436-829
NET Sř1АРE METAL FILMING PROCESSES 1Credit points: 8.33 Coordinator- Mrs S Mal Prerequisites: Nil
Semester 1: 7 lectures, 22 hours of self-paced computer-based tuition and 10 hours of laboratory work
Objectives
On completion students should have a good understanding of metal forming processes arid a working knowledge of processes used in net shape manufacturing of engineering components. The emphasis is on the ability to use practical methods of assessing processing parameters: forces, total work and pressures required for forming and on the ability to design production sequences for sheet metal forming and bulk precision forging of metals: cold, warm and hot.
Content
Background theory and practical methods of assessment and analysis of working parameters required for the design of production sequences, selection of equipment and the design of tools for basic metal forming processes: sheet metal working processes, blanking and piercing, bending, deep drawing, spinning, hydroforming, high energy rate forming. Bulk precision forging used in net shape manufacturing processes: cold forging, warm forging and precision hot forging for high volume production of engineering components.
Assessment
Suэсessful completion of 7 self-paced computer-aided indiіdual exercises and test units, plus 5 brief laboratory reports equivalent to 1000 words each.
436-846
FUNDAMENTALS OF MATERIAL REMOVAL PROCESSES Credit points: 8.33Coоrdiпцor.. Dr E J A Armarego Prerequisites: Nil
261ectures/seminars and 13 hours of tutorials, practice classes and laboratory sessions
Objectives
On completion participants should uiiderstand the: objectives, performance measures and criteria, variables and constraints of the wide spectrum of machining operations; empirical and fundamental approaches to technological performance prediction and the need for such prediction to optimise the economic performance of machining operations; shape generations and chip formation processes; the tool geometry and spedBcation and the engineering science phenomena involved in conventional material removal processes; development of mechanics of cutting analyses for'сlassiгal' and practical machining operations for tool design and performance prediction purposes; fundamental principles of operaton of non- tгaditlопal material removal processes, their applications and capabilities.
Content
The place of machining in modern computer-based manufacturing, objectives, performance measures and criteria, variables and constraints in machining operations, chip formation, rake face friction, shear stress and strain, edge forces and mechanics of cutting analyses for the generic classical orthogonal and oblique cutting operations.
Practical machining operations; the design geometry, specification and manufacture of single point lathe tools and general purpose twist drills; ISO and Australian standard specifications; the cutting action and prediction of forces, Power, chip
flow direction and surface finish in turning and drilling. Predictive models and softwarе for forces and power in turning and drilling based on mechanics of cutting analyses, lathe tool and drill design modifications for improved perfonnaсe, cutting fluid action and application, modem surface coating technology.
Non-traditional machining, mechanisms of processes such as electric discharge machining (ED'), ultrasonic machining and laser beam machining (LEM).
Assessment
Two hours of wńnen tests and assignments (equivalent to 3000 words).
436-839
CASTING PROCESSES Credit points: 8.33Coordinators: Dr E J A Annarego/Dr A) R Smith Prerequisites: Nil
20 lectures/seminars and 19 hours of tutorials, practice classes, plant visits and student presentations
Objectives
On completion participants should have developed: an understanding of the underlying principles and the strengths and weaknesses of a variety of near-net- shape casting processes and factors affecting the selection of the appropriate process for the production of particular products; an understanding of die factors influencing the design of products to be manufactured by a casting process; an appreciation of the use of process modelling and analysis techniques for the different casting processes; an understanding of the basic aspects of casting process control and assessment of the quality of cast products; and an appreciation of the recent developments in casting science and technology.
Content
Near-net-shape casting processes, sand casting, high pressure die casting and squeeze casting, gravity and low pressure die casting, powder metallurgy and spray forming. Product design and prototyping, process modelling and analysis, software for tooling design, process control and engineering for die casting, quality control and product quality assessment.
Assessment
Two hours of short answer tests, a major assignment report (5000 words) and oral presentation.
436-840 UNDERSTANDING AND PROCESSING POLYMERIC MATERIALS
Credit points: 8.33 Coordinator. 0 Delatyckl Prerequisites: Nil
A total of 39 hours of lectures, tutorials, plant visits, laboratory demonstrations and project work
Objectives
On completion students will have gained an understanding of the common characteristics of all polymeric materials and how these can be used to explain the properties and processing behaviour of rubbers, plastics, surface coatings and adhesives.
