ENGR 232 - MANUFACTURING PROCESSES
An introduction to the basic tools, processes and materials of manufacturing. The manufacturing enterprise is examined with special attention to key organizational systems including production and inventory control, quality control, marketing and finance. In addition, fundamental processes of the metals and plastics industries are treated in depth.
1. Amrine, Ritchey, Moodie, & Kmec: Manufacturing Organization and Management, Prentice Hall, 1993.
2. Schey: Introduction to Manufacturing Processes, McGraw Hill, 1999.
office: Armstrong 139
phone: 771 - 2772
web page: http://www.tcnj.edu/~hess/index.html
1. To develop both a theoretical and a practical understanding of how the various forming operations are utilized within the manufacturing production system. (1, 2 & 6)
2. To develop both a theoretical and a practical understanding of material joining processes and an understanding of their contribution to the production system. (1, 2 & 6)
3. To develop both a theoretical and a practical understanding of material casting processes and develop an understanding of the dependent and independent variables which control materials casting in a production setting. (1, 2 & 6)
4. To develop both a theoretical and a practical understanding of conventional and automated machining processes, and to develop an understanding of their contribution to the manufacturing production system. (1, 2 & 6)
5. To develop a fundamental understanding of the elements of manufacturing organization and management which would be applicable to a wide variety of manufacturing and business concerns. (1, 2, 3, 4 & 7)
6. To develop competency in organizing and presenting written and oral reports concerning manufacturing production. (5 & 7)
7. To develop competencies in collaborative learning strategies through inter/intradisciplinary group activities. (2 & 3)
Prerequisites by Topic:
Basic engineering computational skills.
Topics: (one 2 hr. lecture session/wk and one 3 hr. lab session/wk)
Week Topic - Reference
|1.||Lect.||1.1 Intro to Course - Outline Handout|
|1.2 Introduction & Assignment Of Reverse Engineering Exercise -Handout|
|1.3 Intro To Metal Cutting (Single Point Machining) - Schey: pp. 663-672|
|Lab.||1.1 Demo Lathe Turning (Bolt) And Related Safety|
|1.2 Laboratory Organization|
|2.||Lect.||2.1 Joining Metals (Welding Methods)- Schey: pp. 745-786|
|2.2 Polymer Welding -Handout|
|2.3 Welding H.W.|
|Lab.||2.1 Demo Polymer Welding And Related Safety|
|2.2 Demo.Shielded Metal Arc Welding And Related Safety|
|2.3 Open Lab|
|3.||Lect.||3.1 Industrial Activities & Systems - Amrine: Chs. 6 & 24|
|3.2 Cost & Value, Principles Of Engineering Economics - Amrine: Chs. 14 & 15|
|Lab.||3.1 Open Lab|
|4||Lect.||4.1 CNC Programming Of G & M Codes - Handout|
|4.2 Automated Manufacturing - Schey: pp. 34-38 & 679-680 & Handout|
|4.3 Solid Object Printer Processing - Handout|
|Lab.||4.1 Demo CNC Mill Operation And Related Safety|
|4.2 Reverse Engineering Product Analysis Due|
|4.3 Open Lab|
|5||Lect.||5.1 Metals Casting Design Processes - Schey: pp. 185-234|
|5.2 Casting H.W|
|.||5.3 Pro/E Review -Handout|
|Lab.||5.1 Mass Polymer Casting (Silicon Mold) And Related Safety|
|5.2 Open Lab|
|5.3 Welding Lab Due|
|6||Lect.||6.1 General Foundry Practices|
|6.2 Pro/E to CNC Manufacturing Module -Handout|
|Lab.||6.1 Demo Foundry Processes & Mold Construction Plus All Related Safety|
|6.2 Open Lab
6.3 Solid Object Printing Design Due With STL File
|7||Lect.||7.1 Review For Exam|
|7.2 Polymer Casting - Schey: pp. 554-556 & Handout|
|7.3 Pro/E To CNC Manufacturing Module -Handout|
|Lab.||7.1 Pro/E Manufacturing Demo (CNC Milling) Plus Related Safety|
|7.2 Open Lab|
|8||Lect.||8.1 Exam (two hours)|
|Lab.||8.1 Mass Polymer Casting (Polyester or Urethane) Into Silicone Mold Plus Related Safety|
|8.2 Demo. Thermoforming & Blow Molding - Schey: pp. 581-582 & 577-580 & 557-559|
|8.3 Open Lab|
|8.4 Machining Lab Due|
|9||Lect.||9.1 Review Exam|
|9.2 Manufacturing Engineering - Amrine: Ch. 18 & Handout|
|9.3 Production Planning & Control Systems - Amrine: Ch. 18|
|9.4 Control H.W.|
|Lab.||9.1 Demo. Injection & Compression Molding - Schey: pp. 566-570 & 571-572|
|9.2 Open Lab|
|10||Lect.||10.1 Cost-Materials & Labor - BOM & Product Structure Tree -Handout & Amrine: Chs. 14 & 15|
