Overview
This unit offers comprehensive information on material behaviours and manufacturing properties, principles, processes, and technologies. The unit aims to deepen the understanding of the material selection process and enables you to identify appropriate manufacturing processes for a particular product design and development. You will study bulk deformation, material removal, finishing and joining and other modern manufacturing processes. You will also study product design, quality management, and manufacturing in a competitive environment. You will apply information literacy skills to obtain relevant engineering information and identify appropriate standards and practices.
Details
Pre-requisites or Co-requisites
Prerequisites: (ENEG11008 Materials for Engineers or ENEG12005 Materials Science & Engineering) and MATH11218 Applied Mathematics or MATH11219 Engineering Mathematics.
Important note: Students enrolled in a subsequent unit who failed their pre-requisite unit, should drop the subsequent unit before the census date or within 10 working days of Fail grade notification. Students who do not drop the unit in this timeframe cannot later drop the unit without academic and financial liability. See details in the Assessment Policy and Procedure (Higher Education Coursework).
Offerings For Term 2 - 2024
Attendance Requirements
All on-campus students are expected to attend scheduled classes - in some units, these classes are identified as a mandatory (pass/fail) component and attendance is compulsory. International students, on a student visa, must maintain a full time study load and meet both attendance and academic progress requirements in each study period (satisfactory attendance for International students is defined as maintaining at least an 80% attendance record).
Recommended Student Time Commitment
Each 6-credit Undergraduate unit at CQUniversity requires an overall time commitment of an average of 12.5 hours of study per week, making a total of 150 hours for the unit.
Class Timetable
Assessment Overview
Assessment Grading
This is a graded unit: your overall grade will be calculated from the marks or grades for each assessment task, based on the relative weightings shown in the table above. You must obtain an overall mark for the unit of at least 50%, or an overall grade of 'pass' in order to pass the unit. If any 'pass/fail' tasks are shown in the table above they must also be completed successfully ('pass' grade). You must also meet any minimum mark requirements specified for a particular assessment task, as detailed in the 'assessment task' section (note that in some instances, the minimum mark for a task may be greater than 50%). Consult the University's Grades and Results Policy for more details of interim results and final grades.
All University policies are available on the CQUniversity Policy site.
You may wish to view these policies:
- Grades and Results Policy
- Assessment Policy and Procedure (Higher Education Coursework)
- Review of Grade Procedure
- Student Academic Integrity Policy and Procedure
- Monitoring Academic Progress (MAP) Policy and Procedure - Domestic Students
- Monitoring Academic Progress (MAP) Policy and Procedure - International Students
- Student Refund and Credit Balance Policy and Procedure
- Student Feedback - Compliments and Complaints Policy and Procedure
- Information and Communications Technology Acceptable Use Policy and Procedure
This list is not an exhaustive list of all University policies. The full list of University policies are available on the CQUniversity Policy site.
Feedback, Recommendations and Responses
Every unit is reviewed for enhancement each year. At the most recent review, the following staff and student feedback items were identified and recommendations were made.
Feedback from SUTE
More interaction during delivery helps students better.
The lecturer should interact with students more frequently during lectures by asking relevant challenging questions.
Feedback from Students and UC
Industry site visit is exceptionally helpful.
To develop practical knowledge for students, it is recommended that industry site visits should be held in areas of different campus locations, making it easier for students to attend.
Feedback from UC
Industry practice oriented assessment and unit content are making students ready for jobs.
The assessment questions should be based on real-life industry experiences to keep the lectures and tutorials more relevant to modern manufacturing industry practices.
Feedback from Students and UC
Implication of latest research output in unit content (lecture, tutorial, assessment) is creating inspiration for students.
The latest and relevant-to-topic research output should be used in lectures, tutorials and assessments.
Feedback from SUTE
Provide in-depth knowledge of individual manufacturing processes.
Lectures, tutorials, and assessments should reflect clear and in-depth specialist knowledge of individual topics.
- Establish the relationships between the microstructures, mechanical and manufacturing properties of materials
- Explain the mechanics of bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools used to perform these operations
- Analyse the forces, torques, and power requirements for various processing of different materials
- Apply the knowledge of engineering metrology, instrumentation, and quality assurance of manufacturing of products
- Apply engineering standards and practices relevant to materials manufacturing
- Work, learn, and communicate in an ethical, professional manner, both individually and in teams.
