MET 1321- Manufacturing Processes Lab I (1-3-2)

Course Syllabus

 

Professor: Simin Nasseri

Office: K143 (office hours)

Phone: 678-915-7420

Email: snasseri@spsu.edu

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

Please send email for making an appointment.

 

 

*      Tentative Schedule for spring 2007

 

*      All the Materials for this course (Power-Point Presentations)

 

*      Projects

 

*      Quizzes/ Tests

 

 

 

Course texts:

v     Miller R.T. Welding Skills, 3rd edition. American Technical Publishers 2004.

v     Walker, J. R. Machining Fundamentals. The Goodheart-Willcox Co., Inc. 2004.

 

Course Objective:

This course is an introduction to the use and operation of selected industry machinery, various machining operations, selected welding processes and precision measuring instruments. Laboratory projects will emphasize safety and apply selected manufacturing processes, various inspection processes, fixing and engineering materials.

 

Co-requisite:

Manufacturing presses, MET 1311 or concurrently. If you do not meet the co-requisite requirement, you are expected to withdraw from this course, otherwise the instructor reserves the right to remove you from the class and assign a grade of W (or WF if past the drop date).

 

Procedures:

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

v     attendance,

v     projects,

v     quizzes, mid-term and final examinations.

 

Attendance is mandatory and points will be taken off final grade in case of illegitimate absence. There will not be any make-up time for missed laboratory time.

 

Projects will be assigned weekly. All laboratory projects must be completed in the SPSU laboratories. Each laboratory exercise will be performed while in small groups and each student must submit an individual project per the instructions on the lab handout. Mr Meeks (dmeeks@spsu.edu) will be your lab technicians and he will instruct you in welding and machining laboratories.

 

Quizzes are given at the beginning of the classes. These quizzes cover the course materials which were taught in the previous session (or sessions).

 

Midterm and final examinations may be either in the form of multiple choices or short answers, but will be announced well before each test.

 

Grading policy:

 

v     Attendance: 5%

v     Tests, and Midterm Exam: 30%

v     5 Metal joining labs @8 % each: 40%

v     Metal cutting lab project 1: 15%

v     Metal cutting lab project 2: 10%

Total: 100%

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

 

 

Course content- topic coverage:

 

Part 1:

v     Introduction to welding,

v     Welding safety,

v     Gases used in the metal joining processes,

v     Shielded metal arc welding,

v     Oxyacetylene metal welding,

v     Gas metal arc welding,

v     Gas Tungsten arc welding,

v     Inspection and testing welds,

v     Welding terms and symbols

Part 2:

v     Machine tool safety

v     Precision measurement and inspection,

v     Cutting tool selection,

v     Machine tool workholding,

v     Speed and federate calculations,

v     Materials properties.

 

 

Equipment List:

v     A regular pair of slip-joint pliers to handle hot material/ weldments,

v     Safety goggles that enclose any eyeglasses (both top and side) if you would like to have one for your own.

 

 

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 2003-2004 Undergraduate Catalog on A Disruptive Behavior and Academic Dishonesty (page 62).

 

 

 

 

Power-Point Slide Shows:

 

Part 1:

1.      Introduction to Welding (Basic Metal Joining Techniques),

2.      Welding Safety,

3.      Stick Welding, Part 1

4.      Stick Welding, Part 2 Check this: Imperfections

5.      Welding Terms

6.      Oxyacetylene Welding

7.      MIG Welding

        Guidelines (Miller Electric Mfg. Co)

        Learn about MIG welding

8.      TIG Welding

        Learn about TIG welding (Study all sections: Intro, Benefits, Setup, How to Weld, Hints & Tips, Troubleshooting)

9.      Inspection and Testing Welds

10.  Welding Symbols

 

Part 2:

1.      Machine Shop Safety

2.      Lathe Machine Part 1

        Video 1

3.      Lathe Machine Part 2

4.      Lathe Machine Part 3 (Modified)

5.      Lathe Machine Part 4

6.      Measurement Part 1

7.      Measurement Part 2 (Check this website of Clemson University and see all the video clips)

8.      Milling Machine- Part 1

9.      Milling Machine- Part 2



 

 

Projects:

Due dates: Check the schedule and the due date for each project. Bring your project to my office (K143) or give it to Mr Meeks and sign your name. If I am not in my office, place your project in my mailbox in copy room. Grade reductions are considered for late submissions.

