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ISE316

Fall 2010

ISE 316 Manufacturing Engineering I - Processes


Fall 2010 Class Time: Tu, Th. 10:15 11:15 AM. (DAN 218) 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

Instructor: Office:

Professor Richard A. Wysk, Ph.D.. Daniels Hall 414-A

Office Hours: Tu., Th. 11:30AM - 12:30 PM, Teaching Assistants: Li Yang TA Office: DAN 416
Office Hrs: Mon., 4:00-5:00 PM Wed., 4:00-5:00 PM

(or any time I am in my office)

TA1's E-mail: lyang5@ncsu.edu Lab Manager: Mr. Daniel Leonard (drl@ncsu.edu) Room DAN 100-A Prerequisites: Text Book: ISE 216 (Mfg. Eng. Practicum), MAT 200, IE/GC 210 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.

ISE316

Fall 2010

Week 1 Th.

Date 8/20

Topic Introduction of manufacturing The Nature of Materials

Textbook Lecture Notes


Chapt. 1 Chapt. 2

Lab(Th/Fr)

(No Lab)

Tu. Th.

8/24 8/26 8/31 9/2 9/7 9/9 9/14 9/16 9/23 9/25 9/28 9/30 10/5 10/7 10/9 10/11 10/12 10/14 10/19 10/21 10/26 10/28 11/2 11/4 11/9 11/11 11/16 11/18 11/23 11/25 11/30 12/02

Mechanical Properties of Materials Measurement and Inspection (1) Measurement and Inspection (2) Measurement and Inspection (3) Theory of Metal Machining Machining: Process Mechanics Machining: Turning and Related Processes Machining: Milling and Hole-making Processes Cutting Tool Technology Grinding and Other Abrasive Processes Grinding and Other Abrasive Processes Exam 1 - (in-class exam) Metals Fall break Casting: Fundamentals and Solidification Casting: Sand, Permanent Mold and Die Casting Sheet Metal Forming

Lab-I
Intro&Safety Lab-II Metrology Lab-III Casting

Chapt. 2 suppl. Chapt. 2 suppl.


Chapt. 2 suppl Chapt. 21 Chapt. 22 Chapt. 22 Chapt. 23 Chapt. 23 Chapt. 25 Chapt. 25

Tu. Th.

Tu. Th.

Tu. Th.

Lab-IV
Forming

Tu. Th.

Lab-V
Milling

Tu. Th.

Lab-VI
Turning

Tu. Th.

Chapt. 6 Chapt. 10 Chapt. 11 Chapt. 19

Lab-VII
Machining

Tu. Th.

Lab-VIII
Welding

10

Tu. Th.

(No Lab)

11

Tu. Th.

Forming: Bulk Forming: Sheet Shaping Processes for Plastics (No class Spring Holiday) Shaping Processes for Plastics Exam 2 - (in-class exam) Joining: Welding Processes Powder Metallurgy Grinding and Other Abrasive Processes Non-Traditional Machining and Thermal Cutting Non-Traditional Machining and Thermal Cutting Micro-Fabrication Technologies Electronics Assembly and Packaging Thanksgiving no class Nano-manufacturing Review

Chapt. 20 Chapt. 21 Chapt. 13

Product Manufacturing

12

Tu. Th.

g Lab) (No

13

Tu. Th.

Chapt. 13

Product Manufacturing

14

Tu. Th.

Chapt. 31 Chapt. 16 Chapt. 26 Chapt. 26 Chapt. 37 Chapt. 38

Product Manufacturing

15

Tu. Th.

g Product
Manufacturing

16

Tu. Th.

g Project
Report due

17

Tu.

ISE316 Exam 3 (08:00 AM scheduled by the University)

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) Total 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) 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 groups. 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 students 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 assignments 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 States 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.