|10.2 Review Reverse Engineering Project|
|10.3 BOM H.W.|
|Lab.||10.1 Open Lab|
|10.2 Test Solid Object Printing Processing Product|
|10.3 CNC Lab Due|
|11||Lect.||11.1 RE Project Planning|
|Lab.||11.1 Open Lab|
|12||Lect.||12.1 Materials Handling - Schey: pp. 877-880 & Amrine: Ch. 12|
|12.2 Hot & Cold Forming - Schey: Chs. 8 & 9|
|12.3 Cold Work H.W.|
|Lab.||12.1 Open Lab To Cast All Molds|
|13||Lect.||13.1 Injection & Compression Molding Plus Polymer Casting|
|13.2 Thermoforming & Blow Molding
13.3 Reverse Engineering - Status Review
13.4 Presentation Techniques
|Lab.||13.1 Open Lab|
|13.2 Casting Lab Due|
|14||Lect.||14.1 Review for Final Exam|
|Lab.||14.1 Reverse Engineering Presentations - 10 min. each|
|14.2 Reverse Engineering Report Due|
1. CNC programming using G & M codes.
2. Pro/E modeling to CNC manufacturing operations.
3. Word processing required of all reports, research projects and encouraged for all homework assignments.
1. Metal casting design - one (1) aluminum full mold casting exercise performed with design problem analysis of runner, gate and riser systems. Polymer casting - silicon and urethane materials.
2. Machining exercises including one (1) turning exercise with drilling and sawing support activities.
3. Joining processes including one (1) shielded metal arc welding exercise with joints destructively tested plus one (1) plastics welding exercise.
4. CNC programming - writing a program using G & M codes and producing one part machined on a 3-axis milling machine.
5. Subtractive manufacturing design - solid modeling to CNC manufactured parts on a 3-axis CMC milling machine.
6. Polymer processing - parts produced with injection, compression, thermoforming and blow molding equipment.
7. Additive manufacturing design - solid modeling to solid object printing manufacturing with a solid object printer.
8. All students will be assigned to lab groups of three or four. Lab data will be collected by each group and lab reports will be individually written.
1. Students are expected to attend all classes, both lecture and labs.
2. All laboratory activities will be analyzed and documented in a written laboratory report. These reports will be individually prepared on a word processor and will be organized according to the "Laboratory Report Requirements" attached. Laboratory materials, where indicated, will accompany each written report. The laboratory materials and reports will contribute 35% to the final grade.
Note: All laboratory activities and term projects must be submitted or the student risks a grade of "F" for the course.
3. Each student will complete a "Reverse Engineering Project" which will include both a written and oral report. Both parts of the project are due the fourteenth week of the semester. The written part of this project will contribute 20% to the final grade and the oral part of the effort will contribute 10% to the final grade.
4. Students are expected to complete homework assignments prior to the next class meeting, preferably prepared on a word processor. They may however be neatly hand written and turned in on either plain or lined paper.
5. There will be one (1) midterm test plus one (1) final exam. The midterm test is scheduled for the eighth week of the class and the final exam is scheduled for the finals week. Open textbooks and notes will be permitted for parts of each test. The midterm test will contribute 15% to the final grade and the final exam will contribute 20% to the final grade.
6. Group evaluation using the "Group Activities Evaluation form".
1.1 Students will demonstrate proficiency in the techniques of various forming operations. [2, 3, 4 & 5]
1.2 Students will demonstrate a theoretical analysis of various forming techniques and their application to the manufacturing process. [2, 3, 4 & 5]
2.1 Students will demonstrate proficiency in the techniques of various joining operations. [2, 3, 4 & 5]
2.2 Students will demonstrate a theoretical analysis of various joining techniques and their application to the manufacturing process. [2, 3, 4, & 5]
3.0 Students will demonstrate design proficiency in the development of metal casting patterns. [2, 3, 4 & 5]
4.1 Students will demonstrate proficiency in both conventional and automated machining techniques. [2, 3, 4 & 5]
4.2 Students will demonstrate proficiency in programming for CNC operations utilizing G & M codes. [2, 3, 4 & 5]
4.3 Students will demonstrate proficiency in designing parts using Pro/E, and then producing the parts utilizing the CNC 3-axis milling machine and the solid object part printer. [2,5 & 6]
5.0 Students will demonstrate an understanding of the organization and management of the manufacturing process. [3 & 5]
6.0 Students will demonstrate a proficiency in presenting written and oral reports. [2 & 3]
7.0 Students will evaluate the effectiveness of the group's performance by completing the departmental "Group Activities Evaluation Form". 
1. Percentage make-up of grades:
a. Final exam--------------------------- 20%
b. Midterm test------------------------- 15%
c. Lab activities------------------------- 35%
d. Reverse engineering project---------- 30%
(1) Formal written report-------------20%
(2) Oral report--------------10%
2. Letter grade equivalent:
A = 100 - 93 A- = 92.9 - 90 B+ = 89.9 - 87 B = 86.9 - 83 B- = 82.9 - 80 C+ = 79.9 - 77 C = 76.9 - 73 C- = 72.9 - 70 D+ = 69.9 - 67 D = 66.9 - 60 F = 59.9 - 0
Prepared by: Date:
* Numbers in ( ) refer to the Departmental Educational Objectives.
** Numbers in [ ] refer to evaluation methods used to assess student performance.