New Frontiers in Materials Processing Training and Learning II

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Authors: Soraya Plaza, N. Ortega, Ainhoa Celaya, Jose Antonio Sánchez, Luis Norberto López de Lacalle, Borja Izquierdo
Abstract: The European Higher Education Area has entailed some upheaval since it has involved deep changes in university education. Among the subjects taught in technical education such as Manufacturing Technologies, which involve strong experimental contents, the use of specific tools is helpful for better understanding of such subjects. This article highlights the need for the use of simulation tools in the field of manufacturing processes. The student may achieve optimal understanding and learning from them. They can understand, in a more visual way, complex phenomena that govern different processes and the influence of key variables. Applications related to sheet metal forming, forging and casting processes are presented. The main objective is to enable students to better understand the phenomena that govern the processes of moulding and forming, with the invaluable help of simulation software. The final aim is to ensure that the student reaches an optimum knowledge of moulding and forming processes using simulation software.
Authors: Pedro Jose Núñez López, Eustaquio García Plaza, Angel Ramon Martín, A. Egido
Abstract: To date a wide variety of computer aided tools are available for computer numerical controlled (CNC) automated machine-tools. Solid modelling software and 3D computer-aided design (CAD) are know firmly established in the early design stage whereas computer aided machining (CAM) and computer numerical control (CNC) simulator software is employed during the manufacturing stage. Training in the use of these systems is often undertaken in separate technical disciplines and training courses (e.g., graphic representation, mechanical design, computer numerical control programming, computer-aided machining, manufacturing technology, etc.), but students often lack a sound global understanding of these tools and fail to comprehend the full potential of integrating these applications. Thus, the aim is to propose a global methodology for the teaching of computer aided automated machining systems by integrating an array of computer aided tools (3D solid modelling, CAD/CAM software, CNC simulators, DNC communication, etc.) in order to enhance knowledge and develop skills of the entire manufacturing process i.e., to provide practical hands-on tasks from the early design stages to the final stages of the computer aided automated machining of a product.
Authors: Pedrofa Fernández, Braulio Álvarez, D. Blanco, E. Cuesta, Sabino Mateos
Abstract: In this work the development of a virtual machine for the simulation of the sheet metal bending process is presented. The developed software is based on SolidEdge® as commercial CAD base, and allows the student to design the whole sheet metal part in a 3D environment. The application guides the student during all process, including the selection of the press brake and the tools (dies and punches) by means of a graphical interface. Finally, the bending sequence is introduced and the application simulates the bending process. This way the student can see the problems during the manufacturing process, in particular collisions, that arise from the design of the part, from the tools selected or, in most cases, from the bending sequence. Finally, the student should fix these problems in order to manufacture the part.
Authors: Guillem Quintana, Joaquim de Ciurana, Daniel Teixidor, I. Ferrer
Abstract: In milling operations, cutting edge impacts due to the interaction between the cutter and the workpiece excite vibrations. It is possible to distinguish between free, forced and self-excited vibrations. Chatter is a self-excited vibration that can occur in machining processes, and is considered to be a common limitation of productivity and quality. Stability lobes diagrams (SLDs) show the frontier between chatter-free milling operations, i.e. stable dominated by forced vibrations, and operations with chatter, i.e. unstable. These diagrams are usually obtained from impact hammer testing. However, this method requires trained personnel with advanced knowledge and it is not easily applied in engineering studies or operator training. This paper presents an experimental method that allows engineering students and operators-in-training to observe the chatter phenomenon and to distinguish between forced and chatter vibrations and identify process stability diagrams.
Authors: Joaquin López
Abstract: The aim of this work is to emphasize the advantages of the use of free software in computer science education for accurately representing complex interface shapes such as those that arise in casting processes during the filling of a mould cavity or during the solidification of the molten metal. A new scheme, based on free software, for reconstructing complex interface shapes in three dimensions has been specifically developed in order to facilitate its implementation by the students of a PhD course in the Polytechnic University of Cartagena (UPCT). In particular, a procedure to initialize the volume fraction occupied by a fluid body in computacional cells, and another to reconstruct the interface shape based on the initialized volume-fraction distribution, are proposed. Finally, different practical applications of this new scheme are presented.
Authors: Francisco Javier Campa, Luis Norberto López de Lacalle, Aitzol Lamikiz
Abstract: Ever increasingly, universities have to face the demands of their students regarding tools and methods to complete their education in preparation for the industrial environment. On the other hand, the university has to meet a Research and Development function oriented to the improvement of the competitiveness of that environment. These are two different functions that the university must unite to offer an optimum service. Hence, the university needs tools that can meet this dual function: teaching and researching. This paper proposes the concept of a “Glass Machine” as a dual purpose approach based on the adaptation of machine tools to satisfy that dual function. This concept has been applied to a machine tool by means of two machines: a turn-milling centre and a feed-drive test bench, which have been used for practices in the subjects of 4th and 5th year of Industrial Engineering, allowing at the same time the usual research activity of the High Performance Machining Team. In short, this work is about the optimization of the available resources of the university, thus satisfying the needs of the students and the industrial environment.
Authors: Moisés Batista, Manuel Sánchez-Carrilero, Jose Antonio Sánchez, Jorge Salguero, Miguel Álvarez, Alvaro Gómez, Mariano Marcos Bárcena
Abstract: Project Based Learning techniques have given rise to other learning techniques as Research Works Based Learning (RWBL). This technique is especially interested in the teching-learning process of Materials Processing Technologies related disciplines. This work reports on the results of the application of RWBL techniques in a subject of the Cadiz University’s Master in Manufacturing Engineering: Engineering of Non-Conventional Materials Removing Processes. Proposed research works have been designed on the basis of a classic research paper structure: Introduction, State of the Art, Experimental Procedure, Results, Discussion and Conclusions. These proposed works were focused on a comparative analysis of different machining processes, mainly, electro-discharge machining, abrasive waterjet machining and high speed machining. This experience can be considered highly successful because the 100% of the students reached the learning objectives of the subject.
Authors: N. Ortega, Ainhoa Celaya, Soraya Plaza, Aitzol Lamikiz, Inigo Pombo, Jose Antonio Sánchez
Abstract: The adaptation of universities to the European Higher Education Area (EHEA) plays an essential role in society, creating new knowledge, transferring it to students by means of new and more active methodologies aimed at learning that will enable students to put everything they learn into practice. However, such methodologies are not equally applicable in all subjects. Subjects such as Manufacturing Technology, taught at different levels in both undergraduate and graduate levels, are descriptive to a great extent. This descriptive nature must be supported by new technologies if these subjects claim to be more attractive to students. In this paper some examples of successful case studies are presented. They represent the new way of understanding the teaching replacing the old concept of traditional classroom lecture by more interactive ones and, therefore, more attractive to students.
Authors: L. Sevilla, M.J. Martín, F. Martín
Abstract: The implementation of virtual practices, to complement traditional practices has turned out to be an efficient tool to solve the classical problems occurring in the teaching of technological subjects, such as the manufacture engineering field. In the current work, the integration of virtual practice sets is analysed by means of an unified platform, as an extra contribution to previous developments, generating the Manufacturing Virtual Laboratory of the Department of Manufacturing Engineering of the University of Malaga.

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