ISE316
Fall 2010
ISE 316 Manufacturing Engineering I - Processes
Fall 2010
Class Time: Tu, Th. 10:15 – 11:15 AM. (DAN 218)
Instructor:
Office:
Professor Richard A. Wysk, Ph.D..
Daniels Hall 414-A
Office Hours: Tu., Th. 11:30AM - 12:30 PM,
Lab Time: Th. 1:30-4:20 PM. (DAN 118)
Fri. 9:10-11:55 AM. (DAN 118)
Phone: 515-1549
E-mail: rawysk@ncsu.edu
(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 PM
TA1'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.
1
ISE316
Week
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Date
Th.
8/20
Topic
Fall 2010
Textbook
Lab(Th/Fr)
Introduction of manufacturing
Lecture Notes
(No Lab)
The Nature of Materials
Chapt. 1
Tu.
8/24
Mechanical Properties of Materials
Chapt. 2
Lab-I
Th.
8/26
Measurement and Inspection (1)
Chapt. 2 suppl.
Intro&Safety
Tu.
8/31
Measurement and Inspection (2)
Chapt. 2 suppl.
Lab-II
Th.
9/2
Measurement and Inspection (3)
Chapt. 2 suppl
Metrology
Tu.
9/7
Theory of Metal Machining Machining: Process
Chapt. 21
Lab-III
Th.
9/9
Mechanics
Chapt. 22
Casting
Tu.
9/14
Machining: Turning and Related Processes
Chapt. 22
Lab-IV
Th.
9/16
Machining: Milling and Hole-making Processes
Chapt. 23
Forming
Tu.
9/23
Cutting Tool Technology
Chapt. 23
Lab-V
Th.
9/25
Grinding and Other Abrasive Processes
Chapt. 25
Milling
Tu.
9/28
Grinding and Other Abrasive Processes
Chapt. 25
Lab-VI
Th.
9/30
Exam 1 - (in-class exam)
Tu.
10/5
Metals
Chapt. 6
Lab-VII
Th.
10/7
Fall break
Chapt. 10
Machining
Tu.
10/9
Casting: Fundamentals and Solidification
Chapt. 11
Lab-VIII
Th.
10/11
Casting: Sand, Permanent Mold and Die Casting
Chapt. 19
Welding
Tu.
10/12
Sheet Metal Forming
Th.
10/14
Tu.
10/19
Forming: Bulk
Chapt. 20
Product
Th.
10/21
Forming: Sheet
Chapt. 21
Manufacturing
Tu.
10/26
Shaping Processes for Plastics
Chapt. 13
g Lab)
(No
Th.
10/28
(No class – Spring Holiday)
Tu.
11/2
Shaping Processes for Plastics
Chapt. 13
Product
Th.
11/4
Exam 2 - (in-class exam)
Tu.
11/9
Joining: Welding Processes
Chapt. 31
Product
Th.
11/11
Powder Metallurgy
Chapt. 16
Manufacturing
Turning
(No Lab)
Manufacturing
Tu.
11/16
Grinding and Other
Abrasiveand
Processes
Non-Traditional
Machining
Thermal Cutting
Chapt. 26
g
Product
Th.
11/18
Non-Traditional Machining and Thermal Cutting
Chapt. 26
Manufacturing
Tu.
11/23
Micro-Fabrication Technologies
Chapt. 37
g
Project
Th.
11/25
Electronics
Assembly
and Packaging
Thanksgiving
– no class
Chapt. 38
Report due
Tu.
11/30
Nano-manufacturing
12/02
Review
2
ISE316
Exam 3 (08:00 AM scheduled by the University)
3
Fall 2010
ISE316
Fall 2010
COURSE STRUCTURE:
I. KNOWLEDGE BUILD PHASE
– Lecture Outline:
1. Introduction of manufacturing
2. Material removal processes
3. Metal forming and sheet metalworking
4. Casting and molding
5. Grinding and abrasive processes
6. Plastic forming processes
7. Non-traditional processes
8. Joining and welding processes
9. Powder metallurgy processes
10. Micro-fabrication technologies
II. HANDS-ON EXPERIENCE – Manufacturing Labs:
1. Introduction to lab safety and review of machines
2. Product design and Metrology
3. Casting Experiment
4. Metal Forming: Sheet Springback
5. CNC Machining: Machining Centers
6. CNC Machining: Turning Centers
7. Machining: Surface Finish and Lubricant Assessment Experiment
8. Welding and Weld Joint Strength Experiment
9. 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 inclass 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 23
December 2
Physical product due (4:00 PM)
Final report due (4:00 PM)
4
ISE316
Fall 2010
GRADING:
Homeworks
In-class Assignments and Quiz
Labs
Semester Lab Project
Participation
Tests (3)
10% (you are allowed to miss one homework)
15% (you are allowed to miss one in-class assignment)
10%
10%
5%
50% (16.7% + 16.7% + 16.7% of final)
Total
100%
ADMINISTRATIVE POLICIES
1. 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
group’s.
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 student’s 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 assignment’s 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
State’s 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