IE 416 Manufacturing Engineering II - Automation

ISE316 Fall 2010ISE 316 Manufacturing Engineering I - ProcessesFall 2010 Class Time:Tu, Th. 10:15 11:15 AM. (DAN 218)Lab Time: Th. 1:30-4:20 PM. (DAN 118)Fri. 9:10-11:55 AM. (DAN 118)Instructor:Professor Richard A. Wysk, Ph.D..Phone: 515-1549 Office:Daniels Hall 414-AE-mail: rawysk@ncsu.eduOffice Hours:Tu., Th. 11:30AM - 12:30 PM, (or any time I am in my office)

Teaching Assistants: Li Yang TA Office: DAN 416 Office Hrs: Mon., 4:00-5:00 PM Wed., 4:00-5:00 PMTA1's E-mail: lyang5@ncsu.edu Lab Manager:Mr. Daniel Leonard (drl@ncsu.edu) Room DAN 100-A Prerequisites:ISE 216 (Mfg. Eng. Practicum), MAT 200, IE/GC 210 Text Book: Fundamentals of Modern Manufacturing Materials, Processes and Systems, Mikell P. Groover, 4th. Edition, ISBN 978-0-470-467002, Prentice Hall, 2010. Lecture notes and supplement notes distributed in class. Goals: To learn the fundamentals of manufacturing processes. To understand how modern manufacturing systems work. To know how to transform a mechanical design from a drawing to the finished part. Course Objectives: At the conclusion of this course, you should be: 1. Familiar with engineering materials and their mechanical properties, 2. Able to understand, analyze and apply the fundamentals of basic forming and machining processes, tooling and machine tools for manufacturing products, 3. Able to understand tolerances and dimensional, and inspection methods, 4. Able to understand the modern manufacturing techniques, non-traditional manufacturing processes, plastic forming manufacturing and micro-manufacturing technology, 5. Able to design, select and apply the product development, machining operations, the manufacturing cost analysis techniques for product design, planning, and manufacturing, and. 6. Show your experience of machining processes on different machine tools.

WeekDateTopicTextbookLab(Th/Fr)

1Th.

8/20

Introduction of manufacturingThe Nature of MaterialsLecture NotesChapt. 1(No Lab)

2Tu.Th.8/248/26Mechanical Properties of Materials Measurement and Inspection (1)

Chapt. 2Chapt. 2 suppl.Lab-IIntro&Safety

3Tu.Th.8/319/2Measurement and Inspection (2)Measurement and Inspection (3)Chapt. 2 suppl.Chapt. 2 supplLab-IIMetrology

4Tu.Th.9/79/9Theory of Metal Machining Machining: Process Mechanics

Chapt. 21Chapt. 22

Lab-IIICasting

5Tu.Th.9/149/16Machining: Turning and Related ProcessesMachining: Milling and Hole-making Processes

Chapt. 22Chapt. 23Lab-IVForming

6Tu.Th.9/239/25Cutting Tool TechnologyGrinding and Other Abrasive ProcessesChapt. 23Chapt. 25Lab-VMilling

7Tu.Th.9/289/30Grinding and Other Abrasive Processes Exam 1 - (in-class exam) Chapt. 25

Lab-VITurning

8Tu.Th.10/5 10/7MetalsFall break

Chapt. 6Chapt. 10

Lab-VIIMachining

9Tu.Th.10/910/11Casting: Fundamentals and SolidificationCasting: Sand, Permanent Mold and Die Casting

Chapt. 11Chapt. 19Lab-VIIIWelding

10Tu.Th.10/1210/14Sheet Metal Forming

(No Lab)

11Tu.Th.10/1910/21Forming: BulkForming: Sheet

Chapt. 20Chapt. 21ProductManufacturingg

12Tu.Th.10/2610/28Shaping Processes for Plastics(No class Spring Holiday) Chapt. 13

(No Lab)

13Tu.Th.11/211/4Shaping Processes for PlasticsExam 2 - (in-class exam)

Chapt. 13

ProductManufacturing

14Tu.Th.11/9 11/11Joining: Welding ProcessesPowder MetallurgyGrinding and Other Abrasive ProcessesChapt. 31Chapt. 16ProductManufacturingg

15Tu.Th.11/1611/18Non-Traditional Machining and Thermal CuttingNon-Traditional Machining and Thermal Cutting

