MSc (FHEQ Level 7) 2015/16Mechanical Engineering

MSc Mechanical Engineering

Coordinator: Dr AJ WilliamsCompulsory Modules

Semester 1 Modules Semester 2 ModulesEG-M103

Advanced Thermo Fluid Mechanics10 Credits

Dr D Deganello

EG-M07Optimisation and Reliability

10 CreditsProfessor DE Reeve

EG-M106Polymer Processing

10 CreditsDr A Rees

EG-M36Systems Monitoring, Control, Reliability, Survivability,

Integrity and Maintenance10 Credits

Dr K Wada

EG-M85Strategic Project Planning

10 CreditsDr K Wada

EG-M37Additive Manufacturing

10 CreditsDr NPN Lavery

EG-M97Advanced Solid Mechanics

10 CreditsDr C Wang

EG-M47Entrepreneurship for Engineers

10 CreditsDr RJ Holness

EGTM79Environmental Analysis and Legislation

10 CreditsDr GTM Bunting

EG-M73Composite Materials

10 CreditsDr JC Arnold

EG-M83Simulation Based Product Design

10 CreditsDr AJ Williams/Dr D Mcbride

EG-M93Process Metallurgy and Optimisation

10 CreditsDr RS Ransing

Research ProjectEG-D03

MSc Dissertation - Mechanical Engineering60 Credits

Dr AJ Williams

Total 180 Credits

EG-D03 MSc Dissertation - Mechanical EngineeringCredits: 60 Session: 2015/16 Semester 3 (Summer Taught)Module Aims: The module aims to develop fundamental research skills. It comprises the development of supervisedresearch work leading to a dissertation in the field of the Master's degree programme. The specific research topic willbe chosen by the student following consultation with academic staff.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Typically 1 hour per week

i.e 10-15 hrs total contact time. Each student is to be supervised in accordance with the University’sPolicy on Supervision, with a minimum of three meetings held. A careful record should be kept, agreedbetween supervisor and student, of all such formal meetings, including dates, action agreed anddeadlines set.

Lecturer(s): Dr AJ WilliamsAssessment: Other (100%)Assessment Description: The research project and dissertation forms Part Two of the Masters degree. Informationabout dissertation preparation and submission can be found at:http://www.swan.ac.uk/registry/academicguide/assessmentandprogress/dissertationpreparationsubmission/

Additionally, students should refer to:http://www.swan.ac.uk/registry/academicguide/postgraduatetaughtawardsregulations/postgraduatetaughtmastersdegrees/17submissionofdissertation/

The word limit is 20,000. This is for the main text and does not include appendices (if any), essential footnotes,introductory parts and statements or the bibliography and index.

Each student is to submit two soft bound copies and an electronic copy of the dissertation (CD with dissertation in Pdfformat) to the College Postgraduate Administration Team by the deadline of 30th September. Each copy must contain:

• a statement that it is being submitted in partial fulfilment of the requirements for the degree;• a summary of the dissertation not exceeding 300 words in length;• a statement, signed by you, showing to what extent the work submitted is the result of your own investigation.Acknowledgement of other sources shall be made by footnotes giving explicit references. A full bibliography shouldbe appended to the work;• a declaration, signed by you, to certify that the work has not already been accepted in substance for any degree, andis not being concurrently submitted in candidature for any degree; and• a signed statement regarding availability of the thesis.

The dissertation is marked by the supervisor and another member of staff and sent to an External Examiner formoderation. An Internal Exam Board is then held to confirm the mark. Finally, all marks are ratified at the UniversityPostgraduate Taught Examination Board.Moderation approach to main assessment: Universal double-blind markingFailure Redemption: Candidates who fail the dissertation are given an opportunity to resubmit the dissertation within3 months of the result of the examination if a full-time student or 6 months for part-time students. Such students willbe given one formal feedback session, including written feedback on the reasons for failure, immediately followingconfirmation of the result by the University Postgraduate Taught Examination Board. The opportunity to resubmit willonly be offered to students who submit a dissertation and are awarded a fail. Those candidates who do not submit adissertation will not be offered a resubmission opportunity.Assessment Feedback: Informal feedback will be given during regular meetings with supervisors. The supervisorwill also provide an assessment of the project drafting skills during the planning of the dissertation. Work will bereturned according to specified deadlines and accompanied by constructive comment.

A Feedback session will be given to any student who fails their dissertation and is permitted by the Award Board toresubmit their work.

Module Content: Study for the dissertation, which may be based on practical, industrial, or literature work, or anycombination of these, is primarily carried out over a period of about 12 weeks, with the dissertation being submitted atthe end of September. Preparatory work on the dissertation may take place during Part One of the programme butstudents will only be permitted to submit their dissertation following successful completion of Part One.

In conducting the research project and dissertation the student will be exposed to all aspects of modern informationretrieval processes, the organisation and resourcing of research and the organising and presentation of experimentaldata. The student must make inferences on conclusions, based on the evidence provided and supported by the researchwork. Furthermore they must assess the significance of this work in relation to the field and make suggestions abouthow further work could improve or clarify the research problem. The results of the project will be disseminated in asubstantial dissertation demonstrating the student's ability to research a subject in depth.

The student will meet regularly with the supervisor to ensure that the project is well developed and organised.Progress will be monitored.Intended Learning Outcomes: On completion of this module, students should have the ability to:• investigate a research topic in detail;• formulate research aims;• devise and plan a research strategy to fulfil the aims;• carry out research work - undertake a literature search, a laboratory based or computer based investigation or acombination of these;• gather, organize and use evidence, data and information from a variety of primary and secondary sources;• critically analyse information;• make conclusions supported by the work and identify their relevance to the broader research area;• resolve or refine a research problem, with reasoned suggestions about how to improve future research efforts in thefield; and• produce a report (dissertation), with the findings presented in a well organised and reasoned manner.Reading List:Additional Notes: The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of allcoursework and continuous assessment.

