Faculty of Engineering and Architecture

Mechanical Engineering Department

SPRING 2011-12

MECH421 Manufacturing Processes I

CATALOG DESCRIPTION:
Topics include traditional material removal processes (machining and abrasion), CNC machining, as well as
non-traditional material removal processes (EDM, ECM, thermal cutting, etc.). The science behind these
technologies. Assembly processes as welding, brazing, soldering, and fastening will ALSO be covered. The
course emphasizes process capabilities & limitations, relative cost, and guidelines for process selection. The
behavior of materials under processing conditions. Design for manufacturing guidelines. This course
contains hands-on exercises in a machine shop environment.
Credit 3 (2 lecture, 1 lab)
Prerequisites: MECH 340, CIVE 310
Required: yes

LECTURES MEET TIMES: T, TR 11:00 AM - 11:50 AM (50 MIN) BECHTEL BUILDING 108

LAB MEET TIMES: Check schedule

COORDINATOR
Ramsey Hamade, Associate professor of Mech. Engineering
[email protected]
RGB #406 ext.3481
Office hours 09:00-12:00 (M, W) & 09:00-10:30 (T, Th)

PREREQUISITES BY TOPIC
1. Engineering materials and their properties.
2. Statics
3. Strength of materials

TOPiCS
1. Traditional Machining Processes (8 weeks)
2. NC Programming (3 weeks)
2. Abrasion processes (1 week)
3. Non-traditional Metal Removal Processes (1 week)
4. Joining and Assembly Operations (2 weeks)

TEXTBOOK
th
‘Fundamentals of Modern Manufacturing, Materials, Processes, and Systems’; 4 Edition, SI units; M. P.
Groover; Wiley,

REFERENCES
I. Electronic Databases available through the AUB Libraries:
• http://staff.aub.edu.lb/~webjafet/eresources/databases/engineering.html
• Journal of manufacturing science and engineering (1996-) [formerly Journal of engineering for
industry]; American Society of Mechanical Engineers; current issue at JAFET Library; Back issues held at
Engineering Library. Also full text electronic subscription are accessed through http://ojps.aip.org/
II. Printed Material available through the AUB Libraries:
Metal Machining:
• Manufacturing processes and equipment (c2000); Tlusty, Jiri E670.42:T626m:c.1
• Advanced Machining Technology Handbook; J. Brown; E 671.35 B878 a
• Application of Metal Cutting Theory (c1987); F.E. Gorczyca; E 671.53 G661 a.
• Metal cutting principles (1997) Shaw, Milton Clayton; E 671.53 S535m
• Metal cutting theory and practice (1997) Stephenson, David A.
CNC in Metal Machining:
• The CNC workshop; Nanfara, Uccello, and Murphy; Wesley-Longman. (w/ CD-ROM)
• A Pro/Manufacturing tutorial (c2000); Funk, Paul E. E620.004:F982p:c.1
• MasterCAM ® Tutorial Manuals or SurfCAM ® Tutorial Manuals
• Haas Automation CNC Machine Manuals
• Computer numerical control (c1992) Kief, Hans B.
Abrasive Processes:
• Principles of abrasive processing (c1996) Shaw, Milton Clayton,
Welding:
• Advanced welding processes (c1992) Norrish, John
Design for Manufacturing:
• Handbook of Product Design for Manufacturing; Ed. James g. Bralla, Mcgraw-Hill; E671:H236h:c.1
• Design for manufacturing (c2001); Poli, C., E620.004: P766d:c.1 (w/ CD-ROM)
Other References

• class notes and handouts (posted on Moodle).

