MMT global setup plan 1.1, 8 pages.
NPT -241 – TAIZ CURRICULUM DEVELOPMENT PROJECT
Global setup plan
Materials & Manufacturing Technology*)
version 1.2
20091003
Name of programme/course
Master of Engineering & Management, course Materials & Manufacturing Technology.
*) In close consideration with my academic supervisor the name of the course has been
changed from Materials Processing into Materials & Manufacturing Technology, since
this name is – from my point of view – more clear and covers the content and goals of the
course better. I think that the knowledge and understanding of the structure and properties
of materials have to be a goal in itself and not only for the benefit of the understanding of
manufacturing processes. In developing countries all basic materials (e.g. steel rods for
concrete reinforcement) and almost all metal and plastic products are imported, so it is
really important that the local engineering staff has sufficient knowledge, understanding
and skills to evaluate the quality of materials and to test whether materials meet their
specification.
Learning objectives
1. Knowledge and understanding of the structure and properties of materials, in
particular engineering materials like metals, ceramics, polymers and composites.
2. Understanding and skills to evaluate the quality of engineering materials and to test
whether materials meet their specification.
3. Knowledge and understanding of the most important manufacturing processes for
basic metals and products of engineering materials.
4. Understanding of the relationships among the material properties and the process
parameters of manufacturing processes.
5. Knowledge, understanding and skills to make quantitative analyses of manufacturing
processes.
6. Knowledge, understanding and skills to select the most appropriate manufacturing
process for the production of any product or product part, depending on the product
shape, product dimensions, product tolerances and batch size.
7. Knowledge and understanding of product design considerations related to
manufacturing processes.
Summarizing: The main objective of the course is to acquire sufficient knowledge,
understanding and skills about the best way to manufacture any product or part of a
product from engineering materials or to answer for existing products the question ‘How
it’s made?’.
Course schedule and topics per day
The didactical concept of the course is based on a balanced mix of lectures, group
discussions and an immediate application of the knowledge from the courses by solving
problems and working on case studies. By working on more complicated problems and
case studies students have to work together in teams; the number of students in a
working team will be directly related to the complexity of the problem definition.
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MMT global setup plan 1.1, 8 pages.
Student participation in the working teams and group discussions belongs to the
assessment format of the student.
A daily teaching and learning module (four hours) consists of the following activities:
1. A theoretical introduction of the relevant fundamentals, concepts, methods,
processes and techniques by the lecturer.
2. A direct link to the industrial practice, showing product examples and one or two
short video films; incidentally a guest speaker from a Yemen company will be
invited.
3. A group discussion about some topics directly related to the given lecture or some
reflection issues.
4. Applying the knowledge of the module by solving problems (exercises) and
working on case studies in student teams. The results of the case studies have to be
presented for the lecturer and other students.
Schedule Topics per module
Day 1
Introduction: Learning objectives. Course info. Examination requirements.
What is manufacturing? Materials in manufacturing. Manufacturing
processes. Production systems. Product attributes (dimensions, tolerances,
surfaces). Interfaces with other courses of the programme.
Day 2
Material properties: Atomic structure and the elements. Bonding between
atoms and molecules. Crystalline and non-crystalline structures. Engineering
materials. Stress-strain relationships. Hardness. Effect of temperature on
properties. Fluid properties. Visco-elastic behaviour of polymers. Some
physical properties.
Day 3
Engineering materials: Metal alloys. Ferrous metals. Nonferrous metals.
Fundamentals of polymer science and technology. Thermoplastic polymers.
Thermosetting polymers. Elastomers. Short introduction to ceramics.
Introduction to composite materials.
Day 4
Processes for shapeless metal materials (liquid and powder): Fundamentals
of casting: heating, pouring, solidification and cooling. Metal casting
processes, expendable-mould casting, like sand casting, and permanentmould casting processes. Casting quality. Metals for casting. Product design
considerations. Essentials of powder metallurgy. Some rapid prototyping
technologies.
Day 5
Shaping processes for plastics, rubber and composites: Properties of
polymer melts. Extrusion. Production of sheet and film. Fibre and filament
production. Coating processes. Injection moulding. Compression moulding.