The Learning Outcomes for this unit are linked with the Engineers Australia Stage 1 Competency Standards for Professional Engineers in the areas of 1. Knowledge and Skill Base, 2. Engineering Application Ability and 3. Professional and Personal Attributes at the following levels:
Intermediate
1.2 Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences underpin the engineering discipline. (LO: 2I 3I 4I )
1.4 Discernment of knowledge development and research directions within the engineering discipline. (LO: 2I 3I 4I 5N )
1.6 Understanding the scope, principles, norms, accountabilities, and bounds of sustainable engineering practice in the specific discipline. (LO: 5I 6I )
2.3 Application of systematic engineering synthesis and design processes. (LO: 2I 3I )
2.4 Application of systematic approaches to the conduct and management of engineering projects. (LO: 4I )
3.1 Ethical conduct and professional accountability. (LO: 5I 6I )
3.3 Creative, innovative, and proactive demeanor. (LO: 2I 3I 4I)
3.5 Orderly management of self, and professional conduct. (LO: 6I )
Advanced
1.1 Comprehensive, theory-based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline. (LO: 1I 2A 3I 4I )
1.3 In-depth understanding of specialist bodies of knowledge within the engineering discipline. (LO: 1I 2A 3A 4I 5I )
1.5 Knowledge of engineering design practice and contextual factors impacting the engineering discipline. (LO: 2A 3A 4A)
2.1 Application of established engineering methods to complex engineering problem-solving. (LO: 2I 3A 4I 5I )
2.2 Fluent application of engineering techniques, tools, and resources. (LO: 2A 3I 4I)
3.2 Effective oral and written communication in professional and lay domains. (LO: 6A)
3.4 Professional use and management of information. (LO: 5A )
Note: LO refers to the Learning Outcome number(s) that link to the competency and the levels: N – Introductory, I – Intermediate, and A - Advanced.
Refer to the Engineering Undergraduate Course Moodle site for further information on Engineers Australia's Stage 1 Competency Standard for Professional Engineers and course-level mapping informationhttps://moodle.cqu.edu.au/course/view.php?id=1511
Alignment of Assessment Tasks to Learning Outcomes
| Assessment Tasks | Learning Outcomes | |||||
|---|---|---|---|---|---|---|
| 1 | 2 | 3 | 4 | 5 | 6 | |
| 1 - Written Assessment - 30% | ||||||
| 2 - Group Work - 30% | ||||||
| 3 - Online Test - 40% | ||||||
Alignment of Graduate Attributes to Learning Outcomes
| Graduate Attributes | Learning Outcomes | |||||
|---|---|---|---|---|---|---|
| 1 | 2 | 3 | 4 | 5 | 6 | |
| 1 - Communication | ||||||
| 2 - Problem Solving | ||||||
| 3 - Critical Thinking | ||||||
| 4 - Information Literacy | ||||||
| 5 - Team Work | ||||||
| 6 - Information Technology Competence | ||||||
| 7 - Cross Cultural Competence | ||||||
| 8 - Ethical practice | ||||||
| 9 - Social Innovation | ||||||
| 10 - First Nations Knowledges | ||||||
| 11 - Aboriginal and Torres Strait Islander Cultures | ||||||
Textbooks
There are no required textbooks.
IT Resources
- CQUniversity Student Email
- Internet
- Unit Website (Moodle)
All submissions for this unit must use the referencing styles below:
For further information, see the Assessment Tasks.
