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EME 242 Manufacturing Processes           3 credits       Pre: None

Description:
This is an in-depth study course in manufacturing processes.  This course presents and explains a wide variety of manufacturing methods, identifies the types of work and the materials each manufacturing process can be used for, and discusses appropriate design concepts that work well or do not work well for each method.  Students will also gain hands-on experience with the following machine tools and manufacturing methods: lathe, mill, drill press, cut saw, welder, casting process, and simple forming processes. The course will also include tours of local manufacturing facilities to view the practice of commercial manufacturing processes. 

     The importance of this course is to understand that when goods are manufactured, there are limitations imposed on the goods by the methods available to make them, and these limitations must be considered in the design process.

   
Objectives:
      To learn about a variety of manufacturing methods
      To learn about limitations and capability of manufacturing methods
      To gain hands-on skills with common metal working equipment
      To improve problem solving and technical communication competancies
      To develop ability to work as a teams in project completion

Meeting Times:
        For January 2010 Term: Mon-Fri from January 4th to  22nd
        Daily Schedule: M-F
             Lecture at 11:00 - 12:00 a.m. in Science 118
             Video Presentation at 12:00 a.m. in Science 118
             Workshop 1:  8:30 -10:50 a.m. in Science 40
                               2: 1:00 -3:20 a.m. in Science 40

Text:
         Manufacturing Process for Technology by William Fellers and William Hunt

Site Tours:

Lectures:  (to be added to the website as generated)
  Lesson 01:  Introduction to Manufacturing Processes
  Lesson 02:  Measurement
  Lesson 03:  Machining and Material Removal
  Lecture 04:  Material Addition and Nonmechanical Removal Methods
  Lecture 05:  No lecture...lab runs through lecture
  Lecture 06:  Tour Day 1
  Lecture 07:  Casting Processes
  Lecture 08   Forging  and Bending
  Lecture 08:  No Lecture...lab runs late
  Lecture 09:  Welding and Joining
  Lecture 11:  Tour Day 2
  Lecture 12:  Plastic Processing
  Lecture 13  Glass and Ceramic Processes
  Lecture 14:  Finishes and Surface Treatments
  Lecture 15:  Exam

Laboratory:  (to be added to the website as generated)
  Lab 01:  Part ID and Web-site Development
  Lab 02:  Measurement Lab
  Lab 03:  Woodworking Project...Wooden Train Whistle
  Lab 04:  Sheet Metal Project...Match Box
  Lab 05:  Machining Project....Widget
  Lab 06:     on Tour
  Lab 07:  Casting Project...Mold Making
  Lab 08:  Welding Project...Pencil Holder
  Lab 09:  Casting Project:  Pouring the Casts
  Lab 10:  Thermoforming and other catch up work
  Lab 11:   on Tour
  Lab 12:  Project Work Day 1
  Lab 13:  Project Work Day 2
  Lab 14:  Project Work Day 3
  Lab 15:  Project Work Day 4  and Presentations

Web Report Projects:
One of the project of this course was to write a web site which explained the manufacturing methods used to make a small part that each student was given on the fist day of class.  The following links point to each student's web report:

      Lego Block  web report  by Michael Calafiore
      Chain  web report  by David Corcos
      Crayons  web report  by Daniel Dobson
      Coffee Cup   web report  by Mary Gales
      Balloons   web report by Emily Garberson
      Matches  web report by Matthew Hanson
      Copper Elbow web report by Samuel Heston
      Nut and Bolt web report by Andrew Kelchen
      Styrofoam Cup web report by Gautam Lageju
      Craft stick  web report by Daniel Moore
      Plastic Dinosaur Toy  report by Blake Neebel
      Screwdriver: web report by Samuel Ross
      Battery web report by Michael Saydak
      Washer  web report by Joseph Wolter
    

Prerequisites:
There is no course prerequisites, however students are who do have a CAD and website development background will have some advantage. 

Homework and Policy: 
Homework assignments will be attached to Lecture Notes.  Homework will be due the day after it has been assigned.  Late homework will not be accepted.  Homework solutions will be posted on this website as they become available and after the due date.

Homework Solutions: (posted as completed)

Examinations:
There will be a 60 minute closed-book, closed-note exam on the final day of the course.

Grades:
The grade will be entirely determined by the following components:
             Homework and Quizzes…………….…....10%
             Workshop and Lab Work...... ………….  20%
              Project …………………….... …………15%
              Website Development……………………15%
              Final Exam............................. ………….. 20%
              Attendance and Participation..…………....20%

Attendance Policy:
The majority of your learning is expected to be acquired during the hands-on work and by working with others so absence from any class or workshop is discouraged.  Absence from class or workshop will be penalized by loss of 1% of your overall grade for each occurrence.  Excessive tardiness to class will be penalized by a loss of 1/2% of your overall grade for each occurrence.  Absence for a tour day will be a loss of 3% of your grade. 

Links to other interesting related websites:

How Everyday Things are Made ...http://manufacturing.stanford.edu/hetm.html
This site has many videos of different manufacturing processes

 Class Photo:  January 18, 2010

Email: clark.merkel@rose-hulman.edu

Last Modified: Jan 18, 2010  

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