This course will cover numerical simulation techniques used to accurately and efficiently simulate industrial sheet forming processes. A variety of finite element based techniques will be considered including explicit and so-called single and multi-step methods. * Review of sheet forming concepts * Numerical modeling techniques * Contact algorithms, friction * Material modelling, sheet anisotrophy, use of FLDs in formability prediction * Spring - back and trimming * Survey of commercial codes, Pre- and post- processing, CAD interface.
Course starts with a brief introduction to the theory of plasticity, directly applicable to the mathematical and physical analysis of problems in metal forming. A discussion of tribology and material attributes follows. Metallurgical phenomena, accompanying hot and cold forming of metals, are discussed. Application to bulk metal forming (rolling, extrusion, drawing and forging) and sheet metal forming (deep drawing, stretch forming, hydroforming) are considered. The use and limitations are demonstrated. Examples from laboratory experiments and from industrial applications are used to complement the presentation.
Surface Machining represents a major activity in many industries, like in the manufacture of tools and dies. This course addresses the issues of surface representation, and generation of the tool path on CNC milling machines for roughing and finishing of flat and sculptured surfaces. * Introduction to NC Machining: components of CNC machining centre, part programming, programming using a commercial package * Surface definition and properties: Bezier, B-Splines and NURBS, computation of normal, curvature and curvature directions etc., data exchange protocols * Rough Machining and Surfaces: tool wear and breakage, dynamics in surface machining, tool path planning for rough machining of surfaces * Finish Machining of Surfaces: Tool positioning strategies in 3 and 5 axis machining, tool path planning for finish milling, gouge detection and avoidance, verification of tool path.
Robotics: 7 Operating principles: physical configuration & workspace, joint position measurement and control, robot controller operation 7 Kinematics: coordinate frames and transformations, forward and inverse kinematics 7 Programming: motion types & applications, digital I/O and program flow control 7 Sensor-based operation: seam tracking & force feedback control Machine Vision: 7 Operating Principles: imaging sensors, image representation and transmission, image acquisition and storage 7 Image Processing: pixel processing (LUTS), area processing (filtering) 7 Image Analysis: boundary tracing, template matching, segmentation Communication Networks: 7 Data Transmission: asynchronous and synchronous data transmission, baseband and broadband, network topologies 7 Media access control: Ethernet CSMA/CD, Token bus 7 ISO-OSI model: seven layer model functionality 7 MMS: Manufacturing Message Standard concepts and issues
Plant Life Management, including configuration management; time dependent deterioration in plant and assessment of failure probabilities; risk analysis which considers probability of failure and consequences of failure; risk based in-service inspection and various other inputs for safety cases that should (must) be prepared when considering life extension.
Government regulations are becoming tighter regarding noise levels at industrial installations. This course is aimed at acquiring the necessary design tools to implement different measures for reducing noise generated from sources encountered in typical manufacturing environments. * Fundamentals of acoustics, noise analysis and measurement: Acoustic quantities, noise propagation, free and reverberant fields, room acoustics, near and far fields, noise measurements: frequency spectrum, octave and fraction octave filters, microphones, sound level meters, sound intensity measurements. * Noise Control: Response of the human ear to noise, Government regulations, noise level curves, noise control using sound absorption, using walls and partial partitions, using full enclosures and using vibration isolation.
The purpose of this course is to make sound, intelligent selections of materials for safe and efficient structures or components. A unique feature of the course is that it contains the methodology of design and how materials selection should be simultaneously chosen at every stage of the design process - concurrent engineering. The materials selection should be effected through consideration not only of their properties, their processing, and their fabrication, but also their recyclability, recovery, and disposal after their use, involving the concept of life-cycle analysis. * Physical, chemical and mechanical properties of materials that are important for the design of the structure of a component. Microstructure insensitive properties such as density, modulus and coefficient of linear expansion which are unaffected by processing. * Properties such as strength, fracture toughness, fatigue and creep that are affected by processing and the resultant microstructure. How processing influences these properties including corrosion resistance, and the manner in which they change during the fabrication of components. * Processing of metals and alloys. Solid state equilibrium and non-equilibrium transformations. Melting, solidification and casting of metals, including welding. Plastic deformation including rolling and annealing. Thermal processes such as surface treatments. * Processing of non-metals. Extrusion, injection molding, thermoforming of thermoplastic polymers. Fabrication of thermosets. Solidification of glasses. Superplastic forming and forming of glasses. Preparation and fabrication of composite materials. * Design and selection of materials. Performance and selection of ferrous materials for engineering design, considering low alloy steels, tool steels, stainless steels and cast irons. * Performance and selection of non-ferrous materials for engineering performance considering aluminum, magnesium, copper and nickel alloys. * Performance and selection of polymers, ceramics and composites for engineering performance.