p.gudimetla@cqu.edu.au
Week 1
Begin Date: 08 Jul 2024Module/Topic
Lecture 1a: Introduction to the Unit
Lecture 1b: Introduction to Manufacturing
Lecture 1c: Microstructural Aspects & Manufacturing Properties of Engineering Materials
Chapter
Lecture Notes
Reading: Part I - Kalpakjian
Events and Submissions/Topic
Tutorial 1
Week 2
Begin Date: 15 Jul 2024Module/Topic
Lecture 2a: Synthesis of Materials - Solidification Processes, Principles of Metal Casting
Lecture 2b: Metal Casting Processes, Cast Design, Materials & Economics
Chapter
Lecture Notes
Reading: Part II - Kalpakjian, Chapters 10-12
Events and Submissions/Topic
Tutorial 2
Week 3
Begin Date: 22 Jul 2024Module/Topic
Lecture 3a: Fundamentals of Metal Forming - Material behaviour, bulk deformation properties (yield strength, plasticity, strain, strain rate, strain-rate sensitivity, flow stress, ductility), Influence of Temperature, Friction and Lubrication on Metal Forming
Chapter
Lecture Notes
Events and Submissions/Topic
Tutorial 3
Week 4
Begin Date: 29 Jul 2024Module/Topic
Lecture 4a: Bulk Deformation Processes - Rolling and Forging, Processes
Chapter
Lecture Notes
Reading: Part III - Kalpakjian, Chapter 13-14
Events and Submissions/Topic
Tutorial 4
Week 5
Begin Date: 05 Aug 2024Module/Topic
Lecture 5: Extrusion, Deep Drawing: Operations, process control, parameters
Chapter
Lecture Notes
Reading: Part III - Kalpakjian, Chapter 15
Events and Submissions/Topic
Tutorial 5
Vacation Week
Begin Date: 12 Aug 2024Module/Topic
Chapter
Events and Submissions/Topic
Week 6
Begin Date: 19 Aug 2024Module/Topic
Lecture 6a: Sheet Metal Working - Operations, process control, parameters
Chapter
Lecture Notes
Reading: Part III - Kalpakjian, Chapter 16
Events and Submissions/Topic
Tutorial 6
Problem Solving Due: Week 6 Friday (23 Aug 2024) 11:59 pm AEST
Week 7
Begin Date: 26 Aug 2024Module/Topic
Lecture 7a: Mechanics of Metal Cutting - materials properties governing metal cutting, theory of chip formation, force, power and energy relationships, cutting parameters
Lecture 7b: Cutting Tool Technology - Tool life, Tool Materials, Geometry, Cutting Fluids
Chapter
Lecture Notes
Reading: Part IV - Kalpakjian, Chapters 21, 22
Events and Submissions/Topic
Tutorial 7
Week 8
Begin Date: 02 Sep 2024Module/Topic
Lecture 8a: Machining Operations and Machine Tools- Turning, Milling, Drilling, Boring, Shaping, Planing, Broaching
Lecture 8b: Machining Economics
Chapter
Lecture Notes
Reading: Part IV - Kalpakjian, Chapters 23 - 25
Events and Submissions/Topic
Tutorial 8
Week 9
Begin Date: 09 Sep 2024Module/Topic
Lecture 4a: Abrasive Machining - Grinding Technology & Processes
Lecture 4b: Surface Processing Operations
Chapter
Lecture Notes
Reading: Part IV - Kalpakjian, Chapters 26, 34
Events and Submissions/Topic
Tutorial 9
Week 10
Begin Date: 16 Sep 2024Module/Topic
Lecture 10a: Advanced Manufacturing Processes - waterjet, abrasive waterjet, laser, ECM, EDM, Plasma
Lecture 10b: Additive Manufacturing - 3D printing
Chapter
Lecture Notes
Reading: Part IV - Kalpakjian, Chapter 27
Events and Submissions/Topic
Tutorial 10
Manufacturing Process Plan Due: Week 10 Friday (20 Sept 2024) 11:59 pm AEST
Week 11
Begin Date: 23 Sep 2024Module/Topic
Lecture 11a: Forming & Shaping of Plastics
Lecture 11b: Composites Processing
Chapter
Lecture Notes
Reading: Part III - Kalpakjian, Chapter 19
Events and Submissions/Topic
Tutorial 11
Week 12
Begin Date: 30 Sep 2024Module/Topic
Lecture 12a: Advanced Manufacturing Processes - waterjet, abrasive waterjet, laser, ECM, EDM, Plasma
Lecture 12b: Additive Manufacturing - 3D printing
Chapter
Lecture Notes
Reading: Part IV - Kalpakjian, Chapter 27
Events and Submissions/Topic
Tutorial 12
Review/Exam Week
Begin Date: 07 Oct 2024Module/Topic
Chapter
Events and Submissions/Topic
Exam Week
Begin Date: 14 Oct 2024Module/Topic
Chapter
Events and Submissions/Topic
1 Written Assessment
This individual assessment pertains to the content covered in the first six weeks of the term. You will be asked to provide short descriptive answers to questions and solve number problems related to materials, manufacturing principles and bulk deformation processes. You will compile your responses and submit in a single PDF document using the submission link provided on the Unit Moodle. Please refer to the assessment handout on the Unit Moodle for more information.
