Handouts 17 Content (modules) 1.Cutting processes 2.Joining processes 3.Casting 4.Plastics moulding and related processes 5.Particulate processing for metals and plastics 6.Rapid prototyping 7.Metal forming and sheet metalworking 8.Material removal processes 9.Tolerance 10.Manufacturing quality control and production management
Handouts 18 Learning approach 1.Self learning: chapters assigned to read – posted on class website 2.Fill in the blank handouts: posted on class website 3.Fewer lectures: class time will also include other activities 4.Other activities: quizzes, case studies, discussions, videos 5.Case studies: Once every two weeks (Friday) 6.Quizzes: Once every two weeks (Monday) 7.Assignments: posted on class website
Handouts 09 Evaluation Assignments:10 % Quizzes (open book and handouts):15 % Participation:05 % Case study:15 % Final exam (open book):55 % Total: 100%
Handouts 010 Learning resources Text Fundamentals of Modern Manufacturing: Materials, Processes, and Systems Mikell P. Groover, Publisher: Wiley, ISBN 978- 0470-467008 (Edition 2, 3, 4,…)
Handouts 011 Learning resources Company visit: acquire more practical knowledge in manufacturing Hands-on samples of key manufacturing processes Videos of manufacturing processes
Handouts 012 Nature of knowledge Processes to make things Principles Equipment Analysis Synthesis/ design/ selection
Handouts 0 13 Nature of knowledge Analysis: given a process and its input to find its output Synthesis/Selection: given the end result (i.e., the right shape of a part) to find the process and the initial part Process Initial work piece Final work piece Quantitative versus qualitative: if there is a mathematical equation that links the process, initial work piece and final work piece, it is called quantitative; otherwise qualitative
