View
231
Download
2
Category
Preview:
Citation preview
INSY 3800: Materials and Manufacturing Processes (Required for B.I.S.E.)
Department of Industrial & Systems Engineering
Fall 2009
Instructor: Dr. Lewis Payton
E-mail: payton@auburn.edu
Office: DML in Shop Building 2/Phone (334) 844-3315
Office Hours: Mon. & Fri. 1:00 - 2:00 pm
Prerequisites: (MATL 2100) Introduction to Materials Science
Credit Hours: 3
Course Website: Maintained on Blackboard.
Lectures: Mon. & Wed. 9:00 - 9:50 am Shelby Center 1126
Labs: Per Blackboard
2009 Catalog Description: The AU Bulletin description is “Materials, measurement and
quality assurance. Manufacturing processes (casting, forming, materials removal, joining).
Processes and techniques related to manufacturing.”
Required Material:
Text: “Materials and Processes in Manufacturing” 9th Edition, Degarmo et.al. ISBN 0-471-
03306-5.
Dress code: No hats, sunglasses, loose clothing, ties, or jewelry. Closed toe shoes and
slacks are required whenever you are in the lab or on a tour. Hair must be worn up in a high
ponytail or bun. Beards must be neatly trimmed to less than 0.5 inches.
Course Learning Outcomes: Upon completion of this course, the students will:
a) Be able to communicate the design and production process for a simple mechanical
product
b) Be familiar with all the materials used in manufacturing
c) Be familiar with the all the processes used in manufacturing
d) Be familiar with all non-destructive and destructive testing techniques used in
manufacturing
e) Be able to do 2D and 3D CAD drawings of wiring harnesses and other assemblies
f) Be able to do simple sheet metal drawings
g) Be familiar with the concepts of Computer Numerically Controlled machines
h) Be familiar with the FANUC CNC Control languages and MasterCAM
i) Understand the relationships between CAD/CAM/CIM
j) Be familiar with data acquisition methods such as LABVIEW
Grading Policy: The following is a description of how grades will be calculated:
Weighted grades on quizzes, homework assignments, exams, and labs will be based on the
following scale:
Short Quizzes, 10 (drop lowest grade) 300 Points
Homework Assignments 30-50 Points
Exams, 3 300 Points
Final Exam 150 Points
Labs, 12-14 150-200 Points
Total Points Possible 1000 Points
Final course grades will be determined based upon points obtained in course:
Student’s Total Points > 900 A
Student’s Total Points > 800 B
Student’s Total Points > 700 C
Student’s Total Points > 600 D
Student’s Total Points ≤ 600 F
Topics Covered:
Lecture Topics Labs
Safety and Material Safety
Metals and Alloys Mechanical Testing/Load Frame labs
Plastics and Powder Materials Metrology Labs
Composite Materials
Non-destructive testing procedures Part Modeling/Hand Tools
Process Capability/Fundamentals of CASTING SE Schematics/Casting Demos
Advanced Casting Processes/Powder Metallurgy Process Assemblies
Sheet Metal Processes/Forging Processes
Friction in Metal Working/Extrusion Processes Schematic Drawings
Fabrication of Plastics & Composites/Intro to Metal cutting Engineering Calculation Tools
Drilling, milling, broaching, lathes, Gear Production Molded Parts
Non-traditional Machining Methods, Abrasive Machining
Work holding/Rapid Prototyping
CNC Processes/Welding Processes Rendering CNC Operations
Welding Processes/Joining Processes CNC Operations
Electronic Circuit Boards/Golden Rules of Design
ABET Outcomes: Assessments:
(a) An ability to apply
knowledge of
mathematics, science,
and engineering
Students are tested on their understanding of Fundamentals of
Materials Science, including strength of materials and solids,
dislocation dynamics and work hardening as they apply to
modern manufacturing processes in the American Southeast.
Students must exhibit a working knowledge of the terminology
of metal cutting and deformation, plastic formation, composite
formation, powder metallurgy, forging, casting, and rapid
prototyping. Non-destructive testing is emphasized although all
destructive testing methods are also covered for each process.
(c) An ability to design a
system, component, or
process to meet desired
needs
Lab grades from a lab where the students design a manufacturing
cell (part of a manufacturing system)
Lab grades from a lab where the students design a NC process
plan to make a fatigue specimen
Lab grades from a lab where the students design a NC process
plan to make a three axis NC machine (a work holding device).
