Appendix IB. Course Syllabi

IE 248 Introduction to Manufacturing Processes and Specifications

Description:
Theory, applications, and quality issues related to machining and other nontraditional material removal processes. Introduction to metrology, engineering drawings and specifications.

Prerequisites:(or concurrently) Mat E 271

Books:

1. Materials and Processes in Manufacturing, 8^th edition, DeGarmo, Black & Kosher (1997).
2. IE 248 Laboratory Manual, Peters (1999).
3. IE 248 Class Notes, Peters (1999).
4. Reference books (will be) on reserve in Parks Library. These books will be a valuable resource for the laboratory reports.

Objectives:

• Learn the fundamentals of machining operations, what is the mechanics behind the chip formation, the forces and friction that results and the effect of this on the quality of the workpiece. This includes the advantages and limitations of machining processes, the fixturing that is required and ways to automate the process.
• Learn the meanings of engineering drawings including geometric dimensioning and tolerancing.
• Understand the relationship between the functional surfaces of a part, the datums on the print, and how to utilize this in the fixture or measurement scheme.
• Have an understanding of the creative thinking process and apply that to engineering design problems.
• Be able to effectively work as a group to conduct the design projects and the laboratory experiments investigating the manufacturing processes and metrology.

Topics:

1. Overview of manufacturing within industrial engineering career
2. Engineering drawing
3. Design specifications
4. Datums and functional surfaces
5. Geometric dimensioning and tolerancing
6. Measurement instruments and measurement error
7. Machining processes: capabilities and limitations
8. Chip formation and orthogonal cutting model
9. Forces and friction in machining
10. Tool wear in machining
11. Tool materials
12. Surface roughness as a result of machining
13. Fixtures
14. Computer numerical control
15. Lasers and nontraditional material removal processes
16. Creative design and thinking
17. Concurrent engineering
18. Integrated product process development

Class/Laboratory Schedule:
The class meets 2 times a week for 50 minutes. Several teaching strategies are employed as appropriate. The classroom activities are supported by a semi-note packet to allow more time for discussion of the topics. There are 2 in class exams, plus the final, and approximately 10 quizzes or short assignments. The laboratory (which accounts for 40% of the grade), meets in sections of <= 16 students, once each weak for 110 minutes. Approximately half of the lab sessions are dedicated to laboratory experiments. For most of the experiments, the students conduct the experiment and operate the equipment with minimal direction and oversight. The other sessions are used for engineering drawing, engineering design activities, and operation of machine to understand its capabilities.

Contribution of Course to Meeting Professional Component:
The strong laboratory component of this class supports several professional components including conducting experiments, analysis of results, written communication and working as a team. The course also includes modern engineering tools and information and techniques towards engineering problem solving.

Relationship of Course to Program Objectives:
This course supports the objective of being able to integrate the engineering and business processes of an enterprise, particularly by understanding the impact of design and manufacturing on product cost.

How Assessed:
In addition to the end of the semester evaluations conducted by the University, the students in APM coordinate course evaluations about mid semester. I also conduct ‘5 minute’ evaluations when I feel there may be problems or am just curious of the student’s perception of the class.

Actions to Improve the Course:
Based on the feedback from the students, and knowledge I gain from working with industry, the course is constantly updated. At the most basic level, I am constantly gaining more examples, many of them actual parts, that I share with the class as appropriate. Laboratory exercises have gone through a tremendous change over the past 3 years, with plans for additional additions and improvements.

Prepared by: Frank Peters and Shaochen Chen 12/20/99