Week 6 Friday (23 Aug 2024) 11:59 pm AEST
Submission via Online link provided on the Unit Moodle
Week 7 Friday (30 Aug 2024)
- Short answer questions - You will provide succinct answers with neatly labelled diagrams where applicable, and proper referencing (Harvard/Turabian Style)
- Numerical questions - You will present your numerical solutions in a logical structure by providing free body diagrams where applicable, implementing the correct formulas and using the correct system of units to express your final answers. You will make appropriate and valid comments on your final results.
- Establish the relationships between the microstructures, mechanical and manufacturing properties of materials
- Explain the mechanics of bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools used to perform these operations
- Analyse the forces, torques, and power requirements for various processing of different materials
- Apply engineering standards and practices relevant to materials manufacturing
2 Group Work
In this group assessment, you will form a team (2 students maximum) and develop a detailed manufacturing process plan for a given mechanical component or assembly. Your plan will include aspects such as material selection, process selection, manufacturing standards and codes. You will develop manufacturing drawings of the parts that need to be machined based on recommended Australian Standards. You will recommend appropriate machine tools to produce the component for different batch sizes. You will comment on the economies of scale as required. You will submit one group report of your efforts on or before the prescribed due date. Refer to the assessment task sheet on the Unit Moodle for more infomration.
Week 10 Friday (20 Sept 2024) 11:59 pm AEST
Submission via Online link provided on the Unit Moodle
Week 12 Friday (4 Oct 2024)
The following criteria shall be applied to assess your submission:
1. Includes detailed information on materials used, traditional and novel manufacturing methods applied to produce the component, supported by recent research trends
2. Justification of the proposed approach to manufacture the component
3. Detailed manufacturing drawings with all necessary specifications such as dimensional tolerances and surface finish, welding requirements etc., as per Australia Standards
- Explain the mechanics of bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools used to perform these operations
- Apply the knowledge of engineering metrology, instrumentation, and quality assurance of manufacturing of products
- Work, learn, and communicate in an ethical, professional manner, both individually and in teams.
3 Online Test
The online test will be administered in the University Exam week. The test will be made available for one whole week. You are expected to block a duration of time to take the test in one sitting. The test shall comprise of a combination of short answer and multiple choice questions which shall include numerical problems as well. The questions will be based on the contents covered in Week 7 to Week 12 of the term.
Exam Week Friday (18 Oct 2024) 11:59 pm AEST
Online Submission
Your efforts will be assessed based on your ability to provide succinct descriptive answers to short answer questions, the ability to select the correct answers to multiple choice questions by invoking your theoretical knowledge and inputting correct numerical values and units for all numerical problems.
- Establish the relationships between the microstructures, mechanical and manufacturing properties of materials
- Explain the mechanics of bulk deformation and material removal processes as applicable to ductile and brittle materials and the machine tools used to perform these operations
- Analyse the forces, torques, and power requirements for various processing of different materials
- Work, learn, and communicate in an ethical, professional manner, both individually and in teams.
As a CQUniversity student you are expected to act honestly in all aspects of your academic work.
Any assessable work undertaken or submitted for review or assessment must be your own work. Assessable work is any type of work you do to meet the assessment requirements in the unit, including draft work submitted for review and feedback and final work to be assessed.
When you use the ideas, words or data of others in your assessment, you must thoroughly and clearly acknowledge the source of this information by using the correct referencing style for your unit. Using others’ work without proper acknowledgement may be considered a form of intellectual dishonesty.
Participating honestly, respectfully, responsibly, and fairly in your university study ensures the CQUniversity qualification you earn will be valued as a true indication of your individual academic achievement and will continue to receive the respect and recognition it deserves.
As a student, you are responsible for reading and following CQUniversity’s policies, including the Student Academic Integrity Policy and Procedure. This policy sets out CQUniversity’s expectations of you to act with integrity, examples of academic integrity breaches to avoid, the processes used to address alleged breaches of academic integrity, and potential penalties.
What is a breach of academic integrity?
A breach of academic integrity includes but is not limited to plagiarism, self-plagiarism, collusion, cheating, contract cheating, and academic misconduct. The Student Academic Integrity Policy and Procedure defines what these terms mean and gives examples.
Why is academic integrity important?
A breach of academic integrity may result in one or more penalties, including suspension or even expulsion from the University. It can also have negative implications for student visas and future enrolment at CQUniversity or elsewhere. Students who engage in contract cheating also risk being blackmailed by contract cheating services.
Where can I get assistance?
For academic advice and guidance, the Academic Learning Centre (ALC) can support you in becoming confident in completing assessments with integrity and of high standard.
What can you do to act with integrity?
