Department of Engineering Technology
College of Business and Technology
Western Illinois University - Quad Cities Campus
MET 321
Industrial Plastics & Composites Fabrication
3 Credit Hours
Spring Semester 2010
Suite 104 Caxton Building
Instructor: Dr. C. Ray Diez
Office: 135 Knoblauch Hall
Phone: 309/298-1091
Office Hours: QC 5:30 - 6:00 Th
e-mail: cr-diez@wiu.edu
General Course Information:
A.
Catalog Description: The study and application of composite and plastic materials, forming, molding and
other industrial processes.
B.
Textbook References: Strong, A.B. (2008). Fundamentals of composites manufacturing: Materials, methods,
and applications, (2nd ed). Dearborn, MI: Society of Manufacturing Engineers.
Lokensgard, E. (2004). Industrial plastics: Theory and application, 4th ed. Clifton Park, NY: Delmar Learning.
Course Objectives:
A.
To introduce and orient students to plastic and composite materials used in contemporary industry.
B.
To provide students with knowledge and experiences with a variety of forming, molding, and other industrial
processes.
C.
To engage students in discussion, debate, and activities related to the plastics and composites industry.
D.
To provide students with the opportunity to design a mold for either injection molding or composites lay-up.
E.
To instill in students the safety required for the plastics and composites industry.
F.
To provide students the opportunity to tour local plastics and composites industries.
G.
To provide students the opportunity to teach a short plastics or composites topic.
H.
To have student complete three journal article critiques/abstracts on the plastics and composites industry.
I.
Introduce the student to the composites manufacturing sectors of industry
J.
Introduce the student to composite materials and their applications
K.
Identify and describe various types of reinforcement materials and their applications
L.
Identify and describe various types of matrix materials and their applications
M.
Explain the structure of advanced polymer composites, metal matrix composites, and ceramic matrix composites
N.
Identify, describe and utilize appropriate composite processing techniques used to manufacture composite parts
O.
Identify, and describe, appropriate composite material testing procedures
P.
Identify and describe fabrication and assembly techniques of composite materials
Q.
Identify and describe damage control and repair of composite materials
R.
Understand health, safety, and environmental considerations while processing and using composite materials.
Method of Instruction:
The primary method of instruction will be through dialogue based on the outlined topics laboratory activities. This
will be accomplished through class discussions, guest speakers, observation, readings, and individual and/or group
project activities, plastics and composite company site tours, laboratory activities, and both oral and written reports.
Course Requirements:
A.
Each student is expected to read all assignments.
B.
Each student is expected to attend class lectures, sessions with speakers, and exams when scheduled in order to
complete course requirements.
FINAL EXAMINATION -
C.
Thursday, May 13, 2010: 6:00 PM
Each student will be required to write abstracts of three articles pertaining to the field of construction safety
and selected from periodicals pertinent to the profession. Each abstract is not to exceed one single-spaced,
typewritten page or two double-spaced, typewritten pages. At least one abstract article must be taken from
electronic media. Due dates for the journal critiques are as follows:
February 4
February 25
April 1
A topic from Weeks 1-5
A topic from Weeks 6-10
A topic from Weeks 11-16
D.
All students are expected to plan and participate in a group activity. The groups will be the same as required
for that assignment.
E.
All students are required to plan and design a mold for a composite item of their choice. The criteria will be
established by the instructor. This can be completed by an individual or in small groups.
F.
The student will complete all assigned individual and group projects/activities.
G.
The students will be evaluated in the following manner:
a. Quizzes and Class Participation
b. Reports and Journal Critiques
c. Individual and Group Projects/Activities
d. First Examination
e. Final Examination
5%
20%
25%
25%
25%
*WIU Policy - WIU policy – A temporary symbol of I (Incomplete) for a course may be given only when a
student, due to circumstances beyond his or her control, has been unable to complete the course requirements
within the official limits of the term. The circumstances must be documented to the instructor’s satisfaction.
Grading Scale:
The following 10 point scale will be used for this course.
90-100
A
80-89.99
B
70-79.99
C
60-69.99
D
59.99 and below
F
H.
I.
Special Course Costs:
To help cover the costs of this course, special costs of $25.00 will be charged to each student. This is payable to
Kristin in Knoblauch 135 by March 15, 2010. If the Special Course Costs are not paid by March 26th, 2010; those
costs will be doubled and turned over to the University for billing by the University.
Course Outline: (Tentative, final scheduling is being completed).
Week
Topic
pgs &/or site
1
Orientation, Syllabus & Introduction to the course
Introduction to plastics materials
& current status
Handouts
Powerpoint
2
Chemistry of Plastics, Health/Safety, Properties/Testing, &
Ingredients
Powerpoints
3
Characterization & Selection of Commercial Plastics
Machining & Finishing Processes
Powerpoints
4
Plastics processes (Molding, Extrusion, Laminating, Reinforcing,
Casting, Thermoforming, Expansion, Coating, & others
5
Design, Tooling & Mold-making
6
Labs (site to be determined)
7
Test 1. Weeks 1-6
8
Field Trip(s) to plastics/composites Mfg(s).
