Department of Industrial & Manufacturing Engineering & Technology
1. Course Title:
2. Description:
IME 441
Materials Processing I
3 Semester Hours
Principles, techniques, limitations, and applications of metal cutting and forming processes.
Phenomena of tool life, tool wear, surface integrity, resultant properties, and tolerances of these
operations. Traditional forging, rolling, drawing, and extrusion processes; processing limits and
resultant effects on material and component. properties. Non-traditional methods and processing
economics. Extensive laboratory work.
3. Prerequisites:
IME 311, 341 or consent of instructor
4. Textbook:
Manufacturing Processes for Engineering Materials" Fourth Edition, Serope Kalpakjian, Prentice
Hall Publishing Co., 2003
References:
Manufacturing Engineering and Technology, Fifth Edition, Serope Kalpakjian, Prentice Hall
Publishing Co., 2006.
5. Course Objectives:
Contributes to Student Outcomes
Item
Description
EAC MFE
A.
To acquaint and motivate the student with the complex and interdisciplinary nature a b, j
of manufacturing processes through a balanced coverage of relevant fundamentals
and real world problems.
B.
To introduce primary and secondary forming processes and to develop a skill for a, d
analysis of these processes.
C.
To introduce several traditional and non-traditional material removal processes and d, j
to initiate original thinking in judicious selection of a particular process.
D.
To encourage individual initiative in sound analysis of a component with regard to d
strength, material interrelationships that exist among many factors involved and their
impact on practical considerations.
E.
To perform a series of well-designed experiments covering a wide range of topics
c, d, e, i
from measurement of accuracy of machined part to measurement of surface finish,
cutting forces, tool life/wear/temperature.
6. Topics:
1.
LECTURE
 Introduction to Manufacturing
 Mechanical and Metallurgical Behavior of Materials
 Bulk Forming Processes
 Sheet Forming Processes
 Mechanics of Chip Generation
 Energies and Heat in Cutting
 Cutting Tools and Fluids
 Tool Wear and Tool Life
Contributes to Course Objectives (5.)
Objectives
A
A
A, B
A, B
B, C
C, D
C, D
C, D
2.
LABORATORIES
 Introduce the concepts of safety in the labs
 Introduce all the measuring tools used in the labs
 Introduce all the cutting tools used in the labs
 Introduce machine tools such as lathe, drill, and mill
 Lab project on use lathe, drill and mill
E
3.
PAPERS/PROJECTS
To provide open ended lab projects requiring
 Study of the lab project at hand
 Brainstorming the various alternatives
 Getting good feel for the available resources, equipment and time
 Designing experiments
E





Conducting experiments
Recording appropriate responses using both strip chart recorder and data
acquisition system
Charting the data collected from experiments
Critical examination of the effect of process parameters on the measured
responses
Making inferences and making recommendations
7. Class Schedule: Two lecture sessions of 50 minutes and one lab session of 100 minutes per week
8. Contribution of Course to Meeting the Professional Component:
Communications
0.0 hrs
Mathematics
0.0 hrs
Physical and Natural Science
0.0 hrs
Social Sciences and Humanities
0.0 hrs
Technical Content
3.0 hrs
9. Relationship of Course to MFE Student Outcomes: (based on 1 to 5 scales, 5 denotes very strong
continuation to the student outcome and blank cell denotes that the course does not continue the related
student outcome)
Cod
e
a
b
c
d
e
f
g
h
i
j
k
Student Outcomes, A Graduate from the Program Will Have:
Manufacturing Engineering graduates will have an ability to apply knowledge of
mathematics and science to manufacturing processes, materials, and design of
manufacturing systems
Manufacturing Engineering graduates will have an ability to design and conduct
experiments, and to analyze and interpret data related to manufacturing processes, materials
evaluation, and manufacturing systems
Manufacturing Engineering graduates will have an ability to design, select, implement, and
control a manufacturing system and its components or processes to meet desired needs
Manufacturing Engineering graduates will have an ability to function on multi-disciplinary
teams and the ability to apply a concurrent approach and project management to process
and product development
Manufacturing Engineering graduates will have an ability to identify, formulate, and solve
manufacturing engineering problems through a hands-on approach that considers
constraints, costs, benefits, and comparative processes and materials
Manufacturing Engineering graduates will have an understanding of the professional and
ethical responsibilities of a manufacturing engineer
Manufacturing Engineering graduates will have an ability to effectively communicate
technical concepts through appropriate methods
Manufacturing Engineering graduates will have an understanding of the impact of
manufacturing engineering solutions in a global, economic, environmental, and societal
context
Manufacturing Engineering graduates will have a recognition of the need to engage in
lifelong learning
Manufacturing Engineering graduates will have a knowledge of contemporary issues facing
manufacturing engineers
Manufacturing Engineering graduates will have an ability to use the proper techniques,
skills, and modern engineering tools necessary for manufacturing engineering practice
utilizing supporting technologies
10. Prepared by: Iqbal Shareef 10/2013
Reviewed by: Curriculum Committee
Contribution
3.2
3.71
3.25
3.71
—
3
3
3.75
—
2.5
3.25