• The instructor
• Machine shop staff
• The world wide web & Vendors and product catalogs
• SAMPE, Society for Advanced Materials & Processes: Materials Processing, Characterization, and
Testing: http://www.sampe.org/JAM.html
• Society of Manufacturing Engineering (SME)’s Website and Trade Journals: Manufacturing
Engineering and General Manufacturing, & News. http://www.sme.org;
SME's technical association web sites:
A. Metal Forming and Fabricating (Association for Forming and Fabricating
Technologies of SME - AFFT/SME.)
B. Finishing Processes (Association for Finishing Processes of SME - AFP/SME.)
C. Automation and Integration (Computer and Automated Systems Association of
SME - CASA/SME.)
D. Composites Manufacturing (Composites Manufacturing Association of SME -
CMA/SME.)
E. Electronics Manufacturing (Association for Electronics Manufacturing of SME -
EM/SME.)
F. Machining Technology (Machining Technology Association of SME -
MTA/SME.)
G. Machine Vision (Machine Vision Association of SME - MVA/SME.)
H. Manufacturing Research (North American Manufacturing Research Institution
of SME - NAMRI/SME.)
I. Plastics (Plastics Molders and Manufacturers Association of SME -
PMMA/SME.)
J. Robotics (Robotics International of SME - RI/SME.)

YOUR ACTION ITEM I: BROWSE THROUGH AND GET FAMILIAR WITH SOME OF THESE REFERENCES
BEFORE NEXT LECTURE.
COURSE LEARNING OBJECTIVES:

The objectives of this course are for the ME Correlate to ME program objectives
students to:
Become familiar with fabrication techniques1. Develop in students the ability to integrate
traditionally associated with machine shopmechanical engineering fundamentals with
environments such as turning, drilling, and contemporary applications;
milling
1. Develop in students the ability to integrate
mechanical engineering fundamentals with
Associate traditional machining technology contemporary applications;
with the underlying scientific and engineering
principles. 3. Motivate students in order to continually learn
on their own, to think critically and creatively by
allowing them to evaluate new ideas, identify
problems, and advance innovative solutions;
3. Motivate students in order to continually learn
Assess the capabilities and limitations of these
on their own, to think critically and creatively by
fabrication techniques, their relative cost, and
allowing them to evaluate new ideas, identify
the guidelines for their selection.
problems, and advance innovative solutions;
3. Motivate students in order to continually learn
Gain knowledge in the basics of Computer-
on their own, to think critically and creatively by
Numerical Control (CNC) machining
allowing them to evaluate new ideas, identify
processes, technology, and equipment.
problems, and advance innovative solutions;
Get introduced to other material removal 3. Motivate students in order to continually learn
technologies & practices not typically on their own, to think critically and creatively by
associated with a traditional machine shop allowing them to evaluate new ideas, identify
environment such as EDM and ECM problems, and advance innovative solutions;
3. Motivate students in order to continually learn
Become aware of the economic considerations on their own, to think critically and creatively by
associated with metal machining practices allowing them to evaluate new ideas, identify
problems, and advance innovative solutions;
4. Instill in students the necessary interpersonal
Function as team members.
skills to perform professionally in a highly competitive
and dynamically changing profession.
4. Instill in students the necessary interpersonal
Develop their written and oral communication
skills to perform professionally in a highly competitive
skills.
and dynamically changing profession
COURSE LEARNING OUTCOMES:

Applicable Assessed Correlation to ME

At the end of the course, the students should have
Deliverables* program outcomes
1. Learned the principles of traditional machining HW, PQ, Q, R/P, E
k
operations such as lathe, mill, and drill press
2. Applied solid mechanics principles to metal HW, PQ, Q, R/P, E
k
cutting
3. Learned how to estimate cutting tool-life using HW, PQ, Q, R/P, E
k
the Taylor Equation
4. Learned how to calculate the cost of cutting HW, PQ, Q, R/P, E
k
operations
5. Learned how to relate the surface quality to HW, PQ, Q, R/P, E
k
process parameters, tool, and materials used
6. Recognized the capabilities of modern industrial HW, PQ, Q, R/P, E
NC machinery and have written ISO G & M k, j
code for milling and turning
7. Recognized the capabilities of non-traditional HW, PQ, Q, R/P, E
k, j
cutting processes such as EDM and ECM.
8. Recognized the capabilities of abrasion HW, PQ, Q, R/P, E
k, j
processes
9. Recognized the capabilities of non-traditional HW, PQ, Q, R/P, E
k, j
joining techniques
10. Interacted with peers on teams to complete HW, R/P
d, g
written term report and/or oral presentation
11. Demonstrated concrete awareness and necessity R/P
of life-long learning experiences relating to i
manufacturing fabrication processes.