Blow and rotational moulding. Thermoforming. Polymer foam processing.
Product design considerations. Rubber processing and shaping. Processes for
polymer composites, open and closed mould processes, filament winding and
pultrusion.
Day 6
Metal forming (bulk deformation): Material behaviour in metal forming.
Temperature in metal forming. Strain rate sensitivity. Friction and lubrication
in metal forming. Rolling and rolling related processes. Forging and forging
related processes. Extrusion. Wire and bar drawing.
Day 7
Sheet metalworking: Cutting operations. Bending operations. Drawing.
Other sheet-metal forming operations. Dies and presses for sheet-metal
processes. Sheet-metal operations not performed on presses. Bending of tube
stock.
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MMT global setup plan 1.1, 8 pages.
Day 7
(Cont.)
Day 8
Day 9
Day 10
Day 11
Day 12
Property enhancing and surface processing operations: Short introduction
on heat treatment of metals, cleaning and surface treatments, coating and
deposition processes.
Material removal processes: Chip formation in metal machining. Force,
power and energy relationships in machining. Cutting temperature. Turning
and related operations. Drilling and related operations. Milling. Machining
centres and turning centres. Other machining operations. High-speed
machining.
Material removal processes: Tool life. Tool materials. Tool geometry.
Cutting fluids. Machinability. Tolerances and surface finish. Selection of
cutting conditions. Product design considerations. Grinding and related
abrasive processes. Non-traditional machining. Electric discharge processes.
Laser beam machining.
Joining and assembly processes: Fundamentals of welding. Features of a
fusion-welded joint. Welding processes, arc welding, resistance welding,
oxyfuel gas welding and other fusion-welding processes, solid-state welding.
Weld quality. Weldability. Design considerations in welding. Brazing.
Soldering. Adhesive bonding. Fastening methods in mechanical assembly.
Design considerations in assembly.
Manufacturing systems and manufacturing support systems: Numerical
control. Industrial robots. Group technology. Flexible manufacturing systems.
Production lines. Quality control. Metrology. Inspection principles.
Conventional measuring instruments and gages. Measurement of surfaces.
Advanced measurement and inspection technologies.
Summary: Overall overview. Guidelines and recommendations. Material and
manufacturing process selection related to the product function, product
shape, product dimensions, product tolerances, batch size and costs.
Last consultancy.
The content of the course will be highlighted on the basis of product examples, problems,
websites, cases, films, reflection issues, etc.
Proposed textbook
Fundamentals of Modern Manufacturing: Materials, Processes and Systems, 3rd edition, 2007.
Mikell P. Groover, Professor of industrial and systems engineering, Lehigh University (USA)
ISBN: 978-0-471-74485-6. See
http://he-cda.wiley.com/WileyCDA/HigherEdTitle/productCd-0471744859,courseCdE43600,pageType-copy,page-collegeAbout.html
This book is the primary mandatory textbook for the course. It is a well established textbook
that presents almost all manufacturing processes for engineering materials from a theoretical
and practical point of view, including the required background information about the nature
and properties of materials. For the work on case studies some more detailed books are
available in the library.
Assessment format
The assessment will be done for 30% based on the student participation in group discussions
and in the student teams working on case studies and solving course related problems.
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MMT global setup plan 1.1, 8 pages.
Due to the broad scope of the field, it is practically impossible to define appropriate items for
a final assignment, which cover a significant part of the course content. For that reason the
70% for the final assessment have to be done as a written examination. If the number of
participants is relatively low the written examination can be replaced by an oral examination.
Planning and milestone deliverables
Activity
Overall preparation,
selection of books, video
films sources, etc.
