|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.
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
|Teaching and learning activities to achieve learning outcomes|
|Technologies for making artefacts
· Natural and Artificial
· Types of forces: tension, compression, bending, torsion, shear, distortion, etc.
· Types of mechanisms: levers, pulleys, chain and sprockets, gear, cams, couplings etc
· Types of motion: linear, rotary, oscillating, reciprocating
· 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
· Casting, rolling, forging, drawing, bending, shearing
· Machining processes, surface finishing processes, joining processes sawing, shaping, drilling, grinding, planing, slotting,
· 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.
|Operations and precautions in using the following processes;
· Thread cutting,
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
· Milling machines
|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%
Summative assessment: End of semester examination
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