Mechatronics is the integration of mechnaical, electrical, computer and control engineering. This course deals with the analytical tools required to design, model, analyze and control mechatronic systems. Properties of linear and nonlinear systems, system identification methods, process modelling, sensor and actuators, computer interfacing, computer control of machines and processes (PLC and PC based). Laboratories will include PLC based automation applications and PC based advanced robotics.
This course presents the theory and design implementation of several types of sensors and actuators. Sensors discussed include solid-state optical sensors, temperature sensors, velocity sensors, piezoelectric sensors and accelerometers, strain and force sensors, analogue and digital position sensors, and flow sensors, and magnetometers and Hall effect sensors. Theory and modeling of several common actuators including different electric motors, hydraulic and pneumatic motors and cylinders, as well as piezoelectric and magnetostrictive actuators are presented. Component integration, design considerations, and interfacing are studied through examples selected from applications of machine tools, mechatronics, robotics, aerospace systems, and ground vehicles. Four laboratory projects in robotics, vision, pneumatics, and hydraulic systems reinforce understanding of the topics.
Features and advantages of the various welding processes. Welding arc characteristics. Temperature distributions around welds. Metallurgy of the weld metal and heat affected zone in various alloys, including carbon and stainless steels, and aluminum alloys. Origin of various weld defects and methods of detecting them. Static and dynamic design of welded joints. Residual stresses, distortion and fracture of welds.
This course focuses on the strategic management of technology and innovation established firms. We take an evolutionary process perspective. The fundamental ideas underlying the perspective are: (1) that a firms technology strategy emerges from its technological competencies and capabilities, (2) that the technology strategy is shaped by evolutionary external (environmental) and internal (organizational) Forces. The course draws on strategic management, economics and organization theory for analytical tools to address important challenges faced by senior and middle managers in technology based firms. The course is practice oriented. Case studies of various real life situations will require in-depth analysis to be complemented with specific action recommendations. * To develop an awareness of the range, scope and complexity of the issues and problems related to strategic management of technology and innovation * To develop an understanding of the state of the art of strategic management of technology and innovation * To learn how to practically apply theoretical concepts in strategic management of technology and innovation.
This course covers the latest managerial tools on how to integrate the engineering design and manufacturing functions for best overall quality and shortest product development lead time. The scope of the course is multidisciplinary: we will cover both the analytical (quantitative) and qualitative aspects. * Understanding the conflicting constraints and demands on both engineering design and manufacturing * Potential trade-offs between decreased development time and increased product quality * Tools and methods for enhanced interaction: Staggered product release, Quality Function Deployment, rapid prototyping, modular design, CAD/CAM
This course deals with the effective product development project management. The scope is multidisciplinary: we will cover both the analytical (quantitative) and qualitative aspects of how to best run product development projects. It introduces concepts that a development project manager of engineering should know about. It only briefly covers how to manage the whole product design development process. * Linking project selection to technology strategy * How to screen and select projects * How to monitor and review their progress * Resource allocation among projects, timing and links, concurrent engineering * How to staff and lead projects * When to kill a project * Post-project review and learning
Modern supply chain management encompasses the logistics of inventory and transportation flows, whether within a given organization or between that firm and other companies (suppliers, customers) that are part of its business. This course thus deal with models and analyses of the inbound transportation of raw materials, manufactured components and sub-assemblies. Another emphais is the (outbound) physical distribution of finished goods from factory to consumer: freight transportation (various modes, customer service, multi-location inventory management and distribution-centre site selection. Specialized topics (for term projects) may be chosen from among Logistics Information Systems; Global Supply Chain Management; Vehicle Routing; or the Logistics of e-Commerce.
This course provides an introduction to quality management by examining the philosophies, practices, tools, and decisions involved in the management of quality. An applied approach is used in this study. The course begins with a general overview of quality, including the various ways of defining and measuring quality and the Cost-of-quality model. This culminates in an introduction to total quality (TOM) and its three conrnerstones: continuous improvement, customer focus, and total organizational involvement. The remainder of the course examines these cornerstones in greater detail. The objectives of the course are: (1) to develop an appreciation for importance of managing the quality at all levels, and stages of the organization, (2) to introduce techniques for defining, monitoring, and improving quality, and (3) to encourage critical thinking about issues in managing quality, within the organization, and in society in general.