Unit 27:

Learning hours:
NQF level 4:

Manufacturing Process
60
BTEC Higher National - H1

Description of unit
The aim of this unit is to provide learners with a broad and in-depth knowledge of
manufacturing processes and techniques that can be applied to a range of materials
for a variety of manufacturing applications.
Summary of learning outcomes
To achieve this unit a learner must:
1

Select suitable conventional machining processes and techniques for generating

geometrical forms for a given component specification

2 Select suitable moulding and shaping processes for a given component

specification
3 Select suitable non-conventional machining techniques for a given component
specification.

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Content
1

Conventional machining

Component manufacture: specify components for manufacture (eg criteriatolerances, types of material, machining technique, surface texture, material
removal rates, speeds and feeds, cutting times, cutter offsets, table angles)
Machining techniques: production of flat and cylindrical geometry (eg milling,
surface grinding, lapping, planing, turning, cylindrical grinding, centreless grinding,
honing, super finishing, thread milling techniques, jig boring, horizontal boring,
vertical boring, transfer machines)
Tooling requirements: multi-tooth cutting (eg milling, grinding, hobbing, drilling,
reaming, and broaching); single-point cutting (eg turning, planing and slotting);
appropriate cutting angles for given materials; types, advantages and
disadvantages of coolants and cutting fluids used for various materials and
processes (eg advantages - prolonging tool life, increased material removal rate,
improved surface finish; disadvantages - fumes and possible irritations to
operators)
Work-holding techniques: selection of appropriate work-holding devices (eg three
and four jaw chucks, vices, jigs, fixtures, clamping arrangements, vee blocks, angle
plates and magnetic chucks); health and safety issues and limitations of devices
2 Moulding and shaping

Component manufacture: specify components for moulding and shaping (eg criteria
tolerances, type of moulding/shaping technique to be used, limitations of size,
shape and production volume, properties of materials being moulded/shaped,
surface texture, cost factors, post-moulding operations required - machining,
clipping, welding, finishing, etc.)
Moulding processes: casting (eg sand, die, investment and continuous casting);
powder metallurgy; sintering
Shaping processes: extrusion (eg direct, indirect and impact); forging (eg drop,
pressure and upset); rolling; hot and cold presswork (eg forming, bending and deep
drawing); metal spinning
Ceramic materials: range applicable to component (eg metallic carbides,
nitrides and oxides)

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Material properties: changes to the molecular structure and hence the material
properties that may arise from a moulding or shaping operation (eg grain growth,
work hardening, cracking, orientation of grain flow)
Tooling requirements: appropriate tooling and equipment required to produce given
components by moulding and shaping techniques (eg re-usable moulds and nonpermanent moulds, suitable casting materials for a particular casting process);
press tools, punches, dies, press capacity and calculations in terms of tonnage
3 Non-conventional machining

Component manufacture: principle of operation of the non-conventional machining

techniques (eg electro-discharge machining (EDM), wire erosion, ultrasonic
machining, etching of electronic printed circuit boards (PCBs), laser-beam
machining, plasma jet machining); specification of components for non-conventional
machining techniques (eg criteria-tolerances, types of material, suitable
technique, surface texture, material removal rate, cost factors)
Tooling requirements: tooling and ancillary equipment needed to perform nonconventional machining techniques; work-holding techniques; health and safety
issues

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Outcomes and assessment criteria

Guidance
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Delivery
The unit may be delivered as a stand-alone package, or integrated into other appropriate
programmes. If it is delivered in an integrated way, care must be taken to provide tracking
evidence for the outcomes. Centres should also be aware that study and assessment at an
individual outcome level throughout the programme could lead to assessment overload.
Wherever possible a practical approach should be adopted. Learning and assessment can be
across units, at unit level or at individual outcome level. Effort should be made to identify
the relevance of the principles covered.

Assessment
Evidence of outcomes could be in the form of reports of practical activities. This evidence
may be generated in a learner's place of work.
Evidence for this unit is likely to be at individual outcome level to provide maximum flexibility
of delivery. However, centres may wish to consider assemblies that include components
manufactured using the four processes - machining, moulding, shaping and non-conventional
methods. This approach would provide a central theme and may lead to a more coherent use
of the outcomes and assessment criteria.
Evidence may be accumulated by learners building a portfolio record of the activities carried
out in their place of work, or by tutor-led assignments.

Links
This unit is intended to be linked with Unit 7: Materials Engineering and Unit 30: Design for
Manufacture.
Entry requirements for this unit are at the discretion of the centre. However, it is advised
that learners should have completed appropriate BTEC National units or equivalent. Learners
who have not attained this standard may require an element of bridging studies built into
their programme.

Resources
Access to suitable instructional material in the form of books or digital means, whereby the
learner can research various manufacturing processes is desirable. Access to conventional
machine tools and as wide a range of processes, as identified in the content, would also be
desirable.

Support materials
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Textbooks

Kalpakjian S - Manufacturing Engineering and Technology (Addison-Wesley,

2000) ISBN 0201361310

Kalpakjian S -Manufacturing Processes for Engineering Materials - 4th Ed

(Pearson, 2002) ISBN 0130408719

Schey J - Introduction to Manufacturing Processes - 3rd Ed (McGraw Hill,

2000) ISBN 0071169113

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