UNIVERSITY OF MAURITIUS

MODULE SPECIFICATION SHEET

1. GENERAL INFORMATION

Academic Year: 2010/2011

Semester(s): 1 & 2
Title Code Duration (hrs) No of credits
Manufacturing Processes & Metrology MECH Lectures: 60 5
3002Y Practicals: 30
Total: 90

2. PRE-REQUISITE(S)/PRE-REQUIREMENT(S)
Nil

3. AIMS
The main aims of this module are:
- To expose the students to different metal manufacturing processes.
- To provide to the students an understanding and appreciation of the science of Measurement.
- To expose the students to various mechanical measuring instruments, and understand the different degree of
accuracy obtained from different types of instruments.
- To provide a proper insight about the importance of lubrication, wear problems and surface related properties.
- To provide to the students a proper understanding of the different corrosion phenomena, and related protective
techniques.
- To introduce the students to the different NDT testing techniques in Mechanical & Manufacturing engineering.

4. OUTLINE SYLLABUS

Casting, Forming processes, Powder Metallurgy, Metrology (Standards, Dimensional Properties & Errors,
Tolerance, Fits & Gauges, Linear Measurement, Comparators & Angular Measurement, Introduction to Surface
Texture Measurement, Surface Roundness Measurement, Interferometry, Introduction to CMM), Tribology (Wear
Data & Mechanisms, Oil Analysis, Introduction to Maintenance Engineering), Corrosion, Surface Engineering
(PVD, CVD, Plasma Nitriding, Ion implantation, etc.), Testing: Destructive and Non Destructive Testing Methods.

5. LEARNING OUTCOMES

Having studied this module, the students should be able to:

- Use the different instruments available for linear, angular, roundness and roughness measurements.
- Select and use the appropriate measuring instrument according to a specific requirement (in terms of
accuracy, repeatability, etc.).
- Select an appropriate manufacturing process for a given product.
- Design the appropriate gating system for a sand casting system.
- Perform appropriate design calculation for different forming processes.
- Understand the meaning and importance of tribology, and how it affects the performance of a component
during its service life.
- Understand the different wear mechanisms, how they occur, and how to analyse & interpret wear-related
problems.
- Perform basic oil analysis, and select an appropriate lubricant based on a specific tribosystem.
- Identify if a corrosion phenomenon will take place under a specific set of conditions, and identify the type
of corrosion phenomenon which is likely to occur.
- Calculate the corrosion rate of a metal under a specific set of conditions.
- Select appropriate techniques to combat a specific type of corrosion phenomenon.
- Select an appropriate testing technique for the detection of internal defects in metals.

H. Ramasawmy/July 2010
6. COORDINATORS:

Programme Coordinator Module Coordinator

Name D. CALLYCHURN H. RAMASAWMY
Department Mechanical & Prod Engg Mechanical & Prod Engg
Building Engineering Tower Engineering Tower
Room Number 5.2 5.3
Phone No. 403 7841 403 7842
E-mail address d.callychurn@uom.ac.mu haree@uom.ac.mu
Consultation Time 12.00 hrs to 13.00 hrs

7. LECTURER

Name H. RAMASAWMY
Department Mechanical & Prod Engg
Building Engineering Tower
Room Number 5.3
Phone No. 403 7842
E-mail address haree@uom.ac.mu
Consultation Time 12.00 hrs to 13.00 hrs

8. VENUE AND HOURS/WEEK

All lectures will be held in the Engineering Tower or Phase 2 Building, FoE. Practicals will be held in the
Metrology lab, Metallurgy lab and Mechanical Workshop, Phase I building, FoE.

Hours/week: 2 hrs of lecture per week and 1 hr of practical per week.