If an extension is deemed appropriate a Postgraduate Taught Masters ‘Application for Extension to the SubmissionDeadline/ Period of Candidature’ Form will need to be submitted as follows:• 31 August – deadline for Part Two students (non-resit students)• 8 November – deadline for Part Two Students (students who had resits)

EG-M07 Optimisation and ReliabilityCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: This module provides an introduction to some important techniques of optimisation and reliability thatmay be used across a broad range of engineering disciplines. The focus is on understanding the methods through handcalculation rather than the use of particular software packages. Numerical examples are employed to illustrateconcepts and potential applications.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Timetabled lectures and example classes 30 hours;

Directed private study 70 hoursLecturer(s): Professor DE ReeveAssessment: Examination 1 (100%)Assessment Description: Exam - closed book examModeration approach to main assessment: Universal second marking as check or auditFailure Redemption: A supplementary examination will form 100% of the module mark.Assessment Feedback:Examination - Standard College of Engineering exam feedback form.Module Content: Indicative syllabus content:1. Statement of the optimisation problem; objective function; types of constraint; linear programming.2. Least squares techniques3. Maximum likelihood method4. One-Dimensional Minimisation Methods. Direct and indirect methods:unrestricted search; dichotomous search;golden section method; quadratic interpolation; Newton's procedures.5. The Hessian.6. Multidimensional Minimisation Problems - direct methods such as:Taxi-cab; conjugate search procedures; Powell'smethod7. Multidimensional Minimisation Problems - indirect methods such as: Steepest descent method; Newton's method.8. Concepts in reliability theory9. First order reliability methods.Intended Learning Outcomes: The student should:• Understand and be able to set up and carry out the necessary calculations for univariate unimodal optimisationproblems• Be able to use search techniques to determine the optima of unconstrained multivariable systems• Understand and be able to set up and carry out the necessary calculations for First Order Reliability problemsReading List: Reeve, Dominic, Risk and reliability [electronic resource] : coastal and hydraulic engineering /Dominic Reeve, Taylor & Francis, 2009.ISBN: 9780203895528Advanced modern engineering mathematics / Glyn James ... [et al.], Pearson Prentice Hall, 2004.ISBN:9780130454256Edgar, Thomas F, Optimization of chemical processes / Thomas F. Edgar, David M. Himmelblau, Leon S. Lasdon,McGraw-Hill, c2001.ISBN: 0071189777Advanced modern engineering mathematics [electronic resource] / Glyn James ... [et al.], Prentice Hall, 2011.ISBN:9780273719274

Additional Notes: The course assumes good mathematical skills, covered in the pre-requisite modules EG189,EG190 and EG285.Students wishing to take this module but not having the pre-requisites will be expected to demonstrate a goodunderstanding of partial differentiation, Taylor series expansion, matrices, eigenvalues, and probability distributionand density functions in a short assessment at the beginning of the module. Feedback from the assessment willindicate whether supplementary effort to attain this knowledge is required, alongside and outside the demands of thismodule.

Failure to sit an examination or submit work by the specified date will result in a mark of 0% being recorded. TheCollege of Engineering has a ZERO TOLERANCE penalty policy for late submission of all coursework andcontinuous assessment.

Additional notes:

Office hours, lecture notes and other teaching materials will be posted on Blackboard.

EG-M103 Advanced Thermo Fluid MechanicsCredits: 10 Session: 2015/16 Semester 1 (Sep-Jan Taught)Module Aims: This module advances thermofluid flow modelling from that studied at a previous level. Students areassumed to have an understanding of the flow of air and water, but this module advances knowledge into multiphasematerials that may be non-Newtonian and have temperature dependent properties. It also includes study of heattransfer, solidification and melting processes. The aim is to equip the student with the theoretical understanding tosolve problems and to study processes that involve these materials. Examples will be drawn from oil and gasapplications and from processes such as casting of metals, moulding of polymers and melting of powders.Pre-requisite Modules: EG-362Co-requisite Modules:Incompatible Modules:Format: 20 hours lectures, 10 hours tutorial/office hoursLecturer(s): Dr D DeganelloAssessment: Examination (100%)Assessment Description: Formal Exam. 100%. 2 hours. Examination questions will be open ended questions toassess the breadth and depth of understanding of the subject. Students will be asked to show the application ofknowledge gained in the module.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: A supplementary examination will form 100% of the module markAssessment Feedback: The College of Engineering uses a standard college exam feedback form posted on an intranetsite.Module Content: This module advances thermofluid flow analysis and modelling. Students are assumed to have anunderstanding of the flow of air and water, but this module advances knowledge into multiphase materials that may benon-newtonian and have temperature dependent properties.

Melting, solidification, latent heat, phase diagramsConvection, buoyancy and other temperature driven flowsMarangoni effect, surface tension, thermo-capillary convectionMultiphase non-newtonian flows of crude oil (oil,water, gas), polymers, liquid/solid mixtures and thermal propertiesof such mixtures.Reacting flows, including vapourisation of volatile gases from e.g. polymer processes.Laser melting of powders.The use of pumps, compressors, heat exchangers and other process equipment with these fluids.

