Precision Manufacturing
DTU Department of Mechanical Engineering
The PhD course on Precision Manufacturing is dedicated to PhD students with a background in manufacturing engineering. The aim of this course is to enable the students to exploit the capabilities of Precision Manufacturing processes in order to design Precision Engineering products with outstanding performance. The course centres on developing a comprehensive understanding of the necessary conditions, tools and methods of Precision Manufacturing and introducing the basics of Zero Defect Digital Manufacturing. Following this course the students will develop a deep understanding of: 1) precision engineering and precision manufacturing principles, 2) conditions to achieve high precision in manufacturing, 3) advanced manufacturing technologies, 4) tools and methods to implement precision, improve process performance and reduce defects in production. The focus of the course is on tools and methods, while selected processes are discussed to support their presentation and application in practice.
Learning objectives:
A student who has met the objectives of the course will be able to:
- Understand the conditions to achieve high precision manufacturing
- Analyze functional requirements and translate them into design specifications with focus on precision requirements
- Select (apply) suitable advanced manufacturing processes matching the product specifications
- Identify (evaluate) critical issues hindering manufacturing accuracy
- Apply the tools and methods taught to improve manufacturing accuracy
- Perform (apply) theoretical calculations to support decisions concerning process selection and choice of process parameters
- Select (apply) suitable measurement methods for verification of product compliance with design specifications
- Create a strategy for improving manufacturing accuracy in manufacturing scenarios (processes and or components) different from those presented in class
- Apply systematic methods to create a coherent sequence of actions leading to production of precision products
Contents:
The course takes its starting point from the knowledge of basic manufacturing processes. After introducing the relationships between product functionality and process properties and performance, the boundaries of Precision Manufacturing are defined and the requirements for the implementation of Precision Manufacturing are presented. The two necessary conditions for implementation of Precision Manufacturing are described and validated through a number of examples. The four groups of tools and methods for implementation of Precision Manufacturing, namely: 1) Anticipated Process Knowledge (including modelling and simulation, DOE, experimental optimization); 2) Process monitoring, control and feedback, compensation, in situ metrology; 3) high accuracy hardware (machine tools, tools and fixtures); 4) Controlled manufacturing environment will be described and practical implementation to selected processes will be demonstrated. The concept of Concurrent Engineering is introduced in the context of Precision Manufacturing, explaining the need of manufacturing awareness early in the product design process. Precision Manufacturing processes will be introduced with the aid of a suitable framework for their classification and selection. In depth presentation will be given for selected processes, including both theoretical description as well as practical application of the tools and methods for advanced process simulation, optimization and monitoring.