7. EGR 367 Manufacturing Processes Syllabus


Academic Unit: Padnos School of Engineering


Semester: Fall 1999


Class Times: 10-11 am - Mon, Wed, Fri


Lab Times: Sec. 1, Wed., 2-5pm


Description: The objective for this course is to expose the student to as many aspects of

manufacturing as possible in the time available. This will include

properties of materials as well as the processes that convert these materials

into specific products. Particular attention will be given to machining

processes first so that the student may have a perspective for

understanding. This will then be followed with examination of other

manufacturing areas.

Throughout the course frequent assignments and/or quizzes will be used

for each section of material. In addition each student will be expected to

participate in laboratory experiments, plant tours, a minor research project,

and a large final project.


Prerequisites: EGR 250 or equivalent


Instructor: Dr. Hugh Jack

office: EC 716

office hours: 11-12am - Mon, Wed, Fri

phone: (616) 771-6755

email: jackh@gvsu.edu

web: http://claymore.engineer.gvsu.edu


Textbooks: Todd, Manufacturing Processes Reference Book, Industrial Press, 1994

Jack, H. EGR 367 Course Notes, Grand Valley State University


Software: MathCAD

Netscape Communicator



Objective: When done the student should be able to select manufacturing processes and

parameters. Students should also be able to build simple parts.


Instruction Methods: Lectures, labs, projects and discussions.


Tentative Schedule:


Lectures Topic


1 General Introduction

2-10 Cutting Theory and Machine Tools

11 Metal Properties and Heat Treating Review

12-14 Casting Metals

15-18 Molding Plastics

19 Powdered Metal

20-24 Sheet Metal

25-28 Welding, Torch Cutting, Forming

29-30 Painting, Finishing

31-32 Electrical, Chemical Machining

33-34 Composites

35 Rapid Prototyping

36-37 Abrasives

38-39 Quality and Measurement

40 Environmental Issues

FINAL PRESENTATION - 4-6pm wednesday


Experiments: A variety of laboratory experiments will be conducted throughout the term.

The intent of these labs is to introduce you to the concept of each

manufacturing process and to provide you with a hands-on experience in

which you measure process variables and make technical inferences about

them. Each laboratory will be written up in standard laboratory format

including; purpose, apparatus, theory/prelab, procedure/results, discussion,

conclusions. This format will be described further by the instructor. Every

report must be clear, concise, justified and accurate. Several experiments will

require the use of DOE for planning and analysis, as detailed in the laboratory

guide. These experiments include,

1. Metrology and DOE

2. Design for Disassembly (DFD)

3. Heat Treating and Hardness Testing

4. Submit proposals for machining project, and start work

5. Cutting forces and surface roughness

6. Lost foam casting

7. Thermoset plastic casting, composite construction, and

injection/vacuum molding


Plant Tours: During the term we will visit a number of factories. During these visits we

will see a number of manufacturing processes and techniques. To help

recall details at a later date, each student will a resource sheet outlining

interesting details, and drawing useful conclusions. The memos are not to

exceed one page in length, and are to be clear and concise.

1. Scrap Processing Facility

2. Heat Treating

3. Casting

4. machining/lasers, etc

5. Stamping/forming

6. Sheet metal/welding

7. plastic molding/extrusion


Grading: Assignments 15%

Experiments 25%

Final project 30%

Quizzes 25%

Plant Tours (mandatory) 5%


Tests and assignments will be given at natural points during the term as new

material is covered.

Final Project: Each student is expected to produce some thing using at least 10 different

and distinct turning or milling operations. The things may be done

individually or by groups to be assembled into something more complex.

This project involves use of the machines shop, and must have

demonstrable results to pass the course. Some examples of possible

projects are,

miniature cannon (1 person)

small vice (1 person)

small press (small team)

robot frame (large team)


Grading Scale: A 100 - 90

A- 89-80

B+ 79-77

B 76-73

B- 72-70

C+ 69-67

C 66-63

C- 62-60

D+ 59-58

D 57-55