunity to show your learning against the unit learning outcomes.

Rubrics with criteria and standards will be used to evaluate the unit learning outcomes of your work.

The assessment consists of ongoing formative and summative assessments that are based on independent and group work. The assessment items allow you to demonstrate your technical knowledge in the topic, observation of real world and communication skills as well as design in laboratory space.

Unit Grading Scheme

7- point scale

Assessment Tasks

Assessment: Component Design for Manufacture Project

This is a group activity in which each group will design a component from the given drawing/sketch and recommend appropriate and precise manufacturing and cutting conditions.

There will be a show and tell information session in a workshop or at industrial site to observe different metal cutting and finishing operations and use the information to answer a set of related questions with the project.

The report is an assignment eligible for the 48-hour late submission period and assignment extensions.

Assessment: Final Exam (theory)

Final examination is mainly problem-solving questions and conceptual questions with both familiar and unfamiliar questions.

Academic Integrity

Students are expected to engage in learning and assessment at QUT with honesty, transparency and fairness. Maintaining academic integrity means upholding these principles and demonstrating valuable professional capabilities based on ethical foundations.

Failure to maintain academic integrity can take many forms. It includes cheating in examinations, plagiarism, self-plagiarism, collusion, and submitting an assessment item completed by another person (e.g. contract cheating). It can also include providing your assessment to another entity, such as to a person or website.

You are encouraged to make use of QUT’s learning support services, resources and tools to assure the academic integrity of your assessment. This includes the use of text matching software that may be available to assist with self-assessing your academic integrity as part of the assessment submission process.

Further details of QUT’s approach to academic integrity are outlined in the Academic integrity policy and the Student Code of Conduct. Breaching QUT’s Academic integrity policy is regarded as student misconduct and can lead to the imposition of penalties ranging from a grade reduction to exclusion from QUT.

Resources

Resource Materials

Recommended text(s)

Black, J.T., DeGarmo’s Materials and Processing in Manufacturing, 2017, Wiley, 12th Edition

Kalpakjian S., Schmid S.R., Vijay Sekar K.S., Manufacturing Engineering and Technology, 2022, Harlow, United Kingdom Pearson, 8th Edition.

Reference book(s)

Additive Manufacturing (Handbooks in Advanced Manufacturing), edited by Juan Pou; Antonio Riveiro; J. Paulo Davi, Elsevier, 1st edition 2021.

Risk Assessment Statement

You will undertake lectures and tutorials in the traditional classrooms and lecture theatres. As such, there are no extraordinary workplace health and safety issues associated with these components of the unit.

Any practical sessions in the laboratory must be done under the supervision of the lecturer or demonstrator and can be supported by technical staff. In this unit, you will be required to undertake project in laboratory space, and this includes a visit to a workshop or an industrial site under the supervision of QUT staff. If you do not have a general safety induction certificate or sticker you will be denied access to laboratories, visit a workshop and/or industrial site. In any laboratory practicals you will be advised further regarding the requirements for safe and responsible behaviour and will be required to wear appropriate protective items (e.g. closed shoes or gumboot shoes).

Standards/Competencies

This unit is designed to support your development of the following standards\competencies.

Engineers Australia Stage 1 Competency Standard for Professional Engineer

1: Knowledge and Skill Base

1. 
   Relates to: Final Exam (theory)
2. 
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
3. 
   Relates to: Component Design for Manufacture Project

2: Engineering Application Ability

1. 
   Relates to: Final Exam (theory)
2. 
   Relates to: Component Design for Manufacture Project
3. 
   Relates to: Component Design for Manufacture Project, Final Exam (theory)

Course Learning Outcomes

EN54 Master of Advanced Manufacturing

1. Demonstrate and apply advanced and specialist theory-based discipline knowledge and concepts as they relate to contemporary practice in Advanced Manufacturing
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
2. Employ advanced specialist technical skills, analysis approaches, design, and data to the solution of problems in Advanced Manufacturing, critically evaluating solutions against practice-informed performance and whole-of-life requirements
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
3. Implement professional communication and collaborative skills while engaging with stakeholders, exchanging ideas, and presenting complex information to specialist and non-specialist audiences
   Relates to: Component Design for Manufacture Project

EN74 Master of Advanced Manufacturing with Project Management

1. Demonstrate and apply advanced and specialist theory-based discipline knowledge, concepts, methods and practices as they relate to contemporary practice in Advanced Manufacturing and Project Management domains
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
2. Employ advanced specialist technical skills, analysis approaches, design, and data to the solution of problems in Advanced Manufacturing and Project Management domains, critically evaluating solutions and practice-informed performance to deliver whole of life requirements and strategic objectives
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
3. Implement professional communication and collaborative skills while engaging with stakeholders, exchanging ideas, and presenting complex information to specialist and non-specialist audiences in Advanced Manufacturing and Project Management domains
   Relates to: Component Design for Manufacture Project

EN77 Master of Advanced Manufacturing with Data Analytics

1. Demonstrate and apply advanced and specialist theory-based discipline knowledge, concepts, methods and practices as they relate to contemporary practice in Advanced Manufacturing and Data Analytics domains
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
2. Employ advanced specialist technical skills, analysis approaches, design, and data to the solution of problems in Advanced Manufacturing and Data Analytics domains, critically evaluating solutions and practice-informed performance to deliver whole of life requirements and strategic objectives
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
3. Implement professional communication and collaborative skills while engaging with stakeholders, exchanging ideas, and presenting complex information to specialist and non-specialist audiences in Advanced Manufacturing and Data Analytics domains
   Relates to: Component Design for Manufacture Project

EN79 Graduate Diploma in Engineering Studies

1. Demonstrate and apply advanced discipline knowledge, concepts and practices as they relate to contemporary Engineering practice
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
2. Analyse and evaluate Engineering problems using technical approaches informed by contemporary practice and leading edge research to achieve innovative, critically informed solutions
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
3. Apply innovative, systematic approaches to plan, design, deliver and manage Engineering projects in a way that assures sustainable outcomes over their whole lifecycle
   Relates to: Component Design for Manufacture Project, Final Exam (theory)
4. Effectively communicate Engineering problems, related complex data and information, and solutions in contemporary professional formats for diverse purposes and audiences
   Relates to: Component Design for Manufacture Project