Electronics Assembly and PackagingChapt. 26Chapt. 26ProductManufacturingg

16Tu.Th.11/23 11/25Micro-Fabrication TechnologiesThanksgiving no classChapt. 37Chapt. 38ProjectReport due

17Tu.11/3012/02

12Nano-manufacturingReview

Exam 3 (08:00 AM scheduled by the University)

COURSE STRUCTURE:I. KNOWLEDGE BUILD PHASE Lecture Outline:1. Introduction of manufacturing 2. Material removal processes3. Metal forming and sheet metalworking4. Casting and molding5. Grinding and abrasive processes6. Plastic forming processes7. Non-traditional processes8. Joining and welding processes9. Powder metallurgy processes10. Micro-fabrication technologies

II. HANDS-ON EXPERIENCE Manufacturing Labs: 1. Introduction to lab safety and review of machines2. Product design and Metrology 3. Casting Experiment4. Metal Forming: Sheet Springback 5. CNC Machining: Machining Centers 6. CNC Machining: Turning Centers7. Machining: Surface Finish and Lubricant Assessment Experiment8. Welding and Weld Joint Strength Experiment9. Injection Molding Experiment 10. Semester Lab Project product development, design, planning and manufacturing

COURSE ORGANIZATION:This course consists of the following: 1.Lectures - Attendance is required in this class. 2. Homeworks* and In-class Assignments* - Several* homework or in-class assignments* will be given from time to time. The purpose of assignments is to give you a chance to practice what you learned from the class. Try to solve the homework problems by yourself. If you still cannot solve them, come to see me or TAs. In-class assignments will be given during class discussion. No missing in-class assignment will be accepted after class. 3.Labs* - About five lab assignments will be given in the semester. Lab assignments are provided on the IE316 Web page. (*: The exact number of homeworks, labs and in-class assignments will be determined throughout the course of the semester.) 4.Semester Project a semester project of product design and manufacturing is assigned and the semester project along with the completed product need to be completed and presented at the end of the semester. 5.Tests - Three in class tests (including finals) will be given.

SEMESTER PROJECT:November 23Physical product due (4:00 PM)December 2Final report due (4:00 PM)GRADING: Homeworks10% (you are allowed to miss one homework)In-class Assignments and Quiz15% (you are allowed to miss one in-class assignment)Labs10%Semester Lab Project10%Participation 5%Tests (3)50% (16.7% + 16.7% + 16.7% of final) Total100%ADMINISTRATIVE POLICIES1.Attendance is expected at all lectures and is required for laboratory. Missing more than one lab will results in failure for the course. 2.All homework and lab reports must be turned in on-time for credit. 3.Individual and group assignments should be solely the work of the individual or group handing it in. While I encourage you to ask questions for clarification the work should be your own or your groups. 4.Proper attire as defined in the Laboratory Safety Sheet is required to participate in lab and you must be present to receive credit. 5.No after-fact excuse on missing assignment or test will be accepted. If you shall have a job interview you must inform me at least a week ahead of time. After-fact excuse is not acceptable. 6.You must show all calculations or procedures in your test paper/report in order to get full score. 7.This is an engineering course, you are expected to act as a responsible engineer. Every document handed-in must be neatly prepared. Sloppy work may cost you points. 8.Academic Integrity: It is understood and expected that all work turned in under your name is your own work or, if a group assignment, the work of you and your group members, and that you have neither given nor received unauthorized aid. The University policy on academic integrity can be found in the Code of Student Conduct (see Appendix L of the Handbook for Advising and Teaching: www.fis.ncsu.edu/ncsulegal/41.03-codeof.htm).9.Incomplete Grades and Late Assignments: If requested by a student, the grade of Incomplete will be given for work not completed because of a serious, documented interruption in the students work not caused by their own negligence. Only regular Projects and the Final Project will be accepted late, with a reduction of 10% in the assignments grade for each day it is late. In-class assignments cannot be accepted late. 10.Absences and Scheduling Make-up Work: A make-up exam will be scheduled if a student has an excused absence (see http://www.ncsu.edu/provost/academic_regulations/attend/reg.htm for NC States policy on excused absences). There are no make-up in-class assignments or quizzes; the lowest one in-class assignments and the lowest quiz will be dropped in lieu of any absence.

5