9
SPRING BREAK
10
Introduction to Composites and Their Applications, Matrices & Their
Properties, Unsaturated Polyesters, & Epoxies
Powerpoints
Specialty & High-Performance Thermosets, Thermoplastic Composites,
Ceramic & Metal Matrix Composites
Powerpoints
12
Reinforcements, Reinforcement Forms, Quality & Testing, Composite Design
Powerpoints
13
Laboratory Activities (site to be determined)
14
Sandwich Structures, Joints, & Processing Ops., Open Molding (Engineered &
Advanced), Compression molding, Resin Infusion
Powerpoints
Filament Winding/Fiber Placement, Pultrusion, Thermoplastic composite
Processing, Damage Prevention & Repair
Powerpoints
11
15
16
Powerpoints
Powerpoints
Laboratory Activities & Review (site to be determined)
FINAL EXAMINATION - Weeks 10-16 Thursday May 15, 2010 at 6:00 PM
PLUS --- Industry Tours --- TIME(S) TO BE ARRANGED
General Considerations:
A.
Assignments should be completed on time, as scheduled, and according to criteria established by the instructor.
B.
The instructor will be available during posted office hours for general assistance, although a prior appointment
is desired. For assistance other than posted times, please make an appointment with the instructor.
C.
Smoking is NOT permitted in Caxton Building.
D.
Safety glasses will be required for field trips audits/inspections.
E.
Should a problem occur, students should speak to their instructor first. If the problem is not resolved, meet
with the chair of the department. If the problem continues to be unresolved, go to the College of Business and
Technology’s Dean.
Students should observe the following sequence for the resolution of problems:
Student --- Instructor --- Chairperson --- Dean
F.
The last day to drop a course in the spring semester 2010 is April 4.
G.
The instructor reserves the right to alter content if necessary.
Statement on Academic Integrity:
Preamble
Western Illinois University, like all communities, functions best when its members treat one another with
honesty, fairness, respect, and trust. Students have rights and responsibilities
(http://www.wiu.edu/provost/students/) and students should realize that deception for individual gain is an
offense against the members of the entire community, and it is the student's responsibility to be informed and
to abide by all University regulations and policies on Academic Integrity.
Plagiarism, cheating, and other forms of academic dishonesty constitute a serious violation of University
conduct regulations. Students who engage in dishonesty in any form shall be charged with academic
dishonesty.
It is a duty of faculty members to take measures to preserve and transmit the values of the academic
community in the learning environment that they create for their students and in their own academic pursuits.
To this end, they are expected to instill in their students a respect for integrity and a desire to behave honestly.
They are also expected to take measures to discourage student academic dishonesty, to adjust grades
appropriately if academic dishonesty is encountered, and, when warranted, to recommend that additional
administrative sanctions be considered. Grading policies are the exclusive prerogative of the faculty;
administrative sanctions are under the authority of the Director of Student Judicial Programs. This document
provides policies and procedures to be followed when academic dishonesty is encountered.
Definitions of Academic Dishonesty
The following definitions and examples are not meant to be exhaustive. The University reserves the right to
determine, in a given instance, what action constitutes a violation of academic integrity. (See
www.wiu.edu/policies/acintegrity.php for complete descriptions of the following topics:
1.
Plagiarism
2.
Fabrication and Falsification
3.
Cheating
4.
Complicity in Academic Dishonesty
5.
Abuse of Academic Materials
6.
Multiple Submissions
Reporting Academic Dishonesty
All members of the University community share the responsibility and authority to challenge and make
known acts of apparent academic dishonesty. Any student, faculty member, or staff person who has witnessed
an apparent act of student academic dishonesty, or has information that reasonably leads to the conclusion that
such an act has occurred or has been attempted, has an ethical responsibility for reporting said act(s).
Confronting and reporting academic dishonesty can be done in a variety of ways, and people should choose
the manner most appropriate for the circumstances. Acts of apparent academic dishonesty that occur in the
classroom should be reported directly to the course instructor, and/or the course instructor's Department
Chair, and/or the instructor's College Dean. The Council on Admission, Graduation, and Academic Standards
(CAGAS) or the Graduate Council will not accept or act upon anonymous reports, but will hold in strict
confidence the identity of any person reporting a suspected instance of academic dishonesty, unless that
person consents to having his/her identity revealed.
Access & Disabilities:
In accordance with University policy and the Americans with Disabilities Act (ADA), academic
accommodations may be made for any student who notifies the instructor of the need for an accommodation.
For the instructor to provide the proper accommodation(s), you must obtain documentation of the need for an
accommodation through Disability Support Services and provide it to the instructor. It is imperative that you
take the initiative to bring such needs to the instructor's attention, as he/she is not legally permitted to inquire
about such particular needs of students. Students who may require special assistance in emergency
evacuations (i.e. fire, tornado, etc.) should contact the instructor as to the most appropriate procedures to
follow in such an emergency. Contact Disability Support Services at 298-2512 for additional services.
If you have emergency medical information to share with me, if you need special arrangements in case the
building must be evacuated, or if you need accommodations in this course because of a disability, please make
an appointment with me as soon as possible. My office location and hours are at the top of this syllabus. If you
plan to request disability accommodations, you are expected to register with the Disability Support Services
(DSS) at 298-2512.
REFERENCES:
To be provided.