Manufacturing Processes (ME3613)

Pre-requisite(s)

None

Recommended Book(s)

Fundamentals Of Modern Manufacturing: Materials, Processes And Systems, 4th Edition By
Mikell P. Groover, Wiley & Sons

Reference Book(s)

Manufacturing Engineering And Technology, 6th Edition By Kalpakjan & Schmid, Prentice Hall

Course Objectives

This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life. The course objectives are as follows: 1. Recognize, understand and develop working knowledge of broad range of manufacturing processes that are used in the industry. 2. To compare the existing technologies used in casting, shaping, forming, property enhancing, joining and assembly process. 3. To apply the limitations and advantages of different manufacturing processes with an economic point of view to the industry. 4. To learn how component can be manufactured in sustainable manner and learn about the environmental hazards of different manufacturing processes.

Course Learning Outcomes (CLO)

  1. CLO-1: Relate processing operations (shaping, property enhancing and surface processing) with their process dynamics and performance. (C3)
  1. CLO-2: Relate machining operations with their process dynamics and performance. (C3)
  2. CLO-3: Relate joining operations with their process dynamics and performance. (C3)
  3. CLO-4: Compare, organize and select appropriate manufacturing processes, equipment and process parameters. (C4)

Course Contents

Chapter 1 – Introduction to Manufacturing – One lecture
Materials in manufacturing
Manufacturing Processes
Production Systems


Chapter 3 - Mechanical Properties of Materials – Two lectures
Stress–Strain Relationships
Hardness
Effect of Temperature on Properties

 

Chapter 10 – Fundamentals of Metal Casting – Two lectures
Overview of Casting Technology
Heating and Pouring
Solidification and Cooling

 

Chapter 11 – Metal Casting Processes – Three lectures
Expendable and Permanent Mold Casting Processes
Foundry Practice
Casting Quality
Product Design Considerations

 

Chapter 13 – Shaping Processes for Plastics – Four lectures
Properties of Polymer Melts
Extrusion
Injection Molding
Blow Molding and Rotational Molding
Polymer Foam Processing and Forming
Product Design Considerations

 

Chapter 16 – Powder Metallurgy – Two lectures
Characterization and Production of Engineering Powders
Conventional Pressing and Sintering
Alternative Pressing and Sintering
Product Design Considerations

 

Chapter 17 – Processing Of Ceramics – Two lectures
Processing of Traditional Ceramics
Processing of New Ceramics
Product Design Considerations

 

Chapter 18 – Fundamentals of Metal Forming – One lecture
Material Behavior in Metal Forming
Temperature in Metal Forming
Strain Rate Sensitivity

 

Chapter 19 – Bulk Deformation Processes in Metal Working – Three lectures
Rolling
Forging
Extrusion & Drawing

 

Chapter 20 – Sheet Metal Working – Three lectures
Cutting, Bending and Drawing Operations
Dies and Presses for Sheet Metal Processes
Sheet-Metal Operations Not Performed on Presses

 

Chapter 27 – Heat Treatment of Metals – One lecture
Annealing
Precipitation and Surface Hardening
Heat Treatment Methods and Facilities

 

Chapter 28 – Surface Processing Operations – One lecture
Industrial Cleaning Processes
Electroplating
Vapor Deposition Processes

 

Chapter 29 – Fundamentals of Welding – Two lectures
Overview Welding technology
Weld joint
Features of Fusion-Welded Joint

 

Chapter 30 – Welding Processes – Four lectures
Arc Welding
Resistance Welding
Oxyfuel Gas Welding
Other Fusion-Welding Processes
Solid-State Welding
Weld Quality
Weldability
Design Considerations in Welding

 

Chapter 31 – Brazing, Soldering, and Adhesive Bonding – One lecture
Brazing
Soldering
Adhesive Bonding

Mapping of CLOs to Program Learning Outcomes

CLOs/PLOs

CLO:1

CLO:2

CLO:3

CLO:4

PLO:1 (Engineering Knowledge)

 

 

 

 

PLO:2 (Problem Analysis)

 

 

 

PLO:3 (Design Development of Solutions)

 

 

 

 

PLO:4 (Investigation)

 

 

 

 

PLO:5 (Modern Tool Usage)

 

 

 

 

PLO:6 (Engineer & Society)

 

 

 

 

PLO:7 (Environment and Sustainability)

 

 

 

 

PLO:8 (Ethics)

 

 

 

 

PLO:9 (Individual & Team Work)

 

 

 

 

PLO:10 (Communication)

 

 

 

 

PLO:11 (Project Management)

 

 

 

 

PLO:12 (Life Long Learning)

 

 

 

 

Mapping of CLOs to Assessment Modules

Assessment Modules \ CLOs

CLO:1

CLO:2

CLO:3

CLO:4

Assignments (10%)

 

 

 

 

Quizzes (15%)

 

 

 

 

Class participation           (5%)

 

 

 

 

Midterm Exam (20%)

 

 

 

 

Final Exam (50%)