The aim is to equip the student with the theoretical understanding to solve problems and to study processes thatinvolve these materials. Examples will be drawn from oil and gas applications and from processes such as casting ofmetals, moulding of polymers, printing of inks, and melting of powders.Intended Learning Outcomes: Q2 a comprehensive understanding of techniques applicable to their own research oradvanced scholarshipQ7 continue to advance their knowledge and understanding, and to develop new skills to a high levelA1 Use a combination of general and specialist engineering knowledge and understanding to optimise the applicationof thermo fluid mechanics to existing and emerging technology. Maintain and extend a sound theoretical approach inenabling the introduction and exploitation of new and advancing technology and other relevant developments.Including an ability to: Strive to extend own technological capability; Broaden and deepen own knowledge base aboutthermofluid mechanics through research.Reading List: Munson, Bruce Roy, Fundamentals of fluid mechanics: SI units / Bruce Munson, Donald F. Young andTheodore H. Okiishi, Wiley, 2009.ISBN: 9780470398814Coulson, J. M, Coulson & Richardson's Chemical engineering: [print and electronic book] Volume 2, Particletechnology and separation processes / J.F. Richardson and J.H. Harker with J.R. Backhurst and J.H. Harker,Butterworth/Heinemann, 2002.ISBN: 9780750644457Coulson, J. M, Chemical engineering. Volume 1, Fluid flow, heat transfer and mass transfer / J. Coulson, J. F.Richardson with J.R. Backhurst and J.H. Harker, Butterworth-Heinemann, 1999.ISBN: 9780750644440Massey, B. S, Mechanics of fluids / Bernard S. Massey ; revised by John Ward-Smith, Spon Press, 2012.ISBN:9780415602600Cçengel, Yunus A, Thermodynamics : an engineering approach / Yunus A. Cçengel and Michael A. Boles ;adapted by Mehmet Kanog�lu, McGraw-Hill, 2011.ISBN: 9780071311113Massey, B. S, Mechanics of fluids [electronic book] / Bernard Massey ; revised by John Ward-Smith, Taylor &Francis, 2006.ISBN: 9780203012321

Additional Notes: Available to visiting and exchange students

EG-M106 Polymer ProcessingCredits: 10 Session: 2015/16 Semester 1 (Sep-Jan Taught)Module Aims: The module will provide a deeper understanding of the technology of plastics processing. The materialcovered will cross cut the engineering disciplines of advanced manufacturing technology and polymer science tobroaden the technical and industrial context of polymer processing. Within the content of the module simulationsoftware will be applied to industrial case study examples for critical evaluation. In addition, the application ofpolymer replication technologies within the emerging field of micro manufacturing will be presented, focusing on theadvantage and limitations of size effect and length scale integration. The module will included practical demonstrationlaboratories and also include industrial visits.Pre-requisite Modules: eg-m103Co-requisite Modules:Incompatible Modules:Format: 20 hrs lectures

10 hrs laboratory70 hrs Directed private study

Lecturer(s): Dr A ReesAssessment: Examination (50%)

Assignment 1 (50%)Assessment Description: Assignment (individual project) 1500 word reportTwo hour examination, choice of three questions out of four.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: A supplementary examination will form 100% of the module markAssessment Feedback: The student is informed of their provisional assignment mark 3 weeks after assessment,subject to ratification at the Swansea External Examination Board.

Examination feedback is given using the College of Engineering standard form on the intranet.Module Content: Injection moulding: processing cycleMicro injection mouldingMaterial selection criteria and processing considerationComputational simulationShrinkage and warpagePolymer melt rheologyMould cooling systemsIntended Learning Outcomes: After completing this module student will be able to:1) Demonstrate in an industrial context using the appropriate terminology, the principles of the injection mouldingprocess.2) Demonstrate a systematic understanding of knowledge, and a critical awareness of current problems and/or newinsights, much of which is at, or informed by, the forefront of their academic discipline, field of study or area ofprofessional practice.3) Demonstrate a comprehensive understanding of state-of-the-art developments within injection moulding at bothmacro and micro scale.4) Understand how to apply simulation software to optimise the performance of injection moulding for industrial casestudies.5) Through conceptual understanding evaluate critically current research and methodologies and if appropriatepropose new hypothesis6) Have an appreciation of the wider multidisciplinary engineering context and its underlying principles (KU2)7) Use creativity to establish innovative solutions (D4).8) Knowledge of characteristics of particular equipment, processes or products (P1)9) Understanding of the need for a high level of professional and ethical conduct in engineering (S5)Reading List: McCrum, N. G, Principles of polymer engineering / N.G. McCrum, C.P. Buckley, C.B. Bucknall,Oxford University Press, 1988.ISBN: 0198561520Osswald, Tim A, Polymer processing fundamentals / Tim A. Osswald, Hanser ;, c1998.ISBN: 3446195718Pearson, J. R. A, Mechanics of polymer processing / J.R.A. Pearson, Elsevier Applied Science, c1985.ISBN:085334308XBirley, Arthur W, Physics of plastics : processing, properties, and materials engineering / Arthur W. Birley, BarryHaworth, Jim Batchelor, Hanser Publishers, 1991.ISBN: 9780195209181

Additional Notes: Available to visiting and exchange students.The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of all coursework andcontinuous assessment. Late assignments will not be marked.

EG-M36 Systems Monitoring, Control, Reliability, Survivability, Integrityand MaintenanceCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: The module will provide overview of the system engineering aspects of monitoring, control,reliability, survivability, integrity and maintenance. Areas of interest to be studied will encompass an engineeringapplication from mechanical, marine and aerospace. The important underlying system engineering concepts on plan-do-check-act cycle, reliability in relation to quality engineering, design considerations on system survivability,integrity and maintenance will be highlighted and demonstrated with relevant examples. Of particular example will belooked at include but not limited to plant operation (on-condition monitoring, majority voting system and highintegrity protective system), marine and aerospace applications such as commercial satellite assembly-integration-testphases (combination of series and parallel systems). Failure Modes and Effects Analysis and Load (stress)-Strengthanalysis will be introduced and the important links between type of failure, failure rate and safety margin will bequantified.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: 16 hours lectures;

3 hours workshop;1 hour case study;2 hours revision session;78 hours private study (reading, exam preparation)

Lecturer(s): Dr K WadaAssessment: Coursework 1 (20%)

