Manufacturing Process I

COURSE NUMBER & COURSE TITLE: ME 362 Manufacturing Process I INSTRUCTOR:

Credits: 4

Language of instruction: Chinese / English

REQUIRED COURSE OR ELECTIVE COURSE: Required

TERMS OFFERED: Spring semester

COURSE STRUCTURE/SCHEDULE: 1. Lecture-6 classes per week 2. Lab-

PRE-REQUISITES: Material Mechanics Engineering Materials

ASSESSMENT TOOLS: 1. Class Attendance: 10% 2. Homework: 20% 3. Semester exams: 40% (each exam 20%) 4. Project and term paper: 30%

PROFESSIONAL COMPONENT: Engineering Topics: Engineering Science-3credits Engineering Implementation -1credit

TEXTBOOK/READING LIST 1. P.N.Rao. Manufacturing Technology. Beijing: China Machine Press. 2nd edition, 2012. 2. Jianglan Shi, Zhanxi Zhao. Fundamentals of materials forming technology. 2nd edition. China Machine Press, ISBN: 978-7-111-02657-0. 3. Bingheng Lu. Fundamentals of Mechanical Manufacturing Technology. 3rd edition. China Machine Press. ISBN: 978-7-111-07154-9. COURSE DESCRIPTION: This course will enable students to understand manufacturing processes and technology widely used in industry: casting, metal forming, welding, stamp-forming, powder-forming, machining principle, milling, turning, drilling, and grinding, non-traditional machining, will introduce the principle of machining process and machine tool, and cutting tool, will enable students to design typical manufacturing processes according to function and surface quality requirement, and will enable students to analyze the service performance of mechanical products related to manufacturing processes. COURSE OUTCOMES 1. Enables students to be aware of typical manufacturing systems widely used in industry application. (A3) 2. Master the manufacturing processes of casting, forming, welding, and powder forming, stamp-forming to generate bulk workpiece. (A5) 3. Master the principles of metal machining, tool wear, manufacturing processes of turning, milling, drilling, grinding, and broaching to generate the surface integrity of workpiece. (A5) 4. Enable students to design typical manufacturing processes, fixture, and assembly process and master the fundamental manufacturing knowledge to enhance the performance of workpiece. (A5) 5. Enable students to analyze the service performance of mechanical product related to the manufacturing processes. (B1,B3,B8,C3,C4) 6. Enable students to design manufacturing processes according to workpiece material, function requirement, surface quality, batch and economic requirement. (B2,B4) 7. Improve students’ confidence to optimize metal processing according to function and quality requirement of mechanical product. (B2,B4) 8. Improve the effectiveness to solve manufacturing process related problems by team efforts. (B2,B4) RELATED ME PROGRAM OUTCOMES: A5 Engineering fundamentals and skills B2 Identification, analysis and problem solving capacity PREPARED BY:

REVISION DATE: Jan. 16, 2013

Spring 2012 SYLLABUS Subject Title： Manufacturing Process I Subject Code: ME362 Credit Points: 4 Hours Assigned: 64

Lecture

56

Tutorial/Project

8

hours hours

Semester: Spring Pre-requisite: Mechanical principle, Mechanical design, Material science, Material mechanics

Course Description This course will enable students to understand manufacturing processes and technology used in industry: casting, metal forming, welding, stamp-forming, powder-forming, machining principle, milling, turning, drilling, and grinding, non-traditional machining, will introduce the principle of machining process and machine tool, and cutting tool, will enable students to design typical manufacturing processes according to function and surface quality requirement, and will also enable students to analyze the service performance of a mechanical product related to manufacturing processes.

Objectives 1. Enables students to be aware of typical manufacturing system widely used in present industry application. (A3) 2. Master the manufacturing processes of casting, forming, welding, and powder forming, stamp-forming to generate bulk workpiece. (A5) 3. Master the principle of metal machining, tool wear, manufacturing processes of turning, milling, drilling, grinding, and broaching to generate the surface integrity of workpiece. (A5) 4. Enable students to design typical manufacturing processes, fixture, and assembly process and master the fundamental manufacturing knowledge to enhance the performance of workpiece. (A5) 5. Enable students to analyze the service performance of mechanical product related to the manufacturing processes. (B1,B3,B8,C3,C4) 6. Enable students to design manufacturing processes according to workpiece material,

function requirement, surface quality, batch and economic requirement. (B2,B4) 7. Improve students’ confidence to optimize metal processing according to function and quality requirement of mechanical product. (B2,B4) 8. Improve the effectiveness to solve manufacturing process related problems by team efforts. (B2,B4)

Schedule Main topics Metal casting theory and process; Plastic forming theory and process （14 hours）

Hours Content 2 An introduction to manufacturing systems 2 Casting theory 2 Casting process and practice. Non-traditional casting process 2 Cast structure design and practice 2 Plastic forming theory 2 The basic laws for forming and the evaluation of the forming process 2 FLD ； plate forming, non-traditional forming. Tutorial 2 Summary and discuss Metal Joining theory 2 Welding theory. Stress and strain and process; generated from welding process Non-metal forming 2 Metal welding quality; metal pressure theory and welding process. technology; 2 Advance welding method; welding （10 hours） structure design and process. 2 Advanced mechanical joining methods. 2 Advanced manufacturing process related to powder forming, ceramic, compound materials and etc. Tutorial 2 Summary and discuss 2 Semester exam 1 Machining method. 2 Metal machining theory and cutting 2 tool （10 hours） 2

Tutorial

2 2 2

Practice Assigned homework

Assigned homework

Mechanical machining method: turning, Project drilling, milling, grinding, and etc. topics Surface generation principle and discussion non-traditional machining processes Machining principle related with forces, temperature and associated physical phenomenon Cutting tool geometry and materials Cutting tool wear and life prediction. Summary and discuss

Machine tool and 2 fixture design; 2 machined surface 2 quality and 2 manufacturing 2 process control. （10 hours） Tutorial 2 2 Project 6

Machine tool. Jig/fixture design. Location and fixture and error analysis Surface integrity and control Design manufacturing processes

Defense

Report as each group

Grading Criteria:

Summary and discuss Semester exam 2 Practice

2

Assigned homework

Project assigned

Grading will be on an A+/- etc…Scale

Class Attendance: 10% Homework: 20% Semester exams: 40%

(each exam 20%)

Project and term paper: 30%

Textbook 1.

P.N.Rao. Manufacturing Technology. Beijing: China Machine Press. 2nd edition, 2012.

References books 1.

J. T. Black., R. A. Kohser. De Garmo’s Materials & Processes in Manufacturing. 12th edition. John Wiley & Sons. 2012.

2.

Serope Kalpakjian, Steven R.Schmid. Manufacturing Engineering and Technology. China Machine Press.

3.

Jianglan Shi, Zhanxi Zhao. Fundamentals of materials forming technology. 2nd edition. China Machine Press, ISBN: 978-7-111-02657-0.

4.

Bingheng Lu. Fundamentals of Mechanical Manufacturing Technology. 3rd edition. China Machine Press. ISBN: 978-7-111-07154-9.