9. 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, FTP/Telnet

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,