Examination 1 (80%)Assessment Description: Coursework 1 is a group workshop allocated during the lecture series. Examination 1 is astandard College of Engineering examination.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: A supplementary examination will form 100% of the module markAssessment Feedback: The College of Engineering uses a standard college exam feedback form posted on an intranetsite.Module Content: System EngineeringQuality and Reliability EngineeringFMEA, FMECA, QFD, HAZOPS, Programme risk assessmentCondition Monitoring and Protective SystemsMaintenance Management and EngineeringDesign, Durability and Integrity of Engineering Structures and SystemsDesign Considerations on SurvivabilityIntended Learning Outcomes: After completing this module students should be able to:1) Demonstrate wide knowledge and comprehensive understanding of system engineering principles in the areas ofSystems Monitoring, Control, Reliability, Survivability, Integrity and Maintenance.2) Critically evaluate the design problem and understand how to apply design for reliability techniques.3) Solve complex engineering problems by an integrated or system engineering approach.4) Demonstrate knowledge and understanding of risk issues, including hazard, environmental and commercial risk,risk assessment and risk management techniques, and an ability to evaluate programme risk.5) Demonstrate awareness of relevant international regulations and standards pertaining to quality and reliability.6) Understand how to monitor faults in the continuously operating system (in the context of maintenance).Reading List: Mishra, R. C, Reliability and quality management [electronic resource] / R.C. Mishra, Ankit Sandilya,New Age International (P) Ltd., Publishers, c2009.Whole system design : an integrated approach to sustainable engineering / Peter Stasinopoulos ... [et al.], Earthscan,2009.ISBN: 9781844076437Morris, Alan S, Measurement and instrumentation [electronic resource] : theory and application / Alan S. Morris,Reza Langari, Academic Press, c2012.ISBN: 9780123819628Nise, Norman S, Control systems engineering / Norman S. Nise, John Wiley & Sons, Inc, 2011.ISBN:9780470646120Handbook of condition monitoring / edited by B.K.N. Rao, Elsevier Advanced Technology, c1996.ISBN: 1856172341

Additional Notes: Available to visiting and exchange students wishing to learn quality and reliability engineering.The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of all coursework andcontinuous assessment.

Office hours, lectures notes and other teaching materials will be provided on Blackboard.

EG-M37 Additive ManufacturingCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: 1.1 Introduction to Additive Manufacturing1.2 Mechanics of the Powder Bed System1.3 Material feedstock and characterisation1.4 Process Control and AM Defects1.5 Design of Experiments applied to AM1.6 Measurement and analysis of AM properties1.7 Computer Aided Engineering of Additive Manufacturing1.8 Design for AM and part preparation1.9 Socio-Environmental benefits of AMPre-requisite Modules:Co-requisite Modules: EG-M103Incompatible Modules:Format: 10x2hr lectures

10x1hr practical demonstrations8x1hr office hours / example classes

Lecturer(s): Dr NPN LaveryAssessment: Examination 1 (80%)

Coursework 1 (20%)Assessment Description: 2 hr examination where students attempt 3 out of 4 questions.

A practical done in a group worth 20% of the module, but which is graded individually per student.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: Supplementary examination will form 100% of the module mark.Assessment Feedback: A practical done in a group worth 20% of the module, but which is graded individually perstudent. Projects will be assigned and require a written report at the end of term. A number of different projects will beset prior to the start of term for which there will be a level of choice, and may consist on design for AM manufacture,measurement/assessment of properties from actual builds and optimisation of AM manufacturing machine parameters.

During lectures the students will go through example questions. Standard examination feedback form is available forstudents after the exam.

Module Content: 1.1 Introduction to Additive Manufacturing1.1.1 Evolution of technologies from rapid prototyping1.1.2 Patents1.1.3 Main players1.1.4 Types of systems1.1.5 Applications overview1.1.6 Volumes of production1.1.7 Technology Readiness Levels (TRL) compared to casting, powder compaction, NSHIP, forming1.1.8 Applications based on materials1.1.9 Applications based on build rates1.1.10 Applications based on length scales

1.2 Mechanics of the Powder Bed System1.2.1 Powder Delivery System1.2.2 Laser Control1.2.3 Vacuum and argon flow control1.2.4 Oxygen levels1.2.5 Powder-bed1.2.6 Wiper control1.2.7 Sieving & re-using powder1.2.8 Powder handling1.2.9 Power consumption

1.3 Material feedstock and characterisation1.3.1 AM Metal Powders1.3.2 Gas atomisation routes1.3.3 Powder composition1.3.4 Powder morphology1.3.5 Powder rheology and tap density1.3.6 Powder Size Distributions1.3.7 Powder storage & shelf life

1.4 Process Control and AM Defects1.4.1 Main AM defects (porosity, residual stress, geometrical shrinkage, …)1.4.2 Listing the process parameters (Laser power, hatch pattern, exposure time, point distance, hatch distance,support structure, bed thickness, powder size, …)1.4.3 Ishikawa diagram1.4.4 Heating the plate1.4.5 Laser power control1.4.6 Choosing the hatch pattern1.4.7 The materials data file1.4.8 Build rates1.4.9 Design of experiments for parameter exploration1.4.10 Novel developments of in-situ process control

1.5 Design of Experiments applied to AM (John Cherry Invited Lecture)1.5.1 Introduction to DOE1.5.1.1 Traditional experimentation1.5.1.2 OFAT Experimentation & drawbacks1.5.1.3 Interactions & DoE1.5.1.4 Benefits of DoE1.5.2 Designing an experiment1.5.2.1 Full Factorial Designs1.5.2.2 Designing an experiment1.5.2.3 Centre Points1.5.2.4 Replicates1.5.2.5 Blocking1.5.2.6 Factors1.5.3 Analysis, Optimisation and refinement of an AM experiment

1.6 Measurement and analysis of AM properties1.6.1 Surface roughness (Measurement)1.6.2 Density (Microscopy & tensionometer)1.6.3 Hardness (Hardness tester)1.6.4 Elasticity (Ultrasound, Tensile testing)1.6.5 Plastic properties (Tensile testing)1.6.6 Fatigue properties (Fatigue testing)1.6.7 Metallurgy and post-mortem analysis

1.7 Computer Aided Engineering of Additive Manufacturing1.7.1 Micro-models versus macro-models1.7.2 Melt pool modelling1.7.3 Residual Stress Modelling1.7.4 Discrete Element Modelling1.7.5 Shape and topological optimisation1.7.6 Incorporating manufacturing constraints