Mr Meeks will instruct you with welding and will show you the correct techniques and methods.

 

Welding:

 

 

        Your first project is to lay a single pass weld (flat weld), preferably 2 inches long.

Consider this table to see what went wrong in your welding.

 

        Your second project is a butt joint by stick welding.

 

        Your third project is a T-joint (a fillet weld on one side and some tags on the other side).

 

        Your fourth project is a flat weld using MIG welding machine.

Check the following figures to see what went wrong in your MIG welding:

Good

Weld

Travel
Too Fast

Travel
Too Slow

Voltage
Too Low

Voltage
Too High

Amperage
Too Low

Amperage
Too High

Less Stickout
No gas

 

        Your fourth project is corner joint using TIG welding machine.

Machining:

 

Project 1 Lathe project (Detailed procedure is placed in the lab).

 

Project 2: Milling project is a nut (1.25 x 1.25 x .50) with the thread of 5/8 18 UNC 2B. The procedure for making the nut will be explained in the lab.

 

The due date (for both projects) is April 25th or April 26th depending on the class you are in.

 

 

Quizzes/ Tests:

 

Check the schedule and the date of each quiz. The format of the quiz may be either multiple choice or short answers.

 

Your first test will be on Monday Feb 12th (for M/W groups) and on Tuesday Feb 13th (for T/R group). All the materials taught so far (Sections 1 through 6 of the course materials above) are included.

 

Test 1 answers:

1-B

2-A

3-B

4-B

5-B

6-A

7-B

8-B

9-A

10-B

11-B

12-B

13-A

14-A

15-B

16-A

17-B

18-C

19-C

20-C

21-B

22-B

23-C

24-D

25-A

26-B

27-D

28-B

29-B

30-B

31-C

32-A

33-D

34-B

35-D

36-C

37-A

38-E

39-C

40-A

41-B

42-D

43-E

44-D

45-B

46-A

47-C

48-B

49-C

50-E

51-A

52-D

53-B

54-D

55-A

56-C

 

 

 

 

 

 

 

 

 

Your second test will be on Monday Feb 26th (for M/W groups) and on Tuesday Feb 27th (for T/R group). Sections 7 through 8 of the course materials above are included.

 

Test 2 answers:

1-A

2-A

3-B

4-B

5-A

6-B

7-A

8-A

9-A

10-A

11-B

12-A

13-A

14-A

15-A

16-B

17-A

18-A

19-B

20-A

21-B

22-B

23-B

24-B

25-B

26-A

27-D

28-C

29-A

30-B

31-D

32-C

33-A

34-D

35-B

36-B

37-A

38-C

39-C

40-A

41-B

42-D

43-B

44-E

45-D

46-A

47-C

 

 

 

 

 

 

 

 

 

Your mid-term test (test 3) is after the spring break. It is from all the sections you have studied so far (Part 1). It is not a multiple-choice test!

 

Your last test is from the second part, lathe and milling machines. It is a multiple-choice test. It is on Monday 23rd or Tuesday 24th (depending on the class you have).

 

NEW Test 4 answers:

1-B

2-B

3-A

4-A

5-A

6-A

7-B

8-B

9-A

10-B

11-A

12-A

13-A

14-A

15-A

16-B

17-A

18-A

19-B

20-B

21-D

22-B

23-C

24-D

25-B

26-B

27-A

28-D

29-B

30-A

31-C

32-B

33-A

34-B

35-C

36-D

37-B

38-D

39-A

40-C

41-C

42-B

43-A

44-D

45-E

46-C

47-B

48-A

49-D

50-B

51-A

52-D

53-C

54-D

55-C

56-A

57-B

58-B

59-A

60-C

 

 

 

 

 

THERE IS NO FINAL EXAM FOR THIS COURSE.