ENG165-265

Advanced Manufacturing Choices

SPRING 2016

4 Credit Units

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Instructor:

Prof. Marc J. Madou

Chancellor’s Professor

4200 Engineering Gateway Building

(949) 824-6585

email:

Description: Manufacturing processes can be organized by considering the type of energy required to shape the work-piece. In this course, sources of energy considered for machining are mechanical used for cutting and shaping, heat energy such as in laser cutting, photochemical such as in photolithography, and chemical energy such as in electro chemical machining and chemical vapor deposition (CVD). Students, guided by product specifications and a design will decide: 1) When to apply mechanical machining vs. lithography based machining, 2) What type of mechanical machining and what type of lithography based machining to apply, 3) When to employ bottom-up vs. top-down manufacturing, 4) When to choose serial, batch or continuous manufacturing and 5) What rapid prototyping method to select. A logical decision tree will be presented to sort the machining options. Examples from a variety of products ranging in size from nanometers to centimeters will be considered.

Topics:

1. Serial, batch and continuous manufacturing processes.

2. Relative tolerances vs. absolute machining tolerances.

3. Principles of manufacturing processes I. Mechanical energy: e.g., Mechanical Machining , Ultrasonic Machining and Sputtering.

4. Principles of manufacturing processes II. Thermal energy: e.g., Electron Discharge Machining (EDM), Laser Machining (LM), Electron Beam machining and Plasma Arc Cutting

5. Principles of manufacturing processes III. Electrical energy: e.g. , Electrochemical Machining (ECM), Electrochemical Discharge Grinding (ECDG)

6. Principles of manufacturing processes IV. Chemical energy: Chemical Machining (ECM), Photochemical Machining (PCM) e.g., photolithography

7. Next generation lithography tools,

8. Nanomachining tools.

9. Top-down vs. bottom-up machining.

10. Rapid prototyping, layered manufacturing.

11. Matching manufacturing processes to product specification and design.

12. Manufacturing process decision tree.

Textbook: Selected materials from M. J. Madou, “Fundamentals of Micromachining” 3rd Edition, 2011

Pre-requisites: MAE147, MAE150 or consent of instructor.

Grading Policy:

Midterm 30 % (May 16th)
Design Challenge 30 % (June 1st)

Final 40 %