1.8 Design for AM and part preparation1.8.1 CAD (solidworks)1.8.2 Export to STL1.8.3 3D scanning of points1.8.4 STL checking & correction1.8.5 Importing to AUTOFAB1.8.6 Placing the support structures1.8.7 Slicing the STL1.8.8 Using lattices1.8.9 The machine file (MTT file)1.8.10 Freedom of design – compared to CNC/casting1.8.11 Freedom of design – the limitations

1.9 Socio-Environmental benefits of AM1.9.1 Examples of small benefits1.9.2 Brief introduction to life cycle analysis1.9.3 Environmental impact factors1.9.4 The baseline case (CNC machining)1.9.5 Aerospace component1.9.6 Automotive component1.9.7 Tooling component1.9.8 Manufacturing cost breakdown & comparison1.9.9 Examples of big benefits1.9.10 Knowledge driven digital economy1.9.11 Circular manufacturingIntended Learning Outcomes: • The students will learn the basic principles of various AM technologies - includingcapabilities and limitations.• Evaluate and select appropriate AM technologies for specific design-manufacturing applications.• They will have an in-depth understanding of metal-based Powder-bed systems.• They will learn about design constraints, and the practicalities of setting-up builds and running AM machines.• They will understand the causes of errors and failures in AM parts, how to identify and avoid them across a range ofthermophysical properties.• They will learn how scientific methodologies such as Design of Experiments can be used to optimise machineparameters for different materials• They will learn some of the important research challenges in AM, including advanced computer aided engineeringmelt pool/residual stress modelling, which will be reinforced with practical demonstrations using relatively simplemodelling tools.• They will also learn about sustainability aspects which are associated with AM from both and environmental as wellas a societal perspective, and be able to balance the arguments objectively

Reading List: Hausman, Kirk Kalani, 3d printing for dummies / by Kalani Kirk Hausman and Richard Horne, JohnWiley & Sons, Incorporation, 2014.ISBN: 9781118660751Lipson, Hod, Fabricated [electronic resource] : the new world of 3D printing / Hod Lipson, Melba Kurman, JohnWiley and Sons, 2013.ISBN: 9781118350638Selected papers from the 14th Annual Solid Freeform Fabrication Symposium, University of Texas, Austin, Texas, 4-6 August 2003 [electronic resource] / guest editors, David Bourell and R. Ian Campbell, Emerald Group Pub,c2004.ISBN: 0861769171Powder metallurgy research trends [electronic resource] / Lotte J. Smit and Julia H. Van Dijk, editors, Nova SciencePublishers, c2009.ISBN: 1604568526Rapid tooling [electronic resource] : technologies and industrial applications / edited by Peter D. Hilton, Paul F.Jacobs, Marcel Dekker, c2000.ISBN: 0824787889Lombard, Matt, SolidWorks 2013 bible [electronic resource] / Matt Lombard, Wiley, 2013.ISBN: 9781118508404Additional Notes: Available to visiting and exchange students.

EG-M47 Entrepreneurship for EngineersCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: To show the concepts/characteristic behind Enterprise and Entrepreneurs and to demonstrate the skillsallowing an individual or group to operate succesfully in an Entrepreneurial manner in a personal start-up or corporatebusiness environment.

Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Lectures/Workshops - 22 hours

Open door tutorials/workshops - 8 hoursDirected private study 70 hours

Lecturer(s): Dr RJ HolnessAssessment: Group Work - Coursework (80%)

Coursework 1 (20%)coursework reassessment instrument (0%)

Assessment Description: The group assignment will require application of the concepts of entrepreneurship. Theassignment will require the delivery of a presentation and the submission of a lean canvas business plan andsupporting documents.

The individual assignment will consist of a 800 word essay.Moderation approach to main assessment: Partial second markingFailure Redemption:Exam resits according to university regulations.100% coursework.Assessment Feedback: Continous group feedback on "out-comes" of workshops, after submission of course work 1,after completion of presentation and at request during open-tutorials.Module Content: What is an entrepreneur and why enterprise matters; the six dimensions of entrepreneurship,structure and presentation of opportunities, sources and structure of finance, people and teams.

How enterprise is managed internationally, managing early and long-term growth, harvesting and buy-out, sustainingthe flow of ideas within a company, case-studies.Intended Learning Outcomes: Define Enterprise and EntrepreneurshipUnderstand that Entrepreneuship is equally valid in a Corporate environment as in a "start-up" businessBe able to demonstrate how opportunities/ideas can be identified/generatedAnalyse the role of people and what makes a winning teamBe able to contruct a lean canvas business plan and suitable supporting docsUnderstand the myriad sources of finance that can be employed in BusinessDiscuss a case history that lead to successUnderstand that failure can and probably will occur and how to deal with it

Reading List: Mastering enterprise : your single-source guide to becoming an entrepreneur / edited by Sue Birley,Daniel F. Muzyka, FT/Pitman, 1997.ISBN: 0273630318Bridge, Simon, Understanding enterprise : entrepreneurship and small business / Simon Bridge, Ken O'Neill & FrankMartin, Palgrave Macmillan, 2009.ISBN: 9780230552708Additional Notes: The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of allcoursework and continuous assessment

Related assignments are used to assess this module.

EG-M73 Composite MaterialsCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: A detailed coverage of current polymer, metal and ceramic matrix composite systems for applicationsin gas turbines focusing on their performance envelope, advantages and limitations.