Syllabus Prepared by: Dr. Lewis Payton
Date: 8-17-09
INSY 3800 – Manufacturing Systems I
Spring 2012
1 of 3
Course Title: INSY 3800 Manufacturing Systems I Department: Industrial and Systems Engineering Credit Hours: 3 hours (2 hours lecture, 1 hour lab) Designation: Required Prerequisites: None Web site: Blackboard Instructor: John L. Evans
3308 Shelby Transportation jevans@eng.auburn.edu 844-1418
Office Hours: M 1:00 – 2:30 PM W 10:00 to 11:30 AM
G.T.A.: TBD
Course Time and Location: Lecture: Tuesdays/Thursdays, 12:30 PM – 1:45 AM, Shelby 1122; Lab: Wednesdays 3:30-6:00 PM, Shelby Basement Lab Course Text: Mikell P. Groover, Automation, Production Systems, and Computer-IntegratedManufacturing, 3rd Edition, 2007, Prentice Hall, Upper Saddle River, NJ References: Askin, Ronald G., J.B. Goldberg, Design and Analysis of Lean Production Systems, 2001, 1st Edition, John Wiley & Sons, New York, NY; Goldratt, E. M., The Goal, 1992, 2nd Revised Edition, North River Press, Great Barrington, MA. Course Description: Introduction to the design, analysis, and operation of manufacturing systems, the first course in a required two-course sequence including Manufacturing Systems II. Course Objectives: Through class instruction and discussion, homework assignments, exercises and team case studies, students will develop a general understanding of the basic concepts and practical models in manufacturing systems analysis and design, and be able to apply these concepts and models in the design and evaluation of basic manufacturing systems. Course Requirements and Evaluation: Students will be evaluated based on the following assignments and exams: Description Date Weight Exam 1 Week 6 – in class 25% Exam 2 Week 10 – in class 25% Final Exam per AU schedule 35% Team Homework/ Case Studies 15%
Class Policy Statements: Exams will be closed book & closed notes. Grades will be based on minimum of 10 point systems (The instructor may scale grades if appropriate). Students must maintain a weighted average of 55% on the three exams (including final) to be eligible to pass the class with a D average or better. The University academic honesty policies will be strictly enforced. Please refer to the Tiger Cub for details about these policies and procedures. Students with Disabilities: Any student with a disability needing special accommodation should notify the instructor and contact Dr. Kelly Haynes, Director of the Program for Students with Disabilities, located in 1244 Haley Center, Auburn University.
INSY 3800 – Manufacturing Systems I
Spring 2012
2 of 3
Course Topic Outline:
Date Topic Chapter/Reference Lab
1/10 Introduction to Manufacturing Systems Chapter 1
1/12 Manufacturing Operations Chapter 2
1/17 Manufacturing Models (with LP) Chapter 3 Lab #1 - LP
1/19 Manufacturing Models (with LP) Chapter 3 Lab #2 - Automation
1/24 Introduction to Automation Chapter 4
1/26 Industrial Control Systems Chapter 5 Lab #3 – Industrial Hardware
1/31 Hardware Components for Automation Chapter 6
2/7 Computer Numerical Control Chapter 7 Lab #4 - CNC
2/9 Computer Numerical Control Chapter 7
2/14 Industrial Robotics Chapter 8 Lab #5 - Robotics
2/16 Test #1 – Manufacturing Models and Operations
Homework
2/21 Casting Lab #6 - Casting
2/23 Metal Forming Methods Extra Material
2/28 Metal Forming Methods Extra Material Lab #7 – Metal
Forming
3/1 Plastic Molding Operations Extra Material
3/6 Joining and Welding Extra Material Lab #8 – Joining /
Welding 3/8 Joining and Welding Extra Material
3/13 Machining Extra Material
3/15 Machining Extra Material
Lab #9 – Machining
3/27 Test #2 – Manufacturing Processes Chapter 15
3/29 Material Handling & Identification Technologies
Chapter 10
4/3 AS/RS Systems Chapter 11 Lab #10 – AS/RS
INSY 3800 – Manufacturing Systems I
Spring 2012
3 of 3
4/5 RFID Chapter 12
4/10 Manufacturing Systems Chapter 13 Lab #11- RFID
4/12 Single Station Manufacturing Cells Chapter 14
4/17 Manual Assembly Lines Chapter 15 Lab #12- Manual
Stations
4/19 Automated Production Lines Chapter 16 Homework
Team Case 5
4/24 Automated Assembly Lines Chapter 17 Lab #13-
Automated Assembly
4/26 Cellular Manufacturing Chapter 18
5/1 Flexible Manufacturing Systems Chapter 19
TBD Final Exam All Class Material
Contribution to Meeting the Professional Component Manufacturing systems engineering offers the student a comprehensive understanding of the tools and techniques needed to meet the challenging manufacturing environment. Specific focus is placed on the ability of the student to apply his or her knowledge to an actual manufacturing problem. The goal is to ensure the student is ready to meet the need of the manufacturing industry upon completion of this course. Relationship to Program Outcomes While this course relates to several of the department’s stated ABET outcomes, the two outcomes for which assessments are taken are: c) an ability to design a system, component, or process to meet desired needs and g) an ability to communicate effectively. The first outcome (c) is defined in three areas (facility layout, automated storage capacity, and station sequencing) and is intended to show an ability to design specific manufacturing needs based on facility or throughput requirements. The second outcome (g) is intended to evaluate the student’s capability to understand a complex manufacturing engineering problem, formulate a solution and present this solution to the class in a comprehensive manner.
Recommended