MODULE 1: Polymer Processing
Basic polymer science
o Polymer morphology
o Molecular structure versus properties
o Thermoplastics versus thermosets
o Macroscopic polymer properties (viscoelasticity and melt rheology)
o Property characterisation
Introduction to common processing techniques o Extrusion
* Profile extrusion
* Sheet extrusion
* Blown-film extrusion
* Filament extrusion and spinning
o Injection moulding
o Blow moulding
o Thermoforming
MODULE 2: Additive Manufacturing
Introducing physical concepts that underpin additive manufacturing techniques
• Surface energy, and liquid behaviour on surfaces
• Rheology of solutions/suspensions and phase change
• Powder flow characteristics and powder consolidation
Working principles and analysis of common additive manufacturing techniques, including:
• Material extrusion
• Vat polymerisation
• Powder bed fusion and binding
• Inkjet printing
MODULE 3: Plasticity in Metals
Introduction and background
o Fundamentals of metal forming
o Plastic behaviour of metals
MODULE 4: Bulk Metal Forming
Bulk metal forming processes and their analyses
o Extrusion and wire drawing (uniform energy method)
o Concepts of redundant work and mechanical efficiency
o Optimum die design and dead metal zone
o Forging and rolling (force equilibrium method)
o Friction hill; roll flattening and defects in rolling
MODULE 5: Sheet Metal Forming
Introduction to sheet metal forming
o Strain space and stress space; concept of forming limit diagram
o Sheet bending and spring-back