The units will cover the following: The components and their attributes - an overview (reinforcements, matrices andinterfaces), Properties of the matrix materials (Thermosets/thermoplastics, metals, ceramics, structure and mechanicalbehaviour), Properties of fibres and particles (Glass fibres, organic fibres, carbon fibres, ceramic particles and fibres;processing, structure, mechanical response), Composite manufacture (Piles, weaves, performs, moulding pultrusion,filament winding, powder metallurgy, casting spraying), Mechanics of reinforcement (Rule of mixtures, anisotropy,laminate structures, stress- strain response), Basic stress analysis and failure mechanisms (Stress transfer andpartitioning, multiple failure events, progression of fracture, toughness), Fatigue design considerations (Damageprogression, reinforcement effects); Calculations.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules: EGA301Format: 20 hrs Lectures

10 hrs Example classes/Tutorials70 hrs Directed private study

Lecturer(s): Dr JC ArnoldAssessment: Examination (75%)

Assignment 1 (25%)Assessment Description: Assessment is via a 2-hour examination , worth 75% and assignment 1 which is a 1500word essay. The quality of English does not form part of the assessment.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: Resit examinationAssessment Feedback: Standard examination feedback form available for all students after the examination.Students will receive individual feedback comments for the assignment via the Blackboard site.Module Content: A detailed coverage of current polymer, metal and ceramic matrix composite systems, focusing ontheir performance envelope, advantages and limitations.The units will cover the following:- The components and their attributes - an overview (reinforcements, matrices and interfaces), (3 hrs)- Properties of the matrix materials (Thermosets/thermoplastics, metals, ceramics, structure and mechanicalbehaviour), (2 hrs)- Properties of fibres and particles (Glass fibres, organic fibres, carbon fibres, ceramic particles and fibres; processing,structure, mechanical response), (3 hrs)- Composite manufacture (Plies, weaves, preforms, moulding, pultrusion, filament winding, powder metallurgy,casting spraying), (3 hrs)- Mechanics of reinforcement (Rule of mixtures, anisotropy, laminate structures, stress- strain response), (2 hrs)- Basic stress analysis and failure mechanisms (Stress transfer and partitioning, multiple failure events, progression offracture, toughness), (5 hrs)- Fatigue design considerations (Damage progression, reinforcement effects); (4 hrs)Intended Learning Outcomes: A detailed understanding and wide-ranging knowledge of the engineering usage ofcomposite materials.Appreciation of the important inter-relationship between structure, processing and properties for advanced materials.The ability to undertake structural design calculations for composite materials.Reading List: Matthews, F.L, Composite materials [print and electronic book] : engineering and science / F.L.Matthews and R.D. Rawlings, Woodhead Pub, 1999.ISBN: 9781855734739Composite materials for aircraft structures [print and electronic] / [edited by] Alan Baker, Stuart Dutton, DonaldKelly, American Institute of Aeronautics and Astronautics, c2004.ISBN: 1563475405Additional Notes: Available to visiting and exchange students.

EG-M83 Simulation Based Product DesignCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: This module provides an overview of the role that simulation can play in the design process of aproduct. A series of lectures introduce computational modelling and the computational tools and techniques employedin the design process. The application of simulation in the design of a number of industry based research projects ispresented. Computer workshops lead students in using simulation tools and applying the tools in the optimisation ofthe design of a product.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Lectures 10, Computer Lab 20, Reading/Private Study 20, Preparation for Assessment 50Lecturer(s): Dr AJ Williams, Dr D McbrideAssessment: Assignment 1 (20%)

Assignment 2 (80%)Assessment Description: Assignment 1: Mesh Sensitivity Study.This is an individual piece of coursework.Thiscoursework will involve the investigation of the influence of mesh dependence, convergence criteria and physicalphenomena on a simulation solution. The results of the investigation will be presented in a written report (maximumof 20 pages).Assignment 2: Design Optimisation.This is an individual piece of coursework.This coursework will require thestudent to use simulation tools to optimise the design of a component subject to given criteria.The student will also berequired to show their understanding of the role that simulation plays in the design process using examples presentedwithin the module.This coursework will be presented in a written report (maximum of 25 pages).Assignment 3: Supplementary Coursework.This is an individual piece of coursework.This coursework will require thestudent to use simulation tools to investigate and optimise the design of a given device.This coursework will bepresented in a written report(maximum of 25 pages).Moderation approach to main assessment: Universal non-blind double markingFailure Redemption: A supplementary piece of coursework (Assignment 3) will be set which will form 100% of themark. This assessment will cover the learning outcomes of both coursework 1 & 2.Assessment Feedback: Individual written feedback will be given using Blackboard. An overall assessment of thecohort's performance for the coursework will also be published on Blackboard.Module Content: • Introduction to computational modelling and the use of simulation in the design process:Examples, advantages, disadvantages.• Information about commercial packages for each stage of the design process.• Overview of steps involved in the modelling process; Identification of the physics involved, The effect of problem simplifications and assumptions on the solution, Determining an appropriate analysis type, The importance of validation.• Introduction to steps involved in computational modelling CAD and meshing: Examples of common problems associated with these stages of the design process and techniquesto avoid them; importance of solution mesh independence, Solution procedures, simulation solver software, Post-processing, Interpretation of results, visualisation and optimisation,• Introduction to software tools used in this module, CAD, meshing, analysis and visualisation packages• Analysis techniques: Overview of finite difference, finite volume and finite element methods, their advantages anddisadvantages, and common applications for each method type.• Case studies: application of the knowledge gained during the lectures to a) investigate the importance of solutionmesh independence and b) optimise the design of a product using simulation.Intended Learning Outcomes: On completion of this module the student will:-a) Have the ability to apply simulation software and recognise the influence of convergence and mesh dependency onthe solution (EAB-E3m, assessed using coursework 1)b) Be able to design and apply a testing methodology to optimise design parameters. (EAB-D4m, assessed usingcoursework 2)c) Demonstrate an understanding of the modelling process and the role of simulation in design (EAB-US2m, assessedusing coursework 2)d) Present the analysis and information clearly in a written report. (EAB-Q5, assessed using coursework 1 & 2)Reading List:

Additional Notes: Available for visiting students. The College of Engineering has a ZERO TOLERANCE penaltypolicy for late submission of all coursework and continuous assessment.

