Course Outline: EBS 249 – Metal Technology

Course Title Metal Technology II (Manufacturing Processes)
Course Code EBS 249 Course Level: 300 Credit Value: 3 Semester 2
Pre-requisite Pre-Technical Skills, Graphic Communication, Science, Mathematics, English Language, Workshop Management
Course Delivering Mode Face-to- face Practical Activity Work-Base Learning Seminars Independent Study e-learning opportunities Practicum
Course Description for significant learning (indicate NTS, NTECF, BSC, GLE to be addressed The course is designed to enable students acquire the expected knowledge and understanding of metal manufacturing processes and technologies. It is also to help students be able to identify common types of machines used in metal work and further help them to develop the appropriate skills, knowledge and understanding of metal work machines and their uses.
Course Learning Outcome: including INDICATORS for each learning outcome Outcomes: Student will be able to:

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.

Indicators

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

 

 

Unit: Topics: Sub-topics:

 

Teaching and learning activities to achieve learning outcomes
1

 

Technologies for making artefacts

 

Structures:

·         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

Through discussion, lead student-teachers to identify the various technological pieces of knowledge (in structures, forces, mechanisms and energy) needed in the production of metal artefacts.

 

2 Classification of Manufacturing Processes

 

Primary

·         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.

Through discussion, lead student-teachers to mention and describe some ways of classifying manufacturing processes. Let the students take note of. Through discussion, lead student-teachers to classify manufacturing processes into primary, secondary and tertiary processes. Give ample real life examples of artefacts produce by each process.

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

 

3 Bench work

 

Operations and precautions in using the following processes;

·         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

Visit metal workshops to demonstrate the operations. Lay special emphasis on precautions to be taken in using the following processes: cutting/sawing, scraping, chiseling, chipping, filing, drilling, thread cutting, and reaming.                              Note: Encourage female student teachers to participate fully

 

4 Forging ·         Forging tools and equipment

·         Forging processes

·         Forgeable materials

·         Forging temperature

·         Advantages and disadvantages of forging

 

Visit a workshop/blacksmith shop to observe the various types of processes.

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

Take note of heat treatment of metals in forging.

5 Welding ·         Welding tools and equipment

·         Welding types and processes

·         Materials for welding

·         Advantages of welding over other joints

 

Visit or use videos to show and explain welding processes. Use extensive sketches to illustrate welding nozzles and flames. Discuss types and gauges of rods and fluxes used in welding.
6 Sheet metalwork ·         Sheet metal work tools & equipments

·         Sheet metal drawings

·         Sheet metal materials and joints

·         Sheet metal processes

 

Discuss common sheet metal drawings, tools and equipment. Illustrate with drawings and videos where possible. Let students take note of the processes especially in making sheet metal joints
7 Casting Types, methods, materials, tools and equipment for casting

·         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.

Use drawings to show tools and equipment for foundry work. Let students lead discussions on the materials, processes and defects in casting.

Discuss the advantages and disadvantages of casting in metal work.

 

8 Machine tools and Processes

 

Main parts and uses of the following machines

·         Power hacksaw

·         Power drills

·         Lathes

·         Milling machines

·         Planers

 

Show machines to students. Let students identify the main parts of each machine and their functions.

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.

Computer-aided manufacture (CAM)

 

Fundamentals of CAM

·         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

Make a power point presentation. Discuss and explain the concept and benefit of computer –aided manufacture (CAM), types of CAM software, and types of 3D CAD software. Use videos to show the 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)

Formative assessment (Individual and group tasks)

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)

Instructional Resource Textbook, Chart, Pictures, Projectors and Computers, Audio-visuals and animations from YouTube

 

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

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

Garret, J. (1996). Design and Technology (2nd 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

 

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