Manufacturing Processes, MET 1311 (3-0-3)

Course Syllabus

 

Professor:    Simin Nasseri

Office:        Q 231 (office hours)

Phone:         678- 915- 7420

Email:          snasseri@spsu.edu

Web Page:   http://fac-web.spsu.edu/met/snasseri/

 

Any use of my course materials on any other website or networked computer environment for any purpose is prohibited. The materials on this website are copyrighted and any unauthorized use of any materials may violate copyright and other laws (P&P 603). Other instructors can only use the lecture notes by permission and they should not add their names to the slides.

·         Course Text / Objectives­

·         Course Outcomes

·         All the Materials for this course  

·         Procedure and Grading Policy

·         Tests 

·         Homework Assignments 

·         Presentations/ Seminars 

·         Tours

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Course text: OPTIONAL

·         Fundamentals of Modern Manufacturing; Materials, Processes and Systems, by M. P. Groover, 4th Edition, John Wiley & Sons, Inc. ISBN: 978-0-470-46700-8. You can use other editions as well.

 

image008.jpgAbout the book: In this modern, quantitative approach to manufacturing, Mikell Groover offers balanced coverage of the three basic engineering materials, metals, ceramics, polymers, as well as composites along with recently developed manufacturing processes and electronics manufacturing technologies.

 

Throughout Fundamentals of Modern Manufacturing, the emphasis is on manufacturing science and quantitative analysis of manufacturing processes. This emphasis helps students understand the relationships among the material properties and the process variables in a given manufacturing process.

 

image004.jpgAbout the Author: Mikell P. Groover is Professor of Industrial and Manufacturing Systems Engineering at Lehigh University, where he also serves as Director of the Manufacturing Technology Laboratory. He holds the following degrees all from Lehigh: B.A. (1961) in Arts and Science, B.S. (1962) in Mechanical Engineering, M.S. (1966) and Ph.D. (1969) in Industrial Engineering. He is a Registered Professional Engineer in Pennsylvania. His industrial experience includes full-time employment at Eastman Kodak Company as a Manufacturing Engineer.

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Course Objective:

An introduction to industrial manufacturing processes used for converting raw materials into finished products. Various processes, machinery, and operations will be examined with emphasis placed on understanding engineering materials and processing parameters that influence design considerations, product quality, and production costs.

 

Procedures:

Your grade in this course will be determined from your performance on:

·         Attendance and homework Assignments,

·         Seminars and presentations,

·         Tests and final exam.

 

Attendance is mandatory and points will be taken off final grade in case of illegitimate absence (10%).

 

Online assignments: 12 HW assignments are placed on D2L. These are weekly assignments in the form of true/false and multiple choice. (20%)

 

Seminars/Presentations will be assigned after certain modules are covered.

Students will have seminars which are related to manufacturing the things we use every day. They will present short seminars in which they explain how certain objects are manufactured and support their talk by preparing slide shows containing images, video clips, etc (15%)

 

Tests which are in the form of multiple choices, are given at the beginning of the classes. These tests cover the course materials which were taught in the previous session (or sessions). Each test has about 50 questions (average of all tests weighs 40%) and the final exam has about 150 questions (15%).

 

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Grading policy for in-class:

 

·         Attendance:                                                         10%

·         Homework assignments:                                     20%

·         5 Tests:                                                                 40%

·         Final Exam:                                                         15%

·         Seminars/Presentations:                                     15%

Total:                                                               100%

 

 

[90 - 100% = A,   80 - 89% = B   70 - 79% = C   60 - 69% = D   Below 60% = F]

 

 

Course Outcomes:

 

·         Understand basic product design and manufacturability.

·         Describe basic physical and mechanical properties (metals, polymers, ceramics and composites), behaviors, and failure modes and their relevance to manufacturing processes.

·         Describe atomic structure and the elements, bonding between atoms and molecules, crystalline and noncrystalline structures.

·         Describe heat treating methods for metals and their purposes.

·         Describe selected metals forming operations and calculate the associated force and energy requirements.

·         Describe molding and casting processes for metals.

·         Describe the selected shaping processes for polymers.

·         Describe manufacturing processes for powder metal alloys.

·         Understand different machining operations (turning, grinding, EDM, ECM and others) and describe various machineries.

 

ADA/504 Compliance

Students with disabilities who believe that they may need accommodations in this class are encouraged to contact the ATTIC counselor working with disabilities at (678) 915-7361 as soon as possible to better ensure that such accommodations are implemented in a timely fashion.

 

 

Student Conduct

Academic dishonesty and non-academic misconduct, in any form, is not tolerated in the classroom.  This includes, but is not limited to, cheating, plagiarism, and disorderly conduct.  Please refer to sections in the Undergraduate Catalog on “A Disruptive Behavior and Academic Dishonesty”.

