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    Manufacturing Process

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    Law Hui Huang
    This unit provides learners with knowledge of manufacturing processes and techniques. It has 60 learning hours at NQF level 4. Learners will select suitable machining, molding, and non-conventional processes for given component specifications. Content includes conventional machining techniques, molding and shaping processes, and non-conventional machining. Assessment involves practical activities and evidence of learning outcomes.

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    Manufacturing Process

    Uploaded by

    Law Hui Huang
    45 views6 pages
    This unit provides learners with knowledge of manufacturing processes and techniques. It has 60 learning hours at NQF level 4. Learners will select suitable machining, molding, and non-conventional processes for given component specifications. Content includes conventional machining techniques, molding and shaping processes, and non-conventional machining. Assessment involves practical activities and evidence of learning outcomes.

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    Manufacturing Process

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    This unit provides learners with knowledge of manufacturing processes and techniques. It has 60 learning hours at NQF level 4. Learners will select suitable machining, molding, and non-conventional processes for given component specifications. Content includes conventional machining techniques, molding and shaping processes, and non-conventional machining. Assessment involves practical activities and evidence of learning outcomes.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    45 views6 pages

    Manufacturing Process

    Uploaded by

    Law Hui Huang
    This unit provides learners with knowledge of manufacturing processes and techniques. It has 60 learning hours at NQF level 4. Learners will select suitable machining, molding, and non-conventional processes for given component specifications. Content includes conventional machining techniques, molding and shaping processes, and non-conventional machining. Assessment involves practical activities and evidence of learning outcomes.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 6

    Unit 27:

    Learning hours:
    NQF level 4:

    Manufacturing Process
    60
    BTEC Higher National - H1

    Description of unit
    The aim of this unit is to provide learners with a broad and in-depth knowledge of
    manufacturing processes and techniques that can be applied to a range of materials
    for a variety of manufacturing applications.
    Summary of learning outcomes
    To achieve this unit a learner must:
    1

    Select suitable conventional machining processes and techniques for generating


    geometrical forms for a given component specification

    2 Select suitable moulding and shaping processes for a given component


    specification
    3 Select suitable non-conventional machining techniques for a given component
    specification.

    343767208.doc Created on 01/11/2004 09:42:00

    Content
    1

    Conventional machining

    Component manufacture: specify components for manufacture (eg criteriatolerances, types of material, machining technique, surface texture, material
    removal rates, speeds and feeds, cutting times, cutter offsets, table angles)
    Machining techniques: production of flat and cylindrical geometry (eg milling,
    surface grinding, lapping, planing, turning, cylindrical grinding, centreless grinding,
    honing, super finishing, thread milling techniques, jig boring, horizontal boring,
    vertical boring, transfer machines)
    Tooling requirements: multi-tooth cutting (eg milling, grinding, hobbing, drilling,
    reaming, and broaching); single-point cutting (eg turning, planing and slotting);
    appropriate cutting angles for given materials; types, advantages and
    disadvantages of coolants and cutting fluids used for various materials and
    processes (eg advantages - prolonging tool life, increased material removal rate,
    improved surface finish; disadvantages - fumes and possible irritations to
    operators)
    Work-holding techniques: selection of appropriate work-holding devices (eg three
    and four jaw chucks, vices, jigs, fixtures, clamping arrangements, vee blocks, angle
    plates and magnetic chucks); health and safety issues and limitations of devices
    2 Moulding and shaping

    Component manufacture: specify components for moulding and shaping (eg criteria
    tolerances, type of moulding/shaping technique to be used, limitations of size,
    shape and production volume, properties of materials being moulded/shaped,
    surface texture, cost factors, post-moulding operations required - machining,
    clipping, welding, finishing, etc.)
    Moulding processes: casting (eg sand, die, investment and continuous casting);
    powder metallurgy; sintering
    Shaping processes: extrusion (eg direct, indirect and impact); forging (eg drop,
    pressure and upset); rolling; hot and cold presswork (eg forming, bending and deep
    drawing); metal spinning
    Ceramic materials: range applicable to component (eg metallic carbides,
    nitrides and oxides)

    343767208.doc Created on 01/11/2004 09:42:00

    Material properties: changes to the molecular structure and hence the material
    properties that may arise from a moulding or shaping operation (eg grain growth,
    work hardening, cracking, orientation of grain flow)
    Tooling requirements: appropriate tooling and equipment required to produce given
    components by moulding and shaping techniques (eg re-usable moulds and nonpermanent moulds, suitable casting materials for a particular casting process);
    press tools, punches, dies, press capacity and calculations in terms of tonnage
    3 Non-conventional machining

    Component manufacture: principle of operation of the non-conventional machining


    techniques (eg electro-discharge machining (EDM), wire erosion, ultrasonic
    machining, etching of electronic printed circuit boards (PCBs), laser-beam
    machining, plasma jet machining); specification of components for non-conventional
    machining techniques (eg criteria-tolerances, types of material, suitable
    technique, surface texture, material removal rate, cost factors)
    Tooling requirements: tooling and ancillary equipment needed to perform nonconventional machining techniques; work-holding techniques; health and safety
    issues

    343767208.doc Created on 01/11/2004 09:42:00

    Outcomes and assessment criteria

    Guidance
    343767208.doc Created on 01/11/2004 09:42:00

    Delivery
    The unit may be delivered as a stand-alone package, or integrated into other appropriate
    programmes. If it is delivered in an integrated way, care must be taken to provide tracking
    evidence for the outcomes. Centres should also be aware that study and assessment at an
    individual outcome level throughout the programme could lead to assessment overload.
    Wherever possible a practical approach should be adopted. Learning and assessment can be
    across units, at unit level or at individual outcome level. Effort should be made to identify
    the relevance of the principles covered.

    Assessment
    Evidence of outcomes could be in the form of reports of practical activities. This evidence
    may be generated in a learner's place of work.
    Evidence for this unit is likely to be at individual outcome level to provide maximum flexibility
    of delivery. However, centres may wish to consider assemblies that include components
    manufactured using the four processes - machining, moulding, shaping and non-conventional
    methods. This approach would provide a central theme and may lead to a more coherent use
    of the outcomes and assessment criteria.
    Evidence may be accumulated by learners building a portfolio record of the activities carried
    out in their place of work, or by tutor-led assignments.

    Links
    This unit is intended to be linked with Unit 7: Materials Engineering and Unit 30: Design for
    Manufacture.
    Entry requirements for this unit are at the discretion of the centre. However, it is advised
    that learners should have completed appropriate BTEC National units or equivalent. Learners
    who have not attained this standard may require an element of bridging studies built into
    their programme.

    Resources
    Access to suitable instructional material in the form of books or digital means, whereby the
    learner can research various manufacturing processes is desirable. Access to conventional
    machine tools and as wide a range of processes, as identified in the content, would also be
    desirable.

    Support materials
    343767208.doc Created on 01/11/2004 09:42:00

    Textbooks

    Kalpakjian S - Manufacturing Engineering and Technology (Addison-Wesley,


    2000) ISBN 0201361310

    Kalpakjian S -Manufacturing Processes for Engineering Materials - 4th Ed


    (Pearson, 2002) ISBN 0130408719

    Schey J - Introduction to Manufacturing Processes - 3rd Ed (McGraw Hill,


    2000) ISBN 0071169113

    343767208.doc Created on 01/11/2004 09:42:00

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