manufacturing process research

EG 4331 – Manufacturing Processes

Catalog Data

EG4331 Manufacturing Processes 3 Sem. hrs.

Geometric dimensioning and tolerancing standards. Economical and environmental considerations in manufacturing. Selection of materials. Processing methods: casting, injection molding, assembling, machining, etc. Measuring and inspection equipment and techniques. Product data management. Product design and redesign. Rapid prototyping. Labs and projects are required. Prerequisite: EG1301. EG2306

Textbooks and Other Source Materials

Required:	Manufacturing Processes for Engineering Materials (6th Edition), Serope Kalpakjian and Steven Schmid, Pearson Prentice Hall Calculator and laptop
Recommended:	None
Course Home Page:	http://bb.stmarytx.edu

Instructor

Tafesse Borena, PhD, Assistant Professor of Industrial Engineering. (210)436-3906; Email: [email protected], Office Hours: M, T, W. 1:30 - 3:30 pm, Richter Math-Engineering 236

Schedule

Meets three times a week for 50 minutes; 10:20 am - 11:10 am on M,WF., Richter Math-Engineering Cntr 111

Office Hours:M, W, F from 12:30 – 2:00 PM

Prerequisites by topic

EG 1301 Engineering Graphics and Design, EG 2306 Material Science

Course Content

Topics Hours

Introduction 2

Mechanical Behavior of Materials 4

Structure and Manufacturing Properties of Metals 3

Metal Casting Processes 4

Bulk Deformation Processes 5

Sheet-Metal Forming Processes 4

Material Removal Processes – Cutting 4

Material Removal Processes – Abrasive and Non-Traditional 3

Processing of Polymers & composites 2

Additive Manufacturing. 1

Powder Processing Processes – Metals and Ceramics 2

Joining and Fastening Processes 2

Material Selection and Substitution 1

Lab Experiments/demonstration 3

Tests and Exams 4

TOTAL 45.0

Course Objectives and Desired Outcomes

· Learn a broad range of manufacturing processes, including their typical use and capabilities.

· Select a suitable process (or sequence of processes) for the manufacture of a given component.

· Learn thermal and mechanical aspects, such as force, stress, strain, and temperature, of the most common manufacturing processes.

· Calculate force and power to conduct manufacturing processes.

· Suggest changes in component design for the improvement of manufacturability.

· Increase awareness of sustainability in manufacturing

The student should be able to apply the concepts above to accomplish the following:

· Identify, formulate, and solve engineering problems relating to manufacturing by applying mathematics, basic science, and engineering science principles to common manufacturing processes (SO1-3, SO2-3, SO3-3).

· Given a part to be manufactured, identify candidate processes that are capable of creating the part and its features. Weigh tradeoffs and evaluate manufacturing process selections for a various materials, tolerances, and applications (SO6-3, SO8-3, SO15-3).

· Analyze and compute force components, stresses and strains, and temperatures/cooling trends in common manufacturing processes (SO6-3, SO8-3).

· Research and develop a paper series that explores the necessary processes to manufacture a part/component selected by the student (SO10-3, SO12-3).

Grading

Component Weight

Prep Sheets 5

Assignments 10

Manufacturing Paper and lab report 15

Quizzes (4) 20

Mid Term Exam 25

Final Exam 25

TOTAL 100

Item	Deadline
Prep Sheets	Questions will be posted before each class. You are to develop responses and bring 2 hard copies to class – one for you and one for me.
Manufacturing Paper Series and lab reports	Over the course of the semester you will write 1 term paper and two lab reports. Reports should be more than 10 pages in length. E-submission on BB.

Applicable Policies and Procedures:

Please visit the following link to review applicable policies and procedures for this course.

https://gateway.stmarytx.edu/group/mycampus/academics/science-engineering-and-technology

You will need to log into Gateway when prompted, then select Resources from the menu on the left hand side of the page and click on the link “SET Policies and Procedures 2016-2017”

In addition, the following policies apply to this course:

· You are expected to be punctual and attend all sessions. Legitimate absences (such as illness with a note from the doctor) will be considered with appropriate documentation.

· You are expected to be prepared for each session of this class. Preparation includes reviewing assigned material, completing homework problems, and preparing for class discussions. An unprepared student is a liability to his/her class team/partner.

· I expect you to check your email on a regular basis. The only email address that I will use to communicate with you is your St. Mary’s University email address.

· I expect you to check the Blackboard site for this course on a regular basis for readings, lecture PDF’s, and many other support materials.

· Late/Missed submissions, quizzes, and examinations

· Late submissions will not be accepted.

· Requests to reschedule quizzes or examinations must be submitted in writing (email requests preferred) to me at least 7 days in advance for your request to be considered. These requests are approved at my discretion.

· Medical and family emergencies will be considered with appropriate documentation.

· Quality of Work: Neatness is expected in all assignments/lab reports that are turned in; the lack thereof will be penalized.

· All written assignments will be graded for content, originality of thought, clarity of thought and expression, writing style, grammar, and spelling.

MANUFACTURING TERM PAPER SPECIFICATIONS:

· Page limit: 20 pages

· Format

· Times New Roman, 1” margins all around, single-spaced, 3 pt. space between paragraphs

· Submission: Electronic

· Instructions will be posted about the contents of the report

· Submission: Electronic on BB

MANUFACTURING PROCESS LABORAROY

· Submission: Electronic on BB

· Instructions will be posted about the contents of the report