Course Outline: EBS 249 – Metal Technology

CLO 1. demonstrate knowledge of various forces, metal structures,             mechanisms and types of energy needed for making metal             artefacts

CLO 2. demonstrate knowledge and understanding of the classification             of manufacturing processes in metal work

CLO 3. demonstrate knowledge and understanding of the common tools             and processes involved in making metal artefacts. E.g. Bench             work, forging, welding, sheet metal work and casting.

CLO 4. demonstrate knowledge and understanding of metal workshop             layout,             machines and their uses.

CLO 5. demonstrate knowledge and understanding of how Computer-            Aided Manufacturing works.

1. Identify the various metal technologies in the production of metal artefacts

2. Classify manufacturing processes in metal work

3. Demonstrate how to use engineering materials, tools and processes to make metal artefacts

4. Describe the principles of plant layout, identify metal work machines and mention their uses. Mention the advantages and disadvantages of using machine tools

5. Describe Computer-Aided Manufacture (CAM) and how it works. Read schematic presentations of Computer-Aided Manufacturing materials and layouts

·         Natural and Artificial

Forces:

·         Types of forces: tension, compression, bending, torsion, shear, distortion, etc.

Mechanisms:

·         Types of mechanisms: levers, pulleys, chain and sprockets, gear, cams, couplings etc

·         Types of motion: linear, rotary, oscillating, reciprocating

Energy:

·         sources and uses (e.g. Wind, solar, hydro-fuel)

·         Hydraulics and pneumatics: Principles of pneumatics

·         Casting, rolling, forging, drawing, bending, shearing

·         Etc

Secondary

·         Machining processes, surface finishing processes, joining processes sawing, shaping, drilling, grinding, planing, slotting,

Physical process

·         Annealing, normalising, hardening, tempering, patenting, age-hardening.

Pay attention to female students. Give them individual attention to ensure that they take active part in the classification process.

·         Cutting/sawing,

·         Scraping

·         Chiselling,

·         Chipping

·         Filing,

·         Drilling,

·         Thread cutting,

·         Reaming

Manufacture of basic metal items. i.e. tin cans, pair of tongs, hinges, key holders, hooks for cooking pots, etc

·         Forging processes

·         Forgeable materials

·         Forging temperature

·         Advantages and disadvantages of forging

Let students take notes and compare the processes to what they find in books.

Take note of heat treatment of metals in forging.

·         Welding types and processes

·         Materials for welding

·         Advantages of welding over other joints

·         Sheet metal drawings

·         Sheet metal materials and joints

·         Sheet metal processes

·         Common materials for sand and die casting

·         Tools and equipment for sand and die casting

·         Processes in sand and die casting

·         Defects in casting (Identification and action).

·         Focus on the advantages and disadvantages of each process.

Discuss the advantages and disadvantages of casting in metal work.

·         Power hacksaw

·         Power drills

·         Lathes

·         Milling machines

·         Planers

Use educational visit to metal workshop to observe the various types of engineering machines. Using the report of the student teachers, discuss and explain the uses and operations of the machines.

·         The concept of CAM

·         Benefits of CAM

·         Types of CAM software

·         2 Dimensional CAD (2D CAD)

·         3 Dimensional CAD (3D CAD)

Classification of 3D CAD software

·         Wire-frame models

·         Surface models

Practical applications of CAMs in making artefacts

Where possible, use videos and animations from known technical education sites online to enhance delivery.

Note: Encourage female student teachers to participate fully in all the activities

Course Assessment Components (Educative assessment of, for and as Learning)

Exercises             (individual)          20%

Quiz                  (individual)          20%

Weighting: 40%

Summative assessment: End of semester examination

Weighting: 60%

Students will be graded as follows:

A=80-100%; B+=75-79%; B =70-74%, C+ =65-69%, C= 60-64%, D+=55-59, D=50-54, E< 50 (Fail)

Amoakohene, S.K. & Sackey, J.K.N., (1996). Metal Technology. London: MacMillan Education Ltd.

Garret, J. (1996). Design and Technology (2^nd ed.). Cambridge Press..

Rees, D. (1998). CDT-Design and Realization. Essex, U.K.: Longman Group Ltd.

Timings, R.L. (1991), Mechanical Engineering Craft Theory and Related Subjects, Vol. 1&2. Singapore: Longman Ltd.

Bawa, H. S. (1999).Workshop Technology (Vol. 1 & 2). Tata McGraw-Hill Publishing Company Limited: New Delhi