Course Info
Code IND14-102
Duration 5 Days
Format Classroom
Course Summary
There are many stages to processing materials into the desired product. Each material has its own unique properties which will greatly influence how it must be heated, handled, and shaped. Those responsible for working through this process must be highly competent with all the materials and must understand ideal handling techniques and what machines and tools would be most suitable to use to reach the desired outcome.
There must also be a great understanding of the welding process. Welding is the process of joining materials together in a secure way. Different materials can be attached to one another through this method, and those responsible must understand each stage of the process to complete it successfully.
- To understand the importance of material processing within manufacturing.
- To identify and explain the different materials used within manufacturing and why.
- To acknowledge the consequences of poor material processing.
- To assess the various processing operations of metals and plastics.
- To recognise the influence of effective product and machine process design.
- To estimate and calculate the amount of energy and power needed throughout material processing.
- To describe the aspects of stress in metal forming and how to compensate for it.
- To develop various skills, such as welding, to increase the structural strength of materials.
- Senior Engineers
- Quality Control Managers
- Plant Managers
- Procurement Officers
- Material Process and Development Engineers
- Operations Managers
To ensure the participants develop a full understanding of the taught content, they will partake in a variety of different learning methods and exercises including presentations, demonstrations, individual and group activities. This combination of activities will allow the participants full opportunities to process the knowledge and practise any relevant practical skills.
Course Content & Outline
Section 1: Fundamentals of Material Processing
- Understanding the purpose of material processing, its necessity and importance.
- Identifying what materials are typically utilised and how they must be processed.
- Exploring the characteristics of different materials and these dictate the way they must be processed.
- Assessing the technical properties of polymers and composites.
- Investigating the thermal properties of ceramics.
- Examining the mechanical properties of different metals.
Section 2: Solidification Process
- Describing what solidification processes are within manufacturing and why they are needed.
- Identifying what materials will be used for and adjusting the solidification process as necessary.
- Understanding each stage of metal casting – pattern making, molding, pouring, shakeout and heat treatment and inspection.
- Exploring traditional and new technologies that aid in rubber and ceramics processing.
Section 3: Metal Forming and Sheet Metalworking
- Analysing the different types of metal commonly used and their specific properties.
- Examining how a metal’s specific qualities influences the way it must be worked and formed.
- Assessing different metal forming processes and how they may be beneficial for different items – rolling, forging, wire drawing, extrusion, deep drawing and bending.
- Utilising dies and presses to ensure each sheet is consistent and meeting quality expectations.
Section 4: Metal Machining
- Types of machines used throughout the metalworking process and their primary functions.
- Understanding how to use each machine efficiently and safely.
- Identifying each feature of common metal working machines and describing their purpose.
- Assessing the separate tools that can be used in addition or in replacement of a larger machine.
- Recognising when it is most suitable to use each machine or tool.
Section 5: Welding Technology
- Understanding the purpose and necessity of welding.
- Identifying what materials can be welded and how the process and techniques may vary depending on material.
- How to prepare the tools and materials to be welded.
- Ideal welding techniques and how to achieve the ideal finish.
- Common welding defects and utilising techniques to avoid them.
Learn the importance of quality management for your business and explore six techniques of Total Quality Management (TQM) to enhance customer satisfaction, reduce costs, and gain a competitive edge.
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