* Cooperative team homework assignments, HW

Pop quizzes, PQ

Midterm Quiz, Q

End‐of‐term report / presentation, R/P

Final Exam, E
ABET P rogra m Outcome s
a ) S tude nts will ha ve the a bility to a pply knowle dge of ma the ma tics , s cie nce , a nd e ngine e ring.
b) S tude nts will ha ve the a bility to de s ign a nd conduct e xpe rime nts a s we ll a s to a na lyze a nd inte rpre t da ta .
c) S tude nts will ha ve the a bility to de s ign a s ys te m, compone nt, or proce s s to me e t de s ire d ne e ds .
d) S tude nts will ha ve the a bility to function on multidis ciplina ry te a ms .
e ) S tude nts will ha ve the a bility to ide ntify, formula te , a nd s olve e ngine e ring proble ms .
f) S tude nts will ha ve a n unde rs ta nding of profe s s iona l a nd e thica l re s pons ibility.
g) S tude nts will ha ve the a bility to communica te e ffe ctive ly.
h) S tude nts will ha ve the broa d e duca tion ne ce s s a ry to unde rs ta nd the impa ct of e ngine e ring s olutions in a globa l/s ocie ta l con
i) S tude nts will ha ve a re cognition of the ne e d for a nd a n a bility to e nga ge in life long le a rning.
j) S tude nts will ha ve a knowle dge of conte mpora ry is s ue s .
k) S tude nts will ha ve the a bility to us e the te chnique s , s kills , a nd mode rn e ngine e ring tools ne ce s s a ry for e ngine e ring pra ctice
COMPUTER USAGE

Use of NC ISO programming language (G&M code) simulator and/or CAM programs (SurfCAM)

RESOURCES AVAILABLE TO STUDENTS:

Class handouts and presentations will be posted on Moodle.

ASSESSMENT AND EVALUATION

The course grade will be a composite of several measures, including class participation, examination, and a
research component:
1- Cooperative team homework assignments (7.5%)
2- Pop quizzes (approx. 10) (7.5%)
3- End-of-term report / presentation OR Hands-on machining project (10%)
4- Shop Projects (25%)
5- Midterm Quiz (1.5 h) scheduled for April 21, 2012 (SATURDAY) (20%)
6- Final Exam (30%)

Your Action Item 2: students to form teams of twos BY NEXT LECTURE. These teams will be same teams
that submit LECTURE assignments, LAB reports, and end-of-term presentation or project.

CONTRIBUTION OF COURSE TOWARDS MEETING THE PROFESSIONAL COMPONENT

Outcomes (6), (7, and (10) contribute to meeting the Professional Component

ACADEMIC INTEGRITY & STUDENT CONDUCT:

You will be held to an ethical standard higher than the one prevailing in the rest of the country. The
measure (or the yard stick) being the AUB’s Student Code of Conduct.

The AUB catalog defines various forms of academic integrity (AI) violations of the trust between students
and their teachers. Students should familiarize themselves with such violations (including plagiarism and
cheating) as well as the penalties associated with such AI violations.

Your Action Item 3. Students are required to (re)familiarize themselves with the definition (and the
accompanying disciplinary actions) of the code of conduct:
www.aub.edu.lb/sao/Documents/Revised Student Code of Conduct (Approved May 2009).doc

COURSE POLICIES:
Students are expected to attend all classes. In case of absence from any class, students are required to
cover the missed material and inquire about any announcements made during their absence. Although
lecture attendance will not be taken, it is indirectly accounted for through the once-per-week pop quizzes
(1 point per quiz). Attendance will be recorded at the start of all lab sessions. FEA regulations REQUIRE
teachers to FORCE DROP STUDENTS who miss more than one fifth of class sessions.

No exam make-ups will be given. If the reason for missing the exam is deemed acceptable the grades
percentage of the missed exam will be distributed amongst the other course graded activities

Each team of 2 students is expected to work the assignment material independently and submit
assignments on due dates. Late assignments will not be accepted nor corrected.

