DESCRIPTION

 

This course presents a mostly qualitative description of the science, technology, and practice of manufacturing. This includes detailed descriptions of manufacturing processes and the manufacturing enterprise that will help introduce students to important concepts.

 

OBJECTIVES

 

1. ​​An excellent overview of manufacturing concepts is provided with a balance of relevant fundamentals and real-world practices.

2. Lists and process comparisons give students a thorough look at manufacturing processes and operations. The lectures on specific groups of manufacturing processes and operations feature lists of typical parts produced by the processes described in the lecture, as well as a list of competing and alternative processes to produce the same types of parts.

3. A wealth of examples and industrially relevant case studies demonstrate the importance of the subject matter, offer a real-world perspective, and keep students interested and engaged.

4. Superior use of analogies, discussions, and problems motivate students’ interest in the material.

 

GRADEBOOK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GRADING SCALE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

READING MATERIALS

 

[1] R.K. Rajput, A Textbook of Manufacturing Technology: Manufacturing Process, 2007.

 

ACTIVITIES

 

Four kinds of end-of-lecture problems help reinforce concepts in each lecture:

1. Review Questions

2. Qualitative Problems

3. Quantitative Problems

4. Synthesis, Design, and Projects

 

POLICY

 

• Grading Criteria/Timetable: All course activities will be graded within one week of their due date.

• Extenuating Circumstances: If you have extenuating circumstances that prevent you from completing activities or participating in the class, please contact me to make alternative arrangements.  The possibility of alternative arrangements is at the discretion of the instructor.  Active communication is the key to overcoming any hurdles you may encounter during the term.

• Students are expected to be the sole authors of their work. Use of another person's work or ideas must be accompanied by specific citations and references. Though not a comprehensive or exhaustive list, the following are some examples of dishonesty or unethical and unprofessional behavior:

1. Plagiarism: Using another person's words, ideas, or results without giving proper credit to that person; giving the impression that it is the student's own work.

2. Any form of cheating on examinations.

3. Altering academic or clinical records.

4. Falsifying information for any assignments.

5. Submitting an assignment(s) that was partially or wholly completed by another student.

6. Copying work or written text from a student, the Internet, or any document without giving due credit to the source of the information.

7. Submitting an assignment(s) for more than one class without enhancing and refining the assignment, and without first receiving instructor permission. In cases where previous assignments are allowed to be submitted for another class, it is the responsibility of the student to enhance the assignment with additional research and to also submit the original assignment for comparison purposes.

8. Assisting another student with reasonable knowledge that the other student intends to commit any act of academic dishonesty. This offense would include but would not be limited to providing an assignment to another student to submit as his/her own work or allowing another student to copy answers to any test, examination or assignment.

• Academic dishonesty is a serious offense and may result in the following sanctions:

1st offense: Failure of the assignment in which the action occurred.

2nd offense: Failure of the class in which the action occurred.

3rd offense: Expulsion or permanent dismissal from the University.

 

OUTLINE

 

Lecture 1: Introduction and Overview of Manufacturing

1. What Is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production Systems

5. Trends in Manufacturing

 

Lecture 2A: Fundamentals of Metal Casting

1. Overview of Casting Technology

2. Heating and Pouring

3. Solidification and Cooling

 

Lecture 2B: Metal Casting Processes

1. Sand Casting

2. Other Expendable-Mold Casting Processes

3. Permanent-Mold Casting Processes

4. Foundry Practice

5. Casting Quality

6. Metals for Casting

7. Product Design Consideration

 

Lecture 3: Theory of Metal Machining and Cutting-Tool Technology

1. Overview of Machining Technology

2. Theory of Chip Formation in Metal Machining

3. Force Relationships and the Merchant Equation

4. Power and Energy Relationships in Machining

5. Cutting Temperature

6. Tool Life

7. Tool Materials

8. Tool Geometry

9. Cutting Fluids

 

Lecture 4: Machining Operations and Machine Tools

1. Machining and Part Geometry

2. Turning and Related Operations

3. Drilling and Related Operations

4. Milling

5. Machining Centers and Turning Centers

6. Other Machining Operations

7. Machining Operations for Special Geometries

8. High-Speed Machining

 

Lecture 5: Grinding and Other Abrasive Processes & Economic and Product Design Considerations in Machining

1. Grinding

2. Related Abrasive Processes

3. Machinability

4. Tolerances and Surface Finish

5. Selection of Cutting Conditions

6. Product Design Considerations in Machining

 

Lecture 6: Fundamentals of Metal Forming and Bulk Deformation Processes

1. Overview of Metal Forming

2. Material Behavior in Metal Forming

3. Temperature in Metal Forming

4. Strain Rate Sensitivity

5. Friction and Lubrication in Metal Forming

6. Rolling 396

7. Other Deformation Processes Related to Rolling

8. Forging

9. Other Deformation Processes Related to Forging

10. Extrusion

11. Wire and Bar Drawing

 

Lecture 7: Sheet-Metal Working

1. Cutting Operations

2. Bending Operations

3. Drawing

4. Other Sheet-Metal-Forming Operations

5. Dies and Presses for Sheet-Metal Processes

6. Sheet-Metal Operations Not Performed on Presses

7. Bending of Tube Stock

 

Lecture 8: Fundamentals of Welding, Brazing, Soldering, and Adhesive Bonding

1. Overview of Welding Technology

2. The Weld Joint

3. Physics of Welding

4. Features of a Fusion-Welded Joint

5. Brazing

6. Soldering

7. Adhesive Bonding

 

Lecture 9: Welding Processes

1. Arc Welding

2. Resistance Welding

3. Oxyfuel Gas Welding

4. Other Fusion-Welding Processes

5. Solid-State Welding

6. Weld Quality

7. Weldability

8. Design Considerations in Welding