s
Title
Code
Level
Credit rating
Pre-requisites
Type of module
Aims
Learning
outcomes/objectives
Content
Teaching and
Comments/notes
Materials and Manufacture
ME113
4
20
Normal entry requirements
Double module delivered over two semesters
1. To introduce the students to different materials through their property
relationships to meet service conditions.
2. To select materials appropriate to manufacturing processes.
3. To provide students with a fundametal understanding of manufacturing
techniques and processes to enhance appropriate selections to
produce given outputs.
On successful completion of this module students will be able to:
1. Assess the resultant loading and stresses in mechanical components
knowing their function and operating conditions.
2. Carry out effective materials selection to prevent possible failure and to
meet manufacturing and environmental requirements.
3. Select suitable manufacturing processes to meet product specifications
in terms of production quantity, dimensional precision, finish, and prime
manufacturing cost.
Selection and application of materials: evaluation of product functions,
service environments, and the material properties of plain carbon steels,
stainless steels, cast irons, aluminium and its alloys, copper and its alloys,
polymers (plastics), elastomers (rubbers), ceramics, glass; composites.
Types of loading: tension, compression, shear, torsion; bending.
Stress considerations: stress-strain behaviour, the definitions of yield
stress, tensile strength and ductility, Hooke's law, normal (direct) stress and
strain, shear stress, brittle and ductile materials.
Failure analysis: foundations of stress analysis and factor of safety;
introduction to crack propagation mechanism and fatigue failure, creep and
stress relaxation; buckling failure.
Thermal and electrical properties of materials: modification of materials,
phase transformations, thermal processing of materials (glass annealing
and toughening; quenching and annealing of metal alloys, thermoplastics
and thermosetting polymers).
Environmental aspects: embodied energy and life cycle analysis.
Making plastic components: blown film extrusion, blow moulding,
compression moulding, dip moulding, extrusion, plastic gravity casting,
injection moulding, rotational moulding; thermoforming (including vacuum
forming).
Making glass components: float glass, manual and mechanised glass
blowing, glass rod moulding, glass pressing, glass sintering, glass spinning;
glass tube making.
Casting metal components: continuous casting, green sand casting,
disamatic casting, lost foam investment casting, lost wax investment
casting, shell casting, gravity diecasting; high pressure diecasting (hot and
cold chamber).
Deforming metal components: metal spinning (manual and shear);
forging.
Joining components together: mechanical fastenings (permanent and
temporary), adhesives, soldering, brazing, electron beam welding, friction
welding, gas-flame welding, manual metal arc welding; spot welding.
Machining from solid: turning, milling, drilling, tapping; deburring.
Product-related costs: raw materials, purchased complete items, direct
labour, consumable and partial overhead costs, fixed and variable costs,
economic break-even analysis, make or buy decisions and process
selection.
78 hours of lectures; 122 hours of guided independent study.
learning strategies
Learning support
Allocation of study
hours to activities
Assessment tasks
Type of assessment
tasks
Summative
assessment tasks
which lead to the
award of credit or
which are required for
progression
(expressed as a %)
Assessment
Brief description of
module content
and/or aims
(maximum 80 words)
Area examination
board to which
module relates
Module
team/authors/coordi
nator
Semester offered,
where appropriate
Site where delivered
Date of first approval
Date of last revision
Date of approval of
Reading List:
1. Callister, WD, (2000), Materials Science and Engineering, 5th ed, pub
Wiley, ISBN 0 471 39551 X (Core text).
2. Gere, JM, (2001), Mechanics of Materials, 5th ed, pub Brooks Cole
Thomson Learning, ISBN 0 534 37133 7.
3. Groover, MP, (2007), Fundamentals of Modern Manufacturing –
Materials, Processes, and Systems, 3rd ed, John Wiley and Sons,
ISBN 9780471744856.
4. Kalpakjian, S, and Schmid, S, (2007), Manufacturing Processes for
Engineering Materials, 5th ed, Prentice-Hall, ISBN 9780132272711.
5. Philip, M, and Bolton, W, (2002), Technology of Engineering Materials,
pub Butterworth-Heinemann, ISBN 0 7506 5643 3 (Core text).
6. Plummer, S, (2011), Manufacture (Module ME113) Lecture Notes,
University of Brighton. (Core text).
Salient details (e.g. module descriptor, programme of study,
announcements, PowerPoint presentations, lecture and tutorial notes;
coursework assignments) will be accessible via studentcentral. University
library, including access to British Standards; internet access to web-sites.
KIS CATEGORY/Activity type
Study hours
%
CATEGORY: SCHEDULED
Type: Lectures, seminars, tutorials, project
Materials
19.5%
supervision, demonstrations, practical
lectures 39 hrs
classes and workshops, supervised time in
Manufacture
19.5%
workshop/ studio, fieldwork, external visits,
lectures 39 hrs
work-based learning
CATEGORY: GUIDED INDEPENDENT
STUDY
Guided
61%
Type: Independent study including wider
independent
reading/ practice, follow-up work,
study 122 hrs
completion of assessment tasks, revision
etc.
KIS CATEGORY/Activity type
Further
%
details
CATEGORY: WRITTEN EXAM
Type: Written exam/ test (inc. in-class test)
Materials
50%
In-class test
Manufacture
50%
Written exam
CATEGORY: COURSEWORK
Type: Set exercises assessing application
of knowledge, analytical, problem-solving or
evaluative skills.
Materials examination - 50% (LOs 1,2),
Manufacture examination - 50% (LOs 2,3)
Most items we use in our every day lives are manufactured from materials.
This module introduces materials selection appropriate to the manufacturing
process, and manufacture as a way of adding value to material and
describes some of the basic manufacturing processes and environmental
considerations used to make plastic, glass and metal components. The
principles of failure analysis are introduced, such as foundations of stress
analysis, fatigue; creep; fractographic analysis of brittle vs ductile fracture.
Division of Engineering and Product Design Examination Board
Dr Steve Plummer and Dr Elena Sazhina
1 and 2
Moulsecoomb
12/07/2006
11/07/2007
28/06/2012
this version
Version number
Replacement for
previous module
Field for which module
is acceptable and
status in that field
Course(s) for which
module is acceptable
and status in that
course
School home
External examiner
3.0
Resulting merger of modules ME103 and ME106
Aeronautical Engineering, Automotive Engineering and Mechanical
Engineering
MEng/BEng (Hons) Mechanical Engineering Pathways (compulsory)
BSc(Hons) Mechanical and Manufacturing Engineering (compulsory)
School of Computing, Engineering and Mathematics
Dr S Brookes (appointed June 2012)