Indication of the level of
detail of the course
development result
Preparation of day 1
Preparation of day 2
Preparation of day 3
Preparation of day 4
Preparation of day 5
Preparation of day 6
Preparation of day 7
Preparation of day 8
Preparation of day 9
Preparation of day 10
Preparation of day 11
Preparation of day 12
Expected time
duration days
1
Deliverables
2
2
2
2
2
2
2
2
2
2
2
2
Sheets*), relevant exercises and/or cases day 1
Sheets*), relevant exercises and/or cases day 2
Sheets*), relevant exercises and/or cases day 3
Sheets*), relevant exercises and/or cases day 4
Sheets*), relevant exercises and/or cases day 5
Sheets*), relevant exercises and/or cases day 6
Sheets*), relevant exercises and/or cases day 7
Sheets*), relevant exercises and/or cases day 8
Sheets*), relevant exercises and/or cases day 9
Sheets*), relevant exercises and/or cases day 10
Sheets*), relevant exercises and/or cases day 11
Sheets*), relevant exercises and/or cases day 12
Examination example
List of books for the library
List of video film sources
Student’s guide
*) Including photographs of relevant product examples and specification of the chosen video
film passages.
An expected number of development days
Following the deliverables planning a total number of 25 development days is expected.
A possible redesign after the first year has to be discussed later.
Delivery date
The full proposal will be delivered not later than 20100430.
Short CV
The course development will be done by ir. Hans Ponsen. His CV (including personal data,
job history, teaching and other relevant expertise, and publications related to education) has
been added as Appendix B.
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MMT global setup plan 1.1, 8 pages.
Appendix A: Course description from EM program Specification document
Course Description Taiz EM master
Course name
Course code
Materials processing
Lecturer
Course language
English
Course period
Block 2
Examination period
Credits
Course objectives
3
1. Knowledge of engineering materials e.g. metals,
ceramics, polymers, composites and their processing
technologies.
2. Understanding the relationships among the material
properties and the process variables of a manufacturing
process.
3. Skills for quantitative analysis of manufacturing
processes
4. Knowledge and understanding of product design
guidelines
Organization of the course
Activities:
Lectures and student presentations in 10 days.
1
What Is Manufacturing? Materials in Manufacturing. Manufacturing
Processes. Production Systems.
2
Material Properties and Product Attributes.
3
Engineering Materials
4
Solidification Processes
5
Particulate Processing of Metals and Ceramics
6
Metal Forming and Sheet Metalworking
7
Material Removal Processes
8
Property Enhancing and Surface Processing Operations
9
Joining and Assembly Processes, Special Processing and Assembly
Technologies
10 Manufacturing Systems, Manufacturing Support Systems
Course Material
Course Book
Fundamentals of Modern Manufacturing: Materials, Processes,
and Systems, 3rd Edition
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MMT global setup plan 1.1, 8 pages.
Lecture Slides
Case study
Assignments
Example Exam
Mikell P. Groover, Professor of Industrial and Systems
Engineering, Lehigh University
ISBN: 978-0-471-74485-6
©2007 See
http://he-cda.wiley.com/WileyCDA/HigherEdTitle/productCd0471744859,courseCd-E43600,pageType-copy,pagecollegeAbout.html
Blackboard
Blackboard
Blackboard
Software tools that are needed
Tbs
Assessment
Type
Grading
Exercises and final “laboratory”project
30% exercises, 70% final project
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MMT global setup plan 1.1, 8 pages.
Appendix B: Curriculum vitae
-
Name
Address
Phone
Date of birth
Place of birth
E-mail address
: Johannes Matthijs (Hans) Ponsen
: Denekamperdijk 36, 7581 PJ Losser (NL)
: 0031 – 53 – 5388435
: 29th of November 1943
: Coevorden (NL)
: hansponsen@yahoo.com
During my academic education at the Eindhoven University of Technology I obtained a
propaedeutic certificate in Chemical Engineering in 1962 and finished my Master in
Mechanical Engineering in 1968. My Master thesis was dealing with an analysis of the wire
drawing process.
My first job at the University of Twente in Enschede (at that time still the Twente Technical
High School) I got in 1968 and worked there till 1974. I developed and taught a couple of new
courses on manufacturing and forming technology (including laboratory activities) for this
young university. Related to research I participated in an international research programme on
metal extrusion and was member of the International Cold Forging Group.
