Manufacturing Problems & Alternative Processes for Aluminium Car Bodies

Module Learning Outcomes

This Assignment assesses the following module Learning Outcomes (from Definitive Module Document):

1. Explore the principal materials and processes used in vehicle body manufacturing and other automotive applications.

2. Distinguish the properties and service requirements of automotive materials and the reasons for their selection.

3. Assess recyclability of automotive materials, taking account of economic and legislative factors.

4. Recommend and specify materials and processes for a variety of automotive applications.

5. Evaluate the external influences on the vehicle body manufacturing process.

6. Effectively plan their work and communicate the resulting information individually and/or in a group.

Assignment Brief:

Assume that you work for a car manufacturing company and that you are the Assistant Manager for all forming and pressing processes. The company has decided that their next car model which is targeted for medium-volume production will be constructed as a monocoque body structure. The car body will be constructed using aluminium alloys. This is a significant change for the company as all previous models were constructed by using mild steel for the car body. You have been asked by your manager to prepare a concise report of not more than TWO pages to (i) identify any manufacturing problems and any alternative processes that might be needed with regard to forming and pressing as a result of changing from steel to aluminium,alloys (ii) explain why such problems may arise or changes be needed and (iii) propose solutions (these may be alternative processes, parameters, etc.). You may present a list of references on an additional page.

Submission Requirements:

Marks awarded for:

- Brief introduction setting the scene and briefly providing reasons for going to an aluminium vehicle body (10%)

- identifying the potential problems when forming and pressing aluminium alloys (20%)

- giving reasons to explain why there will be problems when forming and pressing aluminium alloys (10%)

- identifying and describing alternative processes to form/press aluminium alloys, identifying any requirements that may arise and how they can be fitted into the manufacturing cycle, discussing benefits of these alternative pressing and forming processes, identifying future needs and trends, etc. (50%)

- overall presentation of the report (5%)

For undergraduate modules, a score of 40% or above represents a pass performance at honours level.

• For postgraduate modules, a score of 50% or above represents a pass mark.

• Late submission of any item of coursework for each day or part thereof (or for hard copy submission only, working day or part thereof) for up to five days after the published deadline, coursework relating to modules at Levels 0, 4, 5, 6 submitted late (including deferred coursework, but with the exception of referred coursework), will have the numeric grade reduced by 10 grade points until or unless the numeric grade reaches or is 40. Where the numeric grade awarded for the assessment is less than 40, no lateness penalty will be applied.

• Late submission of referred coursework will automatically be awarded a grade of zero (0).

• Coursework (including deferred coursework) submitted later than five days (five working days in the case of hard copy submission) after the published deadline will be awarded a grade of zero (0).