Content
Basic composition and properties of polymers: large two- and three-dimensional molecules. The different classes of manufacturing processes: one-dimensional (paints and adhesives), two-dimensional (extrusion of Elm, sheet and tubing, production of fibres) and three-dimensional (injection, bottle, compression, slush and rotational moulding, foam technology, vacuum forming). Laboratory demonstrations and plant visits w
il
serve to illustrate specific processes.Assessment
A project equivalent to 5000 words.
436-833 QUALITY MANAGEMENT AND TECHNOLOGY Credit points: 8.33
Coordinator. Or Ai R Smith Prerequisites: Nil
39 hours, consisting of lectures, discussion sessions and workshops tailored to the needs of the Ø, delivered at the rate of three hours per week
Objectives
By fully participating in this course, students should: obtain an appreciation of the use of quality systems and the certification process in the management of the quality function; understand and be able to interpret the major clauses of the 1S0 9000 series of quality standards, and be able to decide on suitable 'tools for solving technologically-related quality problems.
Content
This unit will address the following topics: what quality is; total quality; approaches to achieving quality; requirements of a quality system; costs of quality and rewards;
150 9000; seven basic tools; other simple' problem solving aids, sampling; and process control.
Assessment
An assignment equivalent to 4000 words, workshop exercises and a one-hour test.
436-834
MODELLING OF MANUFACTURING SYSTEMS I Credit points: 8.33Coordinator. Dr A Wirt Prerequisites: Nil
16 lectures and 20 hours of tutorials/practice classes.
Objectives
On completion students should be able to apply a number of deterministic models to analyse a range of manufacturing systems problems dealing with material handling and flow, using a range of optimisation software tools.
Content
Sequencing and scheduling, assembly lines, facility location and layout, storage and retrieval systems.
Assessment
Two hours of written tests, assignments of 5000 words or equivalent
436-836
ERGONOMICS FOR MANUFACTURING PART 1 Credit points: 8.33Coordinator. Dr E R Hoffman Prerequisites: Nil
29 lectures and 10 hours of tutorials Objectives
On completion students will be familiar with basic concepts of work place design, including the working environment and the limitations and capabilities of the human operator in the workplace.
Content
Workplace design, the working environment, design for assembly, accidents and safety, risk assessment, ergonomics task analysis, task and job design, manual handling, worker fatigue and rest allowances, incentive schemes.
Assessment
Project work of 5000 words or equivalent.
436-831
RELIABILITY AND MAINTENANCE MANAGEMENT Credit points: 8.33Coordinator. Dr Ai R Smith Prerequisites: Nil
39 hours, consisting of lectures, discussion sessions and workshops tailored to the needs of the class, delivered at the rate of three hours per week
Objectives
By fully participating in this course, students should: obtain an appreciation of the use and role of maintenance management systems; understand the contributions that design, manufacture, installation and maintenance can make to reliability of productive plant and products; be able to apply models for determining system reliability and be able to use various analyses for optimising maintenance and replacement decisions.
Content
This unit will address the following topics: maintenance management systems;
causes of component and plant failures; reliability, approaches to enhancing reliabІіty, statistical models of system rehability; optimisation of maintenance periods; optimisation of group replacements; and decision making for production system alternatives.
Assessment
An assignment equivalent to 4lØ words, workshop exercises and a one-hour test.
436-826 INDUSTRIAL PROBLEM SOLVTNG METHODOLOGIES Credit points: 8.33
Coordinator. Dr P Milnеr Prerequisites: Nil
26 lectures and 13 hours of practice dasses/tutońals Objectives
On completion students should: be familiar with the basic concepts of technical problems, systems and signals, criteria, constraints and objectives and their application to the recognition and formulation of problems in a manufacturing context; understand the various ways in which technical problems on be solved and demonstrate proficiency in strategy selection and execution.
Content
Problems and technical problems, the logic of proff erns, problem recognition and fоrmulatiоп; logic of technical problems, systems, signals and states, performance, objectives and constraints, control/management structures; solution strategies;
applications to problems of relevance in manufacturing activities.
Assessment
One 90-minute test and assignments (equivalent to 5000 words in total).
436-843 HUMAN RESOLBCES MANAGEMENT Credit points: 8.33
Coordinator. Dr P Fox Prerequisites: Nil
One two-hour lecture and one one-hour tutorial each week for 13 weeks (39 hours total)
Objectives
On completion students should have an understanding of the role human resources play in using physical and monetary resources to produce goods and services in manufacturing industry.
