Ahad Ali, Ph.D. Assistant Professor  Department of Mechanical Engineering Lawrence Technological University 21000 West Ten Mile Road Southfield, MI 48075 Tel: 248-204-2531, Fax: 248-204-2576 Email: aali@ltu.edu

Center for Integrated Manufacturing Systems Intelligence (CIMSI)

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EME 3023 Manufacturing Processes

Spring 2008

Lecture:         Monday and Wednesday, 2:00 - 3:15 pm

Classroom:     E211

Office hours:   Monday, Thursday and Friday, 3:30 – 5:30pm or by appointment

Office:             E037

Catalog Description:

Relationship between product engineering and manufacturing engineering, casting processes, bulk deformation processes, sheet metal processes, single cutting edge operations, multi-cutting-edge operations, random-cutting-edge operations, non-traditional machining, design for manufacturing, factory of the future.

The Internet Course site: Blackboard my.ltu.edu

Prerequisites: EGE1023 Engineering Materials

Course Content / Syllabus Topics:

         1. Introduction.

                  PART I: MATERIAL PROPERTIES AND PRODUCT ATTRIBUTES.

         2. The Nature of Materials.

         3. Mechanical Properties of Materials.

         4. Physical Properties of Materials.

         5. Dimensions, Tolerances, and Surfaces.

                  PART II: ENGINEERING MATERIALS.

         6. Metals.

         7. Ceramics.

         8. Polymers.

         9. Composite Materials.

                  PART III: SOLIDIFICATION PROCESSES.

         10. Fundamentals of Metal Casting.

         11. Metal Casting Processes.

         12. Glassworking.

         13. Shaping Processes for Plastics.

         14. Rubber Processing Technology.

         15. Shaping Processes for Polymer Matrix Composites.

                  PART IV: PARTICULATE PROCESSING OF METALS AND CERAMICS.

         16. Powder Metallurgy.

         17. Processing of Ceramics and Cermets.

                  PART V: METAL FORMING AND SHEET METALWORKING.

         18. Fundamentals of Metal Forming.

         19. Bulk Deformation Processes in Metal Working.

         20. Sheet Metal Working.

                  PART VI: MATERIAL REMOVAL PROCESSES.

         21. Theory of Metal Machining.

         22. Machining Operations and Machine Tools.

         23. Cutting Tool Technology.

         24. Economic and Product Design Considerations in Machining.

         25. Grinding and Other Abrasive Processes.

         26. Nontraditional Machining and Thermal Cutting Processes.

Textbook:

Groover, Mikell P., Fundamentals of Modern Manufacturing, 3rd Edition, John Wiley & Sons, Inc., ISBN 978-0-471-74485-6.

Grading Policy:        

Class Attendance                                  5%

Homework / Lab Projects                      20%

Mid-term exam #1                                 20%

Mid-term exam #2                                 20%

Final Exam                                            20%

Design Project                                      15%

A         4.0       91 – 100          A-            3.7           87 – 90                    B+           3.3           83 – 86

B         3.0       80 – 82            B-            2.7           74 – 79                    C+           2.3           67 – 73

C         2.0       60 – 66            F              < 60

Academic Honor Code:

Academic integrity and honesty are basic core values of Lawrence Technological University . Lawrence Technological University is committed to creating an academic community that values both individual and collaborative efforts that promote learning and discovery. Such a community expects honesty and integrity in the work of all its members.

Cheating will not be tolerated! LTU’s Academic Honor Code is in effect. Students caught is cheating will receive an F in the course without the chance of recomputation for GPA purposes. A note to this effect will be placed in the student’s file. A second offence will result in expulsion from the university. For details about Academic Honor Code see:  http://www.ltu.edu/currentstudents/honor_code.asp

Course Outlines:

Course Project:

Project will be conducted in teams of 2 persons. For each project, a team will select one component those provided.

The first part of the project will consist of analyzing (material, manufacturing process e.g. cast, forged, machined, molded etc) the component as provided. The design component characteristics (e.g. strength, shape, corrosion resistance, tolerance etc.) should be assessed and the manner in which the elected manufacturing process can produce a product (component) with these characteristics discussed.

For the second part of the project the objective is to suggest alternative approaches to manufacturing the component – this may involve individual changes (e.g. changes in process) or a coordinated suite of changes (e.g. material and process and (possibly?) design). Note that the suggested changes might not necessarily be “improvements”, particularly with respect to cost, but the alternative approach suggested should fulfill, as far as possible, the engineering requirements identified in part 1 – any shortfalls should be clearly stated.

Each student in the group will be required to make one class presentation on one of the above parts of the project. The 10 points (out of 100) attributable to the report will be subdivided as 6 points for content, 4 points for presentation. Note that since each student presenter will have only 5 minutes or so it will be particularly important to identify and focus on the key manufacturing issues.

For each project a typed (or word processed) report of not more than 6 pages total (including title page (if provided), figures, bibliography etc.) is required. This report should follow “normal business practice” for layout etc. (e.g. standard 81/2 x 11 inch paper, at least ¾ inch margins on all sides, type no smaller than 12 point etc.).

Each member of the group will write a report covering both aspects of the project. This report will be an individual effort – a group or joint report is unacceptable and will be graded as zero.