This course emphasizes the materials and processes used in manufacturing. Fundamentals include the properties, structure and nature of materials for manufactured goods, such as ferrous and nonferrous metals and alloys, plastics, composites and ceramics, and the selection of materials for various functions. Casting and form casting processes, mold castings, powder metallurgy, and metal and non-metal fabrication processes (injection moulding) are included. Material transformation processes and numerical control (NC) and computerized numerical control (CNC) machining centers are also covered. Additional assembly and joining processes include gas flame, arc, resistance, welding, brazing and soldering, adhesive bonding, and surface treatment and finishing. Manufacturing production and process quality control are integrated throughout the course.

Course Goals for the Students:

• Describe the relationship of product design, product function, materials used, and manufacturing processes used.
• Compare basic physical, mechanical, manufacturing properties, and testing methods of common engineering materials.
• Compare relative advantages/disadvantages of common engineering materials.
• Understand the relative advantages/disadvantages of common forming and shaping manufacturing processes.
• Understand the relative advantages/disadvantages of common machining manufacturing processes.
• Demonstrate the ability to calculate machining speeds and feeds for specific applications.
• Demonstrate the ability to define and document a manufacturing process.

Course Goals for the Instructor:

• To provide all students the tools necessary to succeed in their pursuit of a deeper understanding of the manufacturing processes of engineering materials.
• To provide all students with an atmosphere conducive to learning.
• To provide sufficient feedback, enabling students to gauge their progress towards achieving their goal in acquiring a mastery of the principles of manufacturing processes.
• To facilitate student learning through the use of appropriate technology and the illustration of engineering parts in real mechanical applications.

SYLLABUS

Class 1 Introduction to manufacturing processes

Class 2 Casting

- Sand casting

- Croning sand casting

- Lost wax casting

- Metallic mould

- Continuous casting

Class 3 Manufacturing with material removal: cutting tools

- Types of cutting tools

- Materials of cutting tools

- Wear mechanisms of cutting tools

- Parameters that influence wear

Class 4 Machining processes and machine tools: Turning

Class 5 Machining processes and machine tools: Turning and Milling

Class 6 Machining processes and machine tools: Milling

Class 7 Machining processes and machine tools: Drilling and Sawing

Class 8 Machining processes and machine tools: Grinding

Class 9 Forming and shaping processes

- Rolling

- Forging

- Extrusion

- Sheet metal forming

Class 10 Assembly processes

- Welding

- Brazing and soldering

- Adhesive bonding

- Riveting

Class 11 Non-metal fabrication processes: injection moulding

Class 12 Surface techniques

Class 13 Manufacturing in a competitive environment

- Cost / volume / profit analysis

- Speed to market