Content
This unit is concerned with the management of human resources in the context of the selection, growth and development of labour resources. It adорts an analytical approach to the employment relationship, alternative contracting methods, skill formation, productivity and wage determination. It concentrates on the recruiting, selection, development and keeping of a stable work-force.
Assessment
Two hours of written tests and an assignment (equivalent to 3000 words)
436-844 ORGANISATIONAL BEHAVIOUR AND MANAGEMENT Credit points: 8.33
Ørdinator.. Dr P Fox Prerequisites: Nil
One two-hour lecture and one one-hour tutorial each week for 13 weeks (39 hours total)
Objectives
On completion students should have gained an overview of organisations and the role management has in maintaining stability and/or initiating changes as indicated by the external environment
Content
This unit aims to increase knowledge of how organisations work and why particular organisational forms exist. It focuses on the modern corporation and on ways of interpreting its behaviour. There is a close analysis of the relationship between organisational structure and innovation and of corporaбons, both large and smal /mediиm sized. Topics include managerial discussion, the internal structure and control apparatus of firms, transaction costs, hierarchies, individual behaviour and motivation.
Assessment
Two hours of written tests and an assignment (equivalent to 3000 words).
436-828 ADVANCED FORMING PROCESSES AND CAD Credit points: 8.33
Coordinator. Mrs S Maj
Prerequisites: 436-829 Net Shape Metal Forming Processes 1 and basic computer programming skills
5 lectures, 4 hours of reporting and project work (equivalent to 30 contact hours) Objectives
On completion students should have: developed their abilities to use references from literature to solve practical engineering problems connected with design for net shape manufacture; acquired skills to apply creatively their knowledge of computer programming to write simple CAD programs related to the problems connected with every day practice of manufacturing engineers. Optional topics involving similar studies in fiеlds other than metal forming will be considered on application.
Content
Methodology used in the design of CAD software with graphical inputs and outputs screens for engineering applications; revision of practical methods of assessment and analysis of working parameters required for the design of production sequences; selection of equipment and the design of tools for precision forging used in net shape manufacturing processes: cold forging, warm forging and precision hot forging for high volume production of engineering components.
Assessment
Written progress report and presentation in week 5, presentation session of a completed CAD package in week 13, fin
al
report and a manual (equivalent to 5000 words).436-845 ADVANCED MODELLING OF MATERIAL REMOVAL PROCESSES
Credit points: 8.33
Coordinator. Dr E J A Armarego
Prerequisites: 436-846 Fundamentals of Material Removal Processes 39 hours with about 18 hours of tectures/seminars and 18 hours of discussion sessions, practice classes and laboratory sessions
Objectives
On completion participants should understand: the specification, performance, capabilities and latest developments in bonded abrasives and processes; the development and application of coning models and software for performance prediction of the major practical machining operations; the theories of tool wear, the variables affecting tool-life and tool-life estimation; the importance of economic optimisation of machining operations in process planning and machine tool and cutting tool design; the development and application of optimisation strategies and software in machining.
Content
Abrasive processes; the specifiØon and manufacture of bonded abrasives; cutting action, performance characteristics and influencing variables, capabilities, optimisation of machining conditions in abrasive processes such as grinding and honing. Recent developments in bonded abrasives and processes.
Conventional material removal processes; the tool design geometry and specification, cutting action and mechanics of cutting analyses for machining 'vidt foran tools, rotary tool cutting processes, turning, drilling, milling and threading operations. Development of predictive cutting models and softwarе for forces, power, chip flow and surface finish for above processes. Tool wear theories, tool failure criteria, tool-life and influencing variables and tool-life testing standards.
Optimisation analyses, strategies and software for single and multipass machining operations such as turning and milling. The importance and application of optimisation in process planning, machine tool and cutting tool design and selection. Canned cycles in C.NC machine tool controlers.
Assessment
Two assignments (equivalent to 3000 words), exercises and a one-hour test.
436
-
832 INDUSTRIAL MEASUREMЕл Т SYSTEMS Credit points: 8.33Coordinator- Dr A J R Smith Prerequisites:
Ni
39 hours, consisting of lectures, discussion sessions and laboratory Basses tailored to the needs of the group, delivered at the rate of diree hours per week
Objectives
By fully participating in this course, students should gain an understалding of the essential role of and implications for metrology in quality systems; know lhe requirements for'accuraté measurement and the statistical processing of readings;
understand the design and operation of computer controlled coordinate measuring machines; be aware of methods for large scale dimensional metrology and their capabilities and limitations.