 

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All the Materials for this course (Summaries of all Chapters and Solved Problems from Groover’s book):

 

Chapter 1: Introduction- Part 1

Chapter 1: Introduction- Part 2

Chapter 2: Nature of Materials

Chapter 4: Physical Properties

Review these problems

Problem 2 video clip

Problem 3 video clip

Problem 4 video clip

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ TEST 1 (Chapters 1, 2 and 4)

 

Chapter 6: Metals- Part 1

Chapter 6: Metals- Part 2

 

Chapter 3: Mechanical Properties- Part 1                                      Greek Alphabet (for your info)

·         Practice Problems    =>      Solutions

·         Groover’s Problems

 

Chapter 3: Mechanical Properties- Part 2                                      (Viscosity of polymers and flow rate is not included)

·         Practice Problems

·         Work on the Brinell hardness numbers                                         (Enter values and see what you get)

 

Video clips on the practice problems above:

·         Chapter 3- Problem 1

·         Chapter 3- Problem 6

·         Chapter 3- Problem 19

·         Chapter 3- Problem 20

·         Chapter 3- Problem 23

·         Chapter 3- Problem 30

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ TEST 2 (Chapters 3, and 6)

Chapter 10: Fundamentals of Metal Casting                    

v  Practice problems from Groover’s book

v  Watch this video clip

 

Chapter 11: Metal Casting Processes- Part 1

Chapter 11: Metal Casting Processes- Part 2

v  Test yourself!

 

Chapter 16: Powder Metallurgy

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ TEST 3 (Chapters 10, 11 and 16)

 

Chapter 18: Fundamentals of Metal Forming

 

Chapter 19: Bulk Deformation Processes in Metal Forming:

v  Rolling                                                                                          Video clips: Steelmaking rolling,  Stresses in rolling, Ring rolling

v  Forging                                                                                         Video clips: Forging (check the DVD which comes with the book)

v  Extrusion                                                                                     Video clips: Metal extrusion, Aluminum extrusion,

v  Wire and Bar Drawing                                                               Video clip: The complete operation

 

Interesting video clips:

1-      Steelmaking (1)

2-      Steelmaking (2)

3-      Steelmaking (3)

4-      Steelmaking (4)

5-      Steelmaking (5)

 

 

Chapter 20: Sheet Metalworking

v  Part 1: (Cutting, Bending and Drawing)                                  Video clips: Punching, Punching/bending, Bending

v  Part 2: (Other Operations, Dies and Presses)                           More on Hydroforming, Video clip on Explosive Forming

 

 

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ TEST 4 (Chapters 18, 19 and 20)

 

Chapter 8: Polymers

v  Types of Polymers                                                                       Learn about Plastic Identification Code

v  Polymer Molecular Structures

v  Physical & Mechanical Properties                                             Recycling plastics  (Please recycle!)

 

 

Chapter 13: Shaping Processes for Plastics

v  Properties of Polymer Melts / Extrusion                                   Video clips: Watch this video clip and this, Watch PVC Extrusion clip

v  Injection Molding                                                                        Video clips: Injection molding, Compression molding

v  Blow Molding                                                                              Video Clip: Blow molding, Automatic bottle blowing machine

 

 

Chapters 21 and 22:

v  Theory of Metal Machining / Machining Operations              Video clips: Shaper milling machine, Planer machine

 

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ TEST 5 (Chapters 8, 13 and 21&22)

 

Cool stuff:

 

Video 1

Video 2

Check this cool website about futuristic materials.

 

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Tests

 

Check the tentative schedule in D2L. Tests will be announced in class or in D2L.

 

 

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Homework Assignments

 

HW assignments are placed in D2L. You have a HW every week. Check the tentative schedule in D2L.

In addition to some homework assignments given to students, each student is asked randomly to answer a question from previous chapters every session. If the student fails to answer the question correctly, some points will be taken off.

 

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Seminars/ Presentations

 

You should choose something we usually use in normal life and talk about it in class and explain how it is manufactured. Make a Powerpoint presentation and support your presentation by figures, videos, etc. The length of presentation should be between 4 to 7 minutes (NOT LESS THAN 4 MINUTES…..and NOT MORE THAN 7 MINUTES!). No time should be wasted for transferring your files into the computer (I come to the class 10 minutes earlier and turn on the computer for you, so you can copy your files).

 

This presentation is worth 20% of your total grade! So take it very seriously.

You can use madehow website or any other website or books/articles and choose something which would take 3 to 7 minutes to talk about (time yourself to know the exact time which is taken to present your seminar!).  Remember that you have to include all the references that you use.

Here are the presentations that my students had before.

               

 

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Tours and other activities

 

As the Society of Manufacturing Engineers (SME) Student chapter Advisor, I will announce our tours, professional talks and other activities on our facebook page.

 

 

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