9. MODULE MAP

Semester 1:

Wk(s) Hr(s) Lecture Title(s) L, P, S, V,

T, Test
1 2 Introduction to Metrology & Dimensional Properties L
2 2 Standards L
3 2 Errors, Accuracy, Repeatability, etc. L
4 2 Tolerance, Fits & Gauges (Calculations based on International Standards) L
5 2 Linear Measurement & Instruments (Micrometers, Verniers, Height Gauge, L
Combination Square, Engineer’s Parallel, DTI, Gauge Block, Length Bars)
6 2 Comparators (Electric & Visual Gauging Head) & Angular Measurement (Sine Bar, L
Bubble Clinometer, Autocollimator, Angle Dekkor, etc.)
7 2 Surface Texture Measurement: measurement principles & equipment L
8 2 Surface Texture Measurement: 2D parameters – Definition, Analysis & Interpretation L
9 2 Surface Roundness Measurement: Methods & Parameters L
10 2 Interferometry + Introduction to Coordinate Measurement Machine + TEST L + TEST
11 2 Sand Casting Processes Part I L
12 2 Sand Casting Processes Part II L
13 2 Sand Casting Processes Part III (Mathematical modeling) L+T
14 2 L
Casting Processes (Shell, investment, Die-casting), Defects
15 2 L
Rolling process

H. Ramasawmy/July 2010
Semester 2:

Wk(s) Hr(s) Lecture Title(s) L, P, S, V,

T, Test
16 2 Forging & Drawing processes L
17 2 Mathematical modeling of Forming processes L
18 2 Powder Metallurgy: Applications, Processes. L
19 2 Introduction to Tribology & Friction L
20 2 Wear Mechanisms: Definition, Analysis & Protective techniques L+T
21 2 Lubrication I L
22 2 Lubrication II L
23 2 Corrosion: Types & Mechanisms I L
24 2 Corrosion: Types & Mechanisms II L
25 2 Corrosion: Mathematical concepts I + TEST L+ TEST
26 2 Corrosion: Mathematical concepts II L
27 2 Corrosion: Monitoring techniques and Protection L+T
28 2 Surface Engineering techniques: Galvanizing, CVD, PVD, nitriding, etc L+T
& Case studies
29 2 Destructive testing methods & Non-destructive methods (Ultrasonic, X- L
ray, Magnetic particles, etc)
30 2 L+T
Revision

Abbreviations: L: Lectures, P: Practicals, T: Tutorials, V: Visits, S: Seminars

10. RECOMMENDED BOOKS/JOURNALS/WEBSITES

 J.F.W. Galyer, C.R.Shotbolt,

Metrology for Engineers, 5th Edition, ELBS Edition, 1993.
 I .C. Gupta,
A Textbook of Engineering Metrology, 4th Edition, Dhanpat Rai Publications, 1994.
 Amstead, B.H., P.F. Oswald and M.L. Begeman,
Manufacturing Processes, 8th Edition, John Wiley and Sons Inc., New York, 1986.
 Neibel, B.W., Alan B. Draper and R.A. Wysk,
Modern Manufacturing Process Engineering, Mc Graw-Hill Publishing Co.,
New York, 1989.
 Kalpakjian, S.,
Manufacturing Engineering and Technology,
2nd Edition, Addison-Wesley Publishing Co., New York, 1992.
 E. Paul DeGarmo, J. Temple Black, and Ronald Kohser,
Materials and Processes in Manufacturing,
7th Edition, Macmillan Publishing Co., New York, 1988.
 John A. Schey,
Introduction to Manufacturing Processes,
2nd Edition, McGraw-Hill Book Co., New York, 1987.
 A. Cameron,
The Principle of Lubrication, Longmans, 1966.
 Raymond G. Bayer,
Mechanical Wear Prediction and Prevention, Dekker Inc, 1994.

H. Ramasawmy/July 2010
 Trevor. M. Hunt,
Handbook of Wear Debris Analysis and Particle Detection in Liquids,
Elsevier Applied Science, 1993.
 Ernest Rabinnowicz,
Friction and Wear of Materials, Second Edition, Wiley-Interscience Publication, 1995.

11. ASSESSMENT

(i) Written Examination:

Paper Structure

Sections (if any): Nil No. of questions to be answered: 6

Multiple Choice Questions: Nil Compulsory Questions (if any): 6

Exams date: NA Paper Duration: 3hrs

Weighting (%): 70 Pass Marks: 40

Total Marks: 100

(ii) Continuous Assessment

Weighting (%): 30

Weighting (%)
Practical(s) 20
Assignments/MiniProjects 20
Test(s): 2 60
Total Marks: 100

H. Ramasawmy/July 2010