Content
This unit will address the following topics: what metrology is; LSO 9001-3 clause 4.11 impact on measurement; geometric tolerancing; analysis of readings;
reduction of errors and uncertainty; basic engineering dimensional metrology equipment; coordinate measuring machines; mid large scale optical 3-D coordinate measurement.
Assessment
An assignment equivalent to 4000 words, laboratory exercises and a one-hour test.
436-841 INTRODUCTION TO PROCESSING OF ADVANCED MATERIALS
Credit points: 8.33 Coordinator: Dr KXia Prerequisites: Nil
Semester 2: 20 lectures and 19 hours of tutorials, plant visits and project work Objectives .
On completion students should be familiar with a variety of new processes developed for manufacturing advanced metallic materials; have a basic understasding of the scientific and technological aspects of these processes and the materials; and appreciate the use of these advanced materials in engineering applications.
Content
Introduction to mivanced maeńas. Metal matrix composites. Semisolid processing.
Squeeze casting. Rapid solidigcation. Nanophase materials. Mechanical milling asd alloying. Surface technology. SuperplasŮc forming. Intermctallic alloys.
Assessment
Project work of 5000 words or equivalent.
436-830 STАTISТICAL QUALITY TOOLS Credit points: 8.33
Coordinator: Dr A J R Smith
Prerequisites: 436-833 Quality Management and Technology, or equivalent 39 hours, consisting of lectures, discussion sessions and workshops tailored to the needs of the class, delivered at the rate of three hours per week
Objectives
By fully participating in this course, students should be able to: fully analyse sampling schemes; design single, double attribute and single variable sampling schemes; choose suitable sampling schemes from published plass; design and use 'Shewhart-type process control charts; design and use cumulative sum charts;
select and use the 'basic seven' tools.
Content
This unit will address the following topics: statistical concepts underpinning sampling and process control; single, double, multiple, sequential, chain, skiplot, anribute and variables sampling; 'Shewhart-type' control charts for individuals, means, dispersion, proportion non-conforming and number non-conforming and non-conformities; histograms; cause and effect diagrams; Pareto analysis; flow- charts, check-sheets and correlation.
Assessment
Two assignments equivalent to 4000 words each, workshop exercises and two hours of written tests.
436-835 MODELLING OF MANUFACTURING SYSTEMS 2 Credit points: 8.33
Coordinator. Dr A Wirth Prerequisites: Nil
19 lectures and 20 hours of mtorialVpractice classes
Objectives
On completion students should be able to apply a number of probabilistic models to analyse a range of time varying manufacturing systems problems, using a range of software tools including a simulation language.
Content
Decision making under risk, inventory management, transfer lines, queuing and simulation models.
Assessment
Two hours of written tests, assignments of 5000 words or equivalent.
436-837 ERGONOMICS FOR MANUFACTURING PART 2 Credit points: 8.33
Coordinator: Associate Professor E R ilоifтал
Prerequisites: 436-836 Ergonomics for Manufacturing Part 1 29 lectures and 10 hours of tutorials
Objectives
On completion of this course, students will be able to evaluate problems related to humans working in industry and, in particular, be familiar with the capabilities and limitations of the human operator in manufacturing systems.
Content
Theoretical basis of time and motion systems, shift work, human information processing and implications for work, interaction of humans 'vith automated machinery, industrial inspection processes, skill development, design and selection of hand tools, evaluation of human work, human factors in the design process, computer integrated manufacturing and human consequences.
Assessment
Project work of 5000 words or equivalent Textbooks
Lecture notes will be distributed. Selected texts will be referred to for particular sections of the course.
436-825 FOUNDATIONS FOR MANUFACTURING SYSTEM MODELLING & CONTROL
Credit points: 8.33 Øгdiпцоr.. Dr P Milner
Prerequisites: 436.826 Industrial Problem Solving Methodologies 26 lectures and 13 hours of practice classes/tutońals Objectives
On completion students should be: familiar with the basic concepts of discrete and . continuous event dynamic systems, unique and chaotic flows, motions and
trajectories, invańance, stability, feedback and control; proficient in the modelling and analysis of the various classes of manufacturing systems in the design of suitable control strategies.
