Ultra-Precision Manufacturing and Metrology

Course structure

This course is based on the highly successful short course series developed by Professors Pat McKeown, and Paul Shore at Cranfield University. With constant updating of content and with newly engaged internationally renowned instructors, this course offers a unique blend of the most current technical knowledge.

What you will learn

This course will give you the basic precision engineering principles and state-of-the-art concepts for designing higher precision and accuracy into your machines, products and processes, whether they are ultra-precision or otherwise.

As an engineer, you will find the basic principles to be simple yet powerful tools for improving machine performance; the latest concepts will put you at the forefront of precision engineering technology. The course will emphasise practical information that you will be able to apply immediately and profitably to your design and manufacturing efforts.

Throughout the course, you are encouraged to engage actively via questions, comments and participation. You are invited to come prepared with questions, issues and problems for discussion in relation to your specific design and manufacturing operations. Break times provide the opportunity for ongoing discussions with the instructors and fellow participants. In addition, the final day of the course includes scheduled time for discussion and debate.

Throughout the course, a very advanced exposure will be given to the state-of-the-art atomic simulations to shed light on the origins of plasticity in materials originating during contact or non-contact mode machining. The attendees will have a chance to go through various case studies on using these simulation tools and seeing how simulations have helped to improve our understanding on the process mechanics of precision manufacturing.

Core content

High precision machine tool metrology

Introduction to precision engineering

• Background, application sectors, industrial trends
• Underlying philosophies of precision engineering

Assessment of machine performance

• Dynamic performance
• Static performance (machine calibration)

Machine metrology and calibration

• Metrology general concepts of traceability, calibration and correction
• Calibration methods – artefact effect, global methods, parametric methods
• Geometric parameters

On-machine workpiece metrology

• Measurement strategy (in-cycle, in-process, process capability)
• Areal techniques

Geometric, texture and surface integrity measurement

• Geometrical tolerancing, standards and definitions
• CMM fundamentals, configurations operation and use
• Surface topography instruments
• Profile and areal surface texture measurement 

Optical metrology for ultra-precision components

• Optical microscopes (white light, confocal and scanning instruments)
• Wide aperture interferometry

Metrology case studies

High precision process technology

Process chain engineering for ultra-precision surface creation

• Preamble of contact mechanics
• Birth of ductile-regime machining from nanoindentation

Ultra-precision turning

• Single-point diamond machining
• Ductile-brittle transition and tool wear problem
• High-precision hard turning of ferrous components

Ultra-precision abrasive machining

• Grinding and polishing

Integrated simulations in the context of precision manufacturing

• Introduction to multiscale simulations
• Post-processing
• Working with high performance computing centres
• Hands on sessions and case studies (access to desktop preferred)

Functional surface coatings

• Deposition methods, challenges to manufacture and surface preparation
• Multilayer and nanocomposite coatings
• Analytical methods
• Optical and astronomical coatings
• Self-cleaning and self-healing coatings

Process design case studies

Who should attend

Engineers working in the machine tool, automotive, aerospace, optics and semiconductor industries and institutes. This course is highly appropriate to individuals involved in purchasing or developing high-value precision engineering facilities where accuracy capability is critical to profitability and success.

Speakers

Dr Saurav Goel
An experienced lecturer, possessing considerable expertise on multi-scale modelling and experiments on manufacturing in general but machining difficult-to-cut materials in particular SPDT and hard turning. Current research interests include deterministic manufacturing solutions for large-scale optics manufacturing.

Dr Claudiu Giusca
Claudiu Giusca’s expertise is in the metrology associated with the use of optical surface topography measuring instruments, surface texture and micro-coordinate measurements and analysis, design and build of primary instrumentation and in-line optical 2D/3D hybrid systems.

Dr Jeff Rao
Jeff Rao has extensive and diverse experience and expertise in the deposition of PVD and other functional coatings. Jeff has worked in diverse areas including automotive and aerospace. He has been the key project manager in significant programmes, which have produced IP related to the deposition of self-healing polymeric coatings designed to minimize wear and reduce friction.

Concessions

20% discount for Cranfield Alumni. 
10% discount when registering 3 or more delegates, from the same organisation at the same time.  

Accommodation fees are not included in the discount scheme. Please ask about our discount scheme at time of booking.

Accommodation options and prices

This course is non-residential. If you would like to book accommodation on campus, please contact Mitchell Hall or Cranfield Management Development Centre directly. Further information about our on campus accommodation can be found here. Alternatively you may wish to make your own arrangements at a nearby hotel. 

Location and travel

Cranfield University is situated in Bedfordshire close to the border with Buckinghamshire. The University is located almost midway between the towns of Bedford and Milton Keynes and is conveniently situated between junctions 13 and 14 of the M1.

London Luton, Stansted and Heathrow airports are 30, 90 and 90 minutes respectively by car, offering superb connections to and from just about anywhere in the world. 

For further location and travel details

Location address

Cranfield University
College Road 
Cranfield 
Bedford 
MK43 0AL