Learning outcomes:
After successfully completing this module, students will be able to classify manufacturing technologies in the context of production technology, know their interfaces to product development, design technology, materials technology and quality management and will be familiar with the basics of manufacturing accuracy. They will be able to take a holistic view of complex and networked production chains for the manufacture of mechanical engineering products and understand the more in-depth and advanced fundamentals of materials technology with regard to the structure and properties of metals (in particular casting defects in alloys, solidification morphology, castability, plastomechanics [introduction], machinability). They will be able to explain how the production processes of primary moulding work and what they can be used for (continuous casting, sand casting, gravity and low-pressure die casting, pressure die casting, centrifugal casting, electroforming, powder technology),
reshaping (massive forming, sheet metal forming, near-net-shape component production), near-net-shape component production (thixoforging, powder and sinter forging, hydroforming and superplastic forming) and cutting (esp. chiseling, filing, sawing, turning, sinking, milling, broaching, grinding, honing, lapping). They will be able to select suitable processes and identify and establish their main manufacturing parameters.
This knowledge will enable them to analyze manufacturing problems, evaluate the technical and economic suitability of metals and manufacturing processes for the production of new products, and select the best manufacturing route (possibly consisting of several manufacturing steps) in terms of product properties and costs. Furthermore, they will be able to recognize and solve simple problems in the conceptual design and establishment of this manufacturing route. Students will also be able to evaluate established manufacturing routes and justifiably demonstrate alternatives for improving product properties or saving costs.
[updated 28.04.2023]
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Module content:
Introduction to production engineering
o Industrial production engineering, tasks and interrelationships of production engineering,
the product development process, classification of production processes
o Manufacturing accuracy: true value, correct value, empirical value, selection of suitable production processes
based on order data, geometry, technology and time values, factors influencing accuracy,
Quality requirements and assurance, quality-oriented production, production metrology, defects
(systematic, random), recording measured valuse, dimensional, form and positional accuracy, surface quality,
shape deviation, roughness parameters, achievable roughness of production processes, functional and
machine accuracy taking into account static, dynamic and thermal disturbances,
tribological tool changes
o Complex 21st century manufacturing chains: interlinking metallurgy, materials and production engineering,
Overview of metallurgical processes for the production of crude metal, production of used metal by way of
primary processing (ingot casting, continuous casting) and forming (rolling, forging, extrusion), followed by further
production processes for the production of the finished component, practical examples.
The technology of primary processing
o Definition, classification and process overview
o Fundamentals of materials engineering: solidification of pure metals and of alloys, casting defects in pure metals
and alloys, technological influence on solidification, solidification morphology, castability, metallic
casting materials.
o Guidelines for designing castings that are suitable for the casting process
o Smelting technology: tasks and mode of operation of cupola, induction, electric arc,
rotary drum, resistance and electron beam furnaces.
o Foundry operation technology: continuous casting, sand casting, gravity and low-pressure die casting, pressure die casting, centrifugal casting
o Electroforming: functionality, production equipment, tools, products
o Powder technology: production route, process overview, powder production (atomising, rotary atomising),
shaping (spray compacting, injection moulding (including Metal Injection Moulding; MIM)), pressing,
powder and sinter forging), sintering (definition, classification, sintering processes).
Forming technology
o Definition, semi-finished product production, workpiece production, advantages of forming
o Fundamentals of materials engineering:
- Plastic behavior: Cold and hot forming
- Introduction to plastomechanics: Stress and distortion state, stress tensor (deviatoric and hydrostatic component), flow conditions (shear stress theory according to Tresca, maximum shear strain energy criterion according to von Mises), flow rule, effective strain, effective strain rate, determining the flow curve, Ludwik equation for unalloyed and low-alloy steels as well as Al alloys
- Deep-drawing steels: Requirements, alloy concepts, production routes, mechanical properties
- Friction: Real material surface, factors influencing friction, laws of friction, wear, lubricants
(requirements, composition, effect)
o Massive forming: Rolling (process variations, flat longitudinal rolling of plates), forging (die forming, free forming), extrusion (direct, indirect, hydrostatic), wire drawing, upsetting, impact extrusion
o Sheet metal forming: Deep-drawing with tools, hydromechanical deep-drawing, electromagnetic forming, stretch-forming
- Near-net-shape manufacturing
o Additive production
- Process variants, materials, technology, advantages, applications
- Procedures: Selective laser sintering, 3D printing, stereolithography
o Thixoforging
o Internal high-pressure forming
o Superplastic forming
Cutting technology (Part I)
o Machining processses
- Definition, classification, process overview, productivity and quality
- Basics of machining processes: Mechanisms of the cutting process and chip formation, cutting and chip sizes in drilling and turning, geometry of the cutting edge, chip types, built-up edge, chip volume ratio and class, influence of cutting speed, depth of cut, feed rate and tool geometry on the chip shape, chip grooves on tools, heat generation during machining and distribution of heat to cooling lubricant, chip, workpiece and tool, tool life, sizes, conditions and criteria, cutting processes with geometrically-defined cutting edge
- Machining process with geometrically-defined cutting edge: chiseling, sawing, filing, turning, drilling, countersinking, reaming, milling, broaching
- Machining process with geometrically indeterminate cutting edge: grinding, honing, lapping
- Machinability: cutting materials, machining behavior of metallic materials, free-machining alloys
(alloy concept, structure, properties), high-speed cutting, cooling lubricants
[updated 28.04.2023]
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