Your access to Moodle is mandatory. Class administration will be conducted mainly through the web: class
note depository, announcements, important milestones and their required dates, grades, etc..
Action Item 4: Verify that you have access to Moodle BY NEXT LECTURE.
Week # Tuesday Thursday
1 (Feb 13) No Classes Syllabus & Introduction
2 (Feb 20) Ch 20 Machining operations Ch 20 Machining operations
3 (Feb 27) Ch 22 Machining operations Ch 20 Machining operations
4 (March 5) Ch 19 Cutting mechanics Ch 19 Cutting mechanics
5 ( March 12) Ch 19 Cutting mechanics Ch 21 Cutting technology
6 ( March 19) Ch 21 Cutting technology Ch 21 Cutting technology
7 (March 26) Ch 22 Economic & product design Ch 22 Economic & product design
considerations considerations
8 (April 2) Ch 22 Economic & product design Ch 35 Numerical control
considerations
9 (April 9) Ch 35 Numerical control Ch 35 Numerical control
10 ( April 16) Ch 23 Abrasive processes Ch 23 Abrasive processes
Mid Term: 1.5 hour ( April 21, 2012
(SATURDAY))
11 (April 23) Ch 24 Non traditional machining Ch 24 Non traditional machining
12 (April 30) Ch 29 Brazing, soldering, and Ch 27 Fundamentals of welding
adhesive bonding
13 ( May 7) Ch 28 welding processes Ch 28 welding processes
14 (May 14) Other manufacturing processes Other manufacturing processes
15 ( May 21) REVIEW LECTURE Reading Period starts May 26 (Saturday)
EXAMS BEGIN Wednesday May 30
MECH421 Manufacturing Processes I
Tentative Shop/Lab Schedule

SPRING 2011-12 (all sessions will be delayed by 1 week if machine shop prefers to give you a safety tour
st
in 1 week).

Week # Topic Room

1 (Feb 13) No Labs
2 (Feb 20) Metrology Shop
3 (Feb 27) Cutting Tools Grinding Shop
4 (March 5) Machining I (Turning) Shop
5 ( March 12) Chip Thickness Shop
6 ( March 19) Machining II (Milling) Shop
7 (March 26) Machining III (Drilling) Shop
8 (April 2) Tool Wear/Life Shop
9 (April 9) NC Simulation 1 Computer Labs
10 ( April 16) NC Simulation 2 Computer Labs
11 (April 23) NC Simulation 3 Computer Labs
12 (April 30) CNC Cutting Exercise 1 Shop
13 ( May 7) CNC Cutting Exercise 2 Shop
14 (May 14) Non traditional Machining: Laser Shop
Cutting & WEDM Demos
15 ( May 21) Welding Exercise / Demo Shop
LAST SESSION (Turn in Project)

LAB Outcomes:

1. Operate lathe, milling machines, drill press, grinding machines.

2. Monitor cutting parameters (speed, feed, depth of cut) through surface finish inspection.

3. Prepare cutters (drills) and dress (re-sharpen) them using a tool grinder.

4. Estimate tool-life (life of the cutting tool).

5. Write CNC programs and conduct CNC machining.

Lab report format

Your lab report should be in the following format.

All reports submitted in different formats will be marked with lower grades.

The lab report

The main sections of the report are:
1. Front Page
2. Objective(s)
3. Problem approach
4. Analysis and calculations
5. Observations
6. Conclusion(s)
7. Appendix

1. The Front Page

Header:
Name of the university (AUB)
Name of the department (ME department)
Name of the Subject (MECH 421)
Number of the Report
Body:
Section number
Due date
Footer:
Professor name
Group names and IDs

2. Objective(s)
Few lines describing the objectives of the lab.

3. Experimental Problem and Proposed Solution (i.e., process plan)

This part describes the problem and the ways followed to perform the experiment.

4. Analysis and calculations

The calculations done and the analysis procedure followed should be written in this part of the report.

5. Observations
Any special observations that happened or observed during the procedure of the experiment are
stated here. Include digital photographs and other supporting material in this section.

6. Conclusion(s)
Results and conclusions of the lab are reported here.

7. Appendix
Contains all graphs and figures that should be attached with the report.