EG-M85 Strategic Project PlanningCredits: 10 Session: 2015/16 Semester 1 (Sep-Jan Taught)Module Aims: At the end of this course students will be able to recognise and define the key characteristics andcomponents of a project, understand the advantages/disadvantages associated with the management of both small andlarge projects, and have an appreciation of the strategic tools and techniques available to enable "Effective ProjectManagement" leading to high performance team. These skills will be reinforced by the completion of a group projectto produce an initial feasibility report (e.g. project plan document) for a major new project.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Lectures and case studies 12 hours

Project Monitoring 8 hours (project briefing, project update and presentations)Private Study 80 hours (completion of project work, exam preparation)

Lecturer(s): Dr K WadaAssessment: Examination 1 (50%)

Coursework 1 (50%)Assessment Description: Coursework 1 is a group project allocated during the lecture series. Examination 1 is astandard College of Engineering examination.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: Examination retake [100%] in the August supplementary period.Assessment Feedback: Informal feedback is given during lectures, examples classes, group presentations, and atgroup work meetings. Formal feedback is given via standard College of Engineering feedback protocols.Module Content: 1) Lectures: series of lectures will be conducted to cover fundamentals of strategy and projectmanagement. Various tools and techniques used by project managers at large in the industry will be demonstratedwith figures/diagrams/tables and further elaborated through relevant examples.[Lecture 1] An introduction to Strategic Project Planning. Why do we need Project Management?[Lecture 2] The Project Manager, Team and Organisation[Lecture 3] Planning the Project[Lecture 4] Budgeting & Risk Management[Lecture 5] Planning, Monitoring & Control[Lecture 6] Project Evaluation & Termination[Lecture 7] Time management & Jung's Theory[Lecture 8] Revision

2) Case study: internal/external guest speaker(s) will be invited to give talks on some of the topics on projectmanagement, an hour session each.

3) Project briefing and update: information on CA (including but not limited to project titles, group allocation, projectmanager/assistant manager nominations, marking scheme, report format, and presentation arrangement) will beannounced during these sessions. Frequently asked questions (FAQs) will be answered in the meantime.

4) Group work and Presentation: dedicated hours will be provided for the group work (i.e. dealing with CA task). Nolectures during these sessions. With regard to CA, dedicated time slots will be arranged for final presentation.Intended Learning Outcomes: After completing this module students should be able to:1. Recognise and define a project.2. Figure out an optimum balance among the three-fold spectrum of Scope (quality), Cost (budget) and Time(schedule). This is a fundamental of project management.3. Comprehensively understand the nature of both small and large projects, the issues related to both scales and thetools available to manage the project. Critically evaluate and apply the tools effectively in projects.4. Plan a project by understanding the key work elements required and assembling them in to a project road map.5. Demonstrate an understanding of the role of a project manager: i) understand the team members' characteristic andtheir needs; ii) delegate project activities and find a way to build high performance team; and iii) understand andevaluate business, customer and user needs.6. Produce a comprehensive project plan containing the project aims, expected timelines, estimated costs, key risks tosuccess.

Reading List: Meredith, Jack R, Project management in practice / Jack R. Meredith [and three others], Wiley,[2014].ISBN: 9781118674666Project management in practice / Samuel J. Mantel... [et al.], Wiley, 2001.ISBN: 0471371629Watson, Mike, Managing smaller projects : a practical guide / Mike Watson, Multi-Media Publications, 2006.ISBN:9781895186857Lock, Dennis, The essentials of project management / Dennis Lock, Gower, 2007.ISBN: 9780566088056Additional Notes: Penalty for late submission of work: ZERO TOLERANCE.Available to visiting and exchange students wishing to enhance project management skills.

Office hours, lecture notes and other teaching materials will be posted on Blackboard.

EG-M93 Process Metallurgy and OptimisationCredits: 10 Session: 2015/16 Semester 2 (Jan - Jun Taught)Module Aims: The module will be presented with real life in-process quality improvement case studies for castingprocesses and cover the necessary metallurgical knowledge required to review the state-of-the-art in the field. It isexpected that the critical literature review will be an exemplar document for foundry process engineers andmetallurgists. It should enable them to evaluate risks and opportunities in their in-process quality improvementprojects as required by the Clause 6.1 of ISO9001:2015 quality standard.

Pre-requisite Modules:Co-requisite Modules: EG-M103Incompatible Modules:Format: Lectures 3 hours per weekLecturer(s): Dr RS RansingAssessment: Class Test 1 - Coursework (40%)

Report (60%)Assessment Description: Guidelines for preparing the reports are available on Blackboard and are discussed in theclass. A compulsory viva is held after submission of the report.

Moderation approach to main assessment: Second marking as sampling or moderationFailure Redemption: Resubmission of the individual elements of the project report.Assessment Feedback: Overall feedback will be given during the oral examination.Module Content: Casting Metallurgy:Introduction to casting metallurgy (ferrous and non-ferrous) including bi-films and 10 rules of casting as proposed byProfessor John Campbell.Nucleation and microstructure evolutionIntroduction to phase diagramsGrain growth and segregation (Micro, macro, gravity and dendritic segregation)Examples on ferrous and non-ferrous alloysSpecific discussion on advanced metallurgy for a nickel based alloy

Process Optimisation:Risk based thinking, organisational knowledge management and management review requirements of ISO9001:2015Introduction to Six Sigma and 7Epsilon approaches

Group project:In-process quality improvement case study with particular focus on using both the internal and external knowledgesources as mentioned in the ISO9001:2015 quality standard in order to satisfy the requirements of its clause 6.1.

Students will use the knowledge gained in the module and undertake an extensive literature review to study theinfluence of metallurgy and microstructure, design and processing conditions on mechanical properties and defects fora given casting alloy and provide qualitative recommendations for process engineers for their in-process qualityimprovement projects.

Intended Learning Outcomes: 1. Develop understanding of process and metallurgical knowledge related to castingprocesses for ferrous/non-ferrous metals and learn how to review and reuse knowledge spread in various externalsources.