In the period of 1974 – 1980 I worked in consultancy and engineering services at Raskin
Nederland in Laren (N.H.). This small enterprise was – as a daughter company of some
important European machine tool manufacturers – specialized in the design and
implementation of complete production lines for the sheet metal and forming industries in the
Netherlands.
In 1980 I made a change to the University of Applied Science in Arnhem (at the time still the
HTS Arnhem), where I was teaching till 1987 a couple of courses in the field of
manufacturing, design engineering, industrial engineering, materials science and applied
mechanics for students in mechanical, electrical and civil engineering. An important task was
to intensify the contacts with industry via student internships and thesis projects, but also
through consultancy and engineering services (new at that time).
In 1987 I have been sent out by the Dutch Government to Curaçao as ‘technical expert’ for
the Netherlands Antilles in the field of manufacturing and materials engineering, to support
the local industry and the University of the Netherlands Antilles (UNA). I developed there a
couple of courses for the small university and for the industry, was involved in the technical
upgrading of a couple of companies, supported the setup of two new production plants and
made a significant contribution to the quality control process of imported materials. During
the period 1987 – 1992 I trained two local counterparts, to take over my job after my
departure.
Since 1992 I was working at the University of Twente, Department of Engineering
Technology, in the Group Design, Production & Management of Prof.dr.ir. F.J.A.M. van
Houten. I was intensively involved in the design and implementation of the new project
oriented curricula of mechanical engineering (see list of publications), was teaching a couple
of manufacturing courses for students in mechanical, industrial and design engineering and
developed and managed a large couple of educational projects. Since 1998 I was coordinator
of the international Master programme Industrial Design & Manufacturing (IDM), a joint
activity of our university with the University of Dortmund (Germany), and later on with the
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MMT global setup plan 1.1, 8 pages.
Aalborg University in Denmark and the University of Strathclyde (Glasgow, Scotland). In
addition, I was the representative of the faculty in some international organizations, like SEFI.
I have been retired in November 2008, after which I developed again in 2009 a new course on
construction elements and taught a manufacturing course for Bachelor students in their last
year. I am co-author of the textbook on manufacturing Industriële Productie.
I am married, have two married daughters and four grandchildren. My most important hobbies
are travelling, walking, cycling and reading.
Publications related to education:
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Ponsen J.M., Kals H.J.J. (1996). A project-oriented starter course in manufacturing.
Proceedings of the SME International Conference on Manufacturing Education. San
Diego (USA), 13-15 March 1996.
Ponsen J.M., Kals H.J.J. (1998). Design and manufacturing in a project-oriented
curriculum. Proceedings of the SME International Conference on Manufacturing
Education. San Diego (USA), 14-16 October 1998.
Ponsen J.M., Mesenhöller E. (2000). The development of an international Masters
program in Industrial Design & Manufacturing. Proceedings of the 28th SEFI Annual
Conference. Paris (France), 6-8 September 2000.
Ponsen J.M., Ruijter C.T.A. (2002). Project-oriented education: Learning by doing.
Proceedings of the First CIRP International Manufacturing Education Conference:
CIMEC-2002. (p 135-144). Enschede (The Netherlands), 3-5 April 2002; ISBN 90-36517346.
Ponsen J.M., Houten F.J.A.M. van, Mantel R.J. (2002). An international Masters program
in Industrial Design & Manufacturing. Proceedings of the First CIRP International
Manufacturing Education Conference: CIMEC-2002. (p 177-186). Enschede (The
Netherlands), 3-5 April 2002; ISBN 90-365-17346.
Ponsen J.M., Ruijter C.T.A. (2002). Improvements in project-oriented education.
Proceedings of the 30th SEFI Annual Conference: The Renaissance Engineer of
Tomorrow. Florence (Italy), 8-11 September 2002; ISBN 88-8304-479-7.
Ponsen J.M., Belt D. van de (2005). How to realize an internationalization component in
engineering curricula. Proceedings of the 33rd SEFI Annual Conference. Ankara (Turkey),
7-10 September 2005.
Ponsen J.M. (2007). Study tour projects. Proceedings of the 35th SEFI Annual Conference.
Miskolc (Hungary), 1-4 July 2007.
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