Fundamentals of Manufacturing Processes

ParklandCommunity College(Champaign Outreach Program)

IT 208–Fall 2005

Instructor:Mandara D Savage, Ph.D.

Class Hours:SU 8:00 – 4:30

Class Room:

Office Hours:M 9-12a,Tu 9-11;1-2p (other times by appointment)

Telephone:618 453.7851

E-mail:

Webpage:

Course Objective

To enable the student to understand the theory and principles of traditional manufacturing processes used by industry such as metal casting, forming and shaping, material removal and joining.

Course Format

Test 1 – 25% / Chapters 1, 2, 4, 5, 7 / Start of second week
Test 2 – 25% / Chapters 9, 10, 11, 12, 14 / Start of third week
Test 3 – 25% / Chapters 15, 18, 19, 21 / 1:00 Sunday
Article Summary 15%
Homework/Quiz 10%

Equipment

  • None required

Grading Policy

Missed exams have a 20% penalty unless an appropriate excuse is approved by the instructor prior to the regularly scheduled exam. The missed exam must be completed on the makeup date set by the instructor. Late assignments will have a 30% penalty.

Academic Conduct

Cheating on examinations, submitting work of other students as your own, or plagiarism in any form will result in penalties ranging from an F on the assignment to expulsion from the university, depending on the seriousness of the offense.

Grade Assignment

A: 90 – 100%

B: 80 – 89%

C: 70 – 79%

D: 60 – 69%

F: < 60%

Major Topics

  • Chapter 1. - An Approach to Manufacturing Processes.
  • Chapter 2. - Properties of Materials.
  • Chapter 4. - Mechanical Methods of Material Removal.
  • Chapter 5. -Electrical Methods of Material Removal.
  • Chapter 7. - Thermal and Other Methods of Material Removal.
  • Chapter 9. - Thermal Methods of Change of Form.
  • Chapter 10. - Powder Methods of Change of Form.
  • Chapter 11. - Mechanical and Other Methods of Change of Form.
  • Chapter 12. - Change of Condition.
  • Chapter 14. - Welding.
  • Chapter 15. - Mechanical Methods of Joining.
  • Chapter 18. - Manufacturing with Plastics.
  • Chapter 19. - Manufacturing with Composites.
  • Chapter 21. - Production Control.

References

Text: Manufacturing Processes for the Technician, (2nd Edition) by Fellers & Hunt, Prentice Hall, ISBN: 0-13-017791-1

Manufacturing videos of “How Everyday Things are Made”:

ARTICLE SUMMARY:

You will be required to turn in one article summary on the date assigned by the schedule. We will discuss these on this day in class so be prepared. The article should come from a journal or magazine that deals with Manufacturing and or Quality type issues. This review should be typed in 12 point font, double spaced and grammatically correct; no contractions, and write it as if it is going to be reviewed by your manager. This is the format that should be followed:

Cover
  • Program Name
  • Course
  • Instructor
  • Your Name
  • Date
/ Main Page
  • Title of Article, Author, Source (volume, pages, etc.)
  • Purpose of Article
  • Key Points (Bullet form recommended)
  • Findings/Conclusions
Format
  • Typed – 12 pt – 1.5 line spacing – 1” margins
  • Number and place name on each page after title page
  • Your summaries are limited to 2 pages excluding title page
  • Summaries will be graded for grammar, spelling, punctuation, etc.
Presentation
  • Be prepared to give a 5 minute(MAX) summary to the class

Detailed Competencies

Upon completion of this course students should know/ understand the following:

Chapter 1 - An Approach to Manufacturing Processes.

  • The Definition of Manufacturing.
  • Identify production tasks by the type of product

Chapter 2. Properties of Materials.

  • Define Stress, Strain, True Stress and Engineering Stress, Yield Strength, and Compression
  • Calculate Stress, Strain, True Stress and Engineering Stress, Yield Strength, Safety Factor and Compression
  • List and describe the 4 categories of chemical bonds.
  • Define material fatigue and creep
  • List materials used to produce iron leading steel.

Chapter 4. Mechanical Methods of Material Removal.

  • Identify the unique characteristics associated with powered mechanical methods of material removal
  • Calculate the optimum feeds and speeds for milling, drilling and turning
  • List and define the two types of milling machine configurations
  • List the 3 major functions of cutting

Chapter 5. Electrical Methods of Material Removal.

  • Identify the general operating principles of EDM

Chapter 7. Thermal and Other Methods of Material Removal.

  • Describe the process of oxy-fuel cutting and laser cutting

Chapter 9. Thermal Methods of Change of Form.

  • Identify the unique characteristics for each casting process
  • Describe the Investment Casting process
  • List the advantages of Investment Casting over Sand Casting
  • Describe how to select a casting process
  • Identify a given casting process as either expendable mold or permanent mold

Chapter 10. Powder Methods of Change of Form.

  • List the advantages of, and the products made from Powder Metal
  • List and describe the order of operations in Powder Metallurgy

Chapter 11. Mechanical and Other Methods of Change of Form.

  • Define Forging
  • Describe the fundamental characteristics of extrusion
  • Describe the process of Coining and Heading
  • Describe the reasons for using lubrication in forging
  • Describe the fundamental characteristics of rolling
  • List the common material change of form mechanical methods

Chapter 12. Change of Condition.

  • Describe the different methods of softening steel
  • Describe the different methods of hardening steel
  • Describe the difference between Martensite and Austinsite

Chapter 14. Welding.

  • Identify the different types of bonds associated with gas welding
  • Identify the flame characteristics associated with different types of gas welding
  • Identify the unique applications for each type of arc welding
  • List the advantages and disadvantages of arc welding

Chapter 15. Mechanical Methods of Joining.

  • Identify the unique applications for fasteners
  • Identify the different types of fasteners for shafts
  • Translate the nomenclature used to identify a thread

Chapter 18. Manufacturing with Plastics.

  • Define key terms associated with polymers and plastics and describe the difference between the two.
  • Differentiate between thermoplastics and thermosets, and identify the use for each.
  • Identify the correct plastics process used to make uniquely different products

Chapter 19. Manufacturing with Composites.

  • Describe the use of different types of fabrics and the importance of the fabric direction
  • Describe the difference between simple and advanced composites
  • Identify the manufacturing techniques of composites
  • List the advantages and disadvantages of plastics and composites

Chapter 21. Production Control.

  • Describe the difference between Jigs and Fixtures
  • Describe the difference between CAD/CAM
  • Define computer integrated manufacturing
  • List essential components of robotics and describe their function
  • Describe the disadvantage of Just-in-time scheduling

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The instructor reserves the right to modify this syllabus at any time throughout the course.