How are designs turned into products? What resources, materials and methods are used and what set of activities goes under the heading of 'manufacturing'? This free course will introduce manufacturing as a system and will describe some of the many different ways of making products. We will illustrate how the required properties of the materials in a product influence the choice of manufacturing process used.
Overview
Syllabus
- Introduction
- Learning outcomes
- 1 Introduction
- 1 Introduction
- 1.1 Making a product
- 1.2 The manufacturing process
- 1.3 Component parts
- 1.4 What is manufacturing?
- 1.5 Product design specification (PDS)
- 1.6 A PDS checklist
- 1.7 Product form and function
- 1.8 Product design
- 1.9 Engineering or industrial design?
- 1.10 Marketing
- 1.11 Product value
- 1.12 Manufacturing processes: making things
- 1.13 Gears and gearing
- 1.14 Getting into shape: some basics
- 1.15 Scales of material structure
- 1.16 Classifying shapes
- 1.6.1 (2D) continuous
- 1.16.2 (3-D) - Shapes
- 2 Casting
- 2 Casting
- 2.1 Introduction
- 2.2 Properties for processing – casting
- 2.3 Types of casting
- 2.3.1 Permanent pattern
- 2.3.2 Permanent mould
- 2.3.3 Expendable mould and pattern
- 2.4 Casting processes
- 2.5 Casting metals
- 2.6 Casting plastics
- 2.7 Casting microstructure and defects
- 2.8 Casting our gearwheel
- 3 Forming
- 3 Forming
- 3.1 Introduction
- 3.2 Properties for processing – forming
- 3.3 Forming v casting
- 3.4 Forming processes
- 3.5 Extrusion
- 3.6 Rolling
- 3.7 Metal forging
- 3.8 Forming our gearwheel
- 3.9 Failure of replacement gears
- 3.10 Powder processing techniques
- 4 Cutting
- 4 Cutting
- 4.1 Introduction
- 4.2 Cutting processes
- 4.3 The mechanics of machining
- 4.4 Hardness
- 4.5 Types of tool material
- 4.6 Machining our gearwheel
- 5 Joining
- 5 Joining
- 5.1 Introduction
- 5.2 Mechanical joining
- 5.3 Adhesive joints
- 5.4 Brazing and soldering
- 5.5 Glues
- 5.6 Welding
- 5.7 Solid-state welding
- 5.8 Fusion welding
- 5.9 Joining (assembling) our gearwheel
- 6 Making the gearwheel
- 6 Making the gearwheel
- 6.1 Introduction
- 6.2 Production costs
- 6.3 Looking ahead
- 7 Surface engineering
- 7 Surface engineering
- 7.1 Introduction
- 7.2 Case study 1: The kitchen knife
- 7.2.1 Increase the hardness of the steel
- 7.2.2 Make the knife out of a harder material
- 7.2.3 Engineer the cutting edge to retain the sharpness
- 7.3 Stainless steel
- 7.4 Wear
- 7.5 Physical vapour deposition
- 7.6 Plasma spraying
- 7.7 Case Study 2: Optical coatings
- 7.8 Optical terms
- 7.8.1 Refractive index
- 7.8.2 Dispersive power
- 7.8.3 Scattering
- 7.9 Materials selection
- 7.10 Scratch-resistant coatings
- 7.11 Anti-reflective coatings
- 7.12 Concluding remarks
- Conclusion
- Appendix I Table of hardness values
- Acknowledgements
Tags
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Reviews
5.0 rating, based on 1 Class Central review
4.7 rating at OpenLearn based on 20 ratings
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The course was highly beneficial in bridging the gaps between various topics I had previously learned but struggled to fully understand. It provided clear explanations and practical insights that deepened my knowledge and resolved my confusion on several key concepts. The structure was well-organized, and the content was delivered in an engaging and easy-to-follow manner. I especially appreciated how complex ideas were broken down into simpler terms, making them easier to grasp.