2. Understand the risk based thinking and organisational knowledge management requirements of the ISO9001:2015standard.

3. Develop understanding of guidelines for manufacturing defect free castings.

Reading List: Campbell, John, Complete casting handbook [electronic resource] : metal casting processes,metallurgy, techniques and design / John Campbell, Elsevier, 2011.ISBN: 9780080964232Additional Notes: Available to visiting and exchange students.The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of all coursework andcontinuous assessment. Late assignments will not be marked.

EG-M97 Advanced Solid MechanicsCredits: 10 Session: 2015/16 Semester 1 (Sep-Jan Taught)Module Aims: This module covers material that is important to Engineers when working in an advanced designenvironment where non-linear effects such as large displacement, plasticity and creep are to be considered.Pre-requisite Modules: EG-262Co-requisite Modules:Incompatible Modules:Format: 20 hours lectures/practical FEA, 10 hours tutorial/office hoursLecturer(s): Dr C WangAssessment: Examination (80%)

Assignment 1 (20%)Assessment Description: Written Exam 80%Group assignment based on a study of non-linear FEA 20%.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: A supplementary examination will form 100% of the module markAssessment Feedback: Written feedback on the group report.The College of Engineering uses a standard College exam feedback form posted on an intranet site.Module Content: Plasticity - post-yield stress-strain constitutive relations, development of the plastic zone, plasticbending and torsion, plastic buckling and collapse, residual stresses, spring back, low cycle fatigue

Creep - stress-strain constitutive relations, Norton-Bailey and other creep laws, analysis of creep problems, stressredistribution, plasticity-creep interaction

Large displacement analysis - curved beams, gross deformation

Analysis of bolted and welded joints - bolt pre-tension, load distributions, strength and analysis of welded joints

Codes of Practice - pressure vessels, corrosion and thermal effects, linearisation of point load stresses

Non-linear finite element analysis - material behaviour models, incremental analysis, examplesIntended Learning Outcomes: A knowledge and understanding of advanced theories associated with non-linearmaterial and component behaviour; plasticity, creep and large displacements and how such behaviours are numericallymodelled within a finite element code.

An ability to apply these advanced theories to practical problems such as plastic bending and torsion, residual stressesand spring back, plastic buckling and low cycle fatigue.

An ability to use finite element analysis for predicting the non-linear behaviour of components and structures and tointerpret the predictions in a meaningful way.

A knowledge and understanding of design codes of practice applied to such components as pressure vessels andpiping structures.

Reading List: Ross, C. T. F, Strength of materials and structures: [print and electronic book] / John Case, LordChilver and Carl T. F. Ross, Arnold, 1999.ISBN: 9780340719206Shames, Irving Herman, Elastic and inelastic stress analysis / Irving H. Shames and Francis A. Cozzarelli, PrenticeHall, 1992.Additional Notes: The College of Engineering has a ZERO TOLERANCE penalty policy for late submission of allcoursework and continuous assessment.Notes, worked examples and past papers for this module can be found on Blackboard.Not available to visiting and exchange students.Office hours, prior to examinations, will be posted up on the notice board outside the lecturer's office.

EGTM79 Environmental Analysis and LegislationCredits: 10 Session: 2015/16 Semester 1 (Sep-Jan Taught)Module Aims: This module presents the principles of life cycle analysis and Circular Economy. It covers theassessment of resource conservation by optimal use of resources, including consideration of primary extractionprocesses, design/manufacturing/fabrication, improving product life and end of life usage. It also reviews the currentand planned European legislation that is of relevance to materials and energy and considers its implementation in theUK.Pre-requisite Modules:Co-requisite Modules:Incompatible Modules:Format: Lectures 25

Directed private study 35Preparation of assignments 40

Lecturer(s): Dr GTM BuntingAssessment: Assignment 1 (50%)

Assignment 2 (50%)Assessment Description: Assignment 1 - a 2500 word report based around information gathering, review andcollation.Assignment 2 - a numerical analysis of an LCA Case Study, coupled with a written report on interpretation of thefindings.The quality of the written English is not assessed in either assignment.Moderation approach to main assessment: Universal second marking as check or auditFailure Redemption: Submission of additional assignment.Assessment Feedback: Each student will receive the mark and individual feedback comments on each piece ofsubmitted coursework, via the Blackboard site.Module Content: • The concepts of lifecycle analysis and Circular Economy.• Principle of energy and resource conservation from 'cradle to grave' and ‘cradle to cradle’..• A review of the methodology of LCA, including inventory analysis, data sources and environmental impactassessment.• Case studies from various sectors of engineering and waste management will be covered.• The current environmental legislative framework, especially as it relates to energy and waste, including UN, EU andUK legislation.• The effects of economic, social and political pressures on sustainable business activities.Intended Learning Outcomes: • An understanding of the principles of life cycle analysis and the differentapproaches that have been used.• An appreciation of the application of LCA to industry.• Familiarity of the significant legislation relevant to energy and waste and an understanding of legislation as a keydriver for sustainable business activities.• An understanding of the circular economy and how it relates to new opportunities for industry.• Recognition of the need to evaluate 'cradle to grave' impact of products in terms of resource and energy conservationand environmental impact.• An appreciation of the complexity of legislative, social and political pressures on technological development.Reading List: Braungart, Michael, McDonough, William, Cradle to cradle : remaking the way we make things,Vintage, 2009.ISBN: 0099535475Henrikke Baumann & Anne-Marie Tillman, The hitch hiker's guide to LCA : an orientation in life cycle assessmentmethodology and application, 2004.ISBN: 9789144023649 9144023642Ciambrone, David F, Environmental life cycle analysis / David F. Ciambrone, Lewis Publishers, 1997.ISBN:9781566702140Frankl, Paolo, Life cycle assessment in industry and business : adoption patterns, applications and implications / PaoloFrankl, Frieder Rubik ; with contributions by Matteo Bartolomeo ... [et al.], Springer, c2000.ISBN: 3540664696Additional Notes: Available to visiting and exchange students.