Content
Abstract systems: systems and sets, manufacturing establishments as technological complexes and artefacts as systems; dynamic systems: open and closed systems, signals and states, axiom schemes, system dynamics as flows in state space, relationships to equations of motion and transfer functions, topological transforsnation groups for autonomous systems, continuous and discrete topologies and their relationship to various forms of analog and digital systems, motions and transitions; control system: system partitions, flow without uniqueness, attainable states, conks of attainability; optimum/optimising control schemes, general statements of the control problem, regulators and servomechanisms; control system properties: causality, anticipation, reachability, controllability, observability, invariant sets, limit sets; prolongations, attractors and repulsors, stability and asymptotic stability, stability of motions and stability of transitions; modelling and analysis of manufacturing systems: selection of management strategies.
Assessment
Three hours of wńпeп tests and one assignment (equivalent to 4000 words).
436-842 MARKET RESЕАRCН AND coNSCМER BEHAVIOUR Credit points: 8.33
Coordinator Dr P Fox Prerequisites: Nil
One two-hour lecture and one one-hour tutorial each week for 13 weeks (39 hours total)
Objectives
On completion students should be aware of the information needs of modern organisations in their strategic marketing plans.
Content
This unit deals, in the first place, with the importance of information in effective marketing and the many varied marketing research tools and techniques used appropriately to investigate marketing problems. The unit then describes the psychological and situational factors that influence consumer decision making. It considers the consumer as a member of many groups with which the buyer plays a role, holds a status and shares values and norms. Culture, subculture dass and various social institutions that affect our behaviour are examined.
Assessment
Two hours of written tests and an assignment (equivalent to 3000 words).
436-838 BUSINESS MANAGEMENT Credit points: 8.33
Coordinator ir E J Co1vi1le Prerequisites: Nil
26 hours of lectures and 13 hours of tutorials, practical lasses and oral presentations delivered ai the rete of three hours per week
Objectives
On completion of this subject, partidpants should have: general understanding of the 8nаcial and general management requirements of a manufacturing firm;
awareness of the marketing, accounting, legal, personnel, contractual and purchasing issues relevant to manufacturing and their iпteпelaбonships with shop floor activity, appreciation of a number of stretegies for local and international competitiveness; su83cient knowledge to place lhe appropriate emphasis on each of the principal financial performance measures.
Content
Production, marketing and financial skills and the organisation of a firm's activities, internally and externally, including incorporation. Financial data, such as profit and loss statements, balance sheets, funds movements and cash flow calculations.
Performance evaluation measures including break-even point and applicable financial ratios. Supply management methods and control of sub-contractors.
Nature and place of management infrastructure components, such as quality control, production planning, cost control and information services. Importance of the inclusion of people, their knowledge, skills, participation and communication within technologically advancing firms.
Assessment
Two hours of wriпeп tests and tutorial submissions to an equivalent of 3000 words.
436-827 ACHIEVEMENTS IN АUsТRАLIAN MANUFACTURING Credit points: 8.33
Coordinator Dr P diner Prerequisites: Nil
13 lectures, 26 hours of seminars and directed research Objectives
On completion students should have: familiarity with the sources of information on economic development, innovation and manufacturing policy in Australia and other countries; apprecIation of the development of manufacturing industries in Australia at both a macro and a micro level; proficiency in the analysis and interpretation of evidence; experience in both wńnen and ore] presentations of arguments.
Content
A critical examination of the development of Australia manufacturing industries since 1800, with a focus upon technology transfer of both products and process equipment, innovalton, manufacturing policy and technological change.
Assessment
Contributions to seminars and a research essay (equivalent to 6000 words).
AECI Best Practice' Semester
436-824 LEARNING FROM BEST PRACTICE MANUFACTURING COMPANIES
Credit points: 50
Coordinator. Dr G Kakos (nEd) Prerequisites: Nil
209 hours of lectures, seminars, briefing sessions, company visits and oral presentations
Objectives
On completion of this semester subject students will have acquired a working knowledge of best practice principles in a variety of manufacturing environments and be able to commence implementation of these principles at their own place of work
Content
Orientation Unit: Principles of Best Practice Organisations; company visits and appraisals: briefing sessions, site visits, debriefing sessions, orel presentation of findings and report submission.
Assessment
A major report equivalent to 20,000 words and oral presentation of findиgs (weighting 85%) and two hours of written tests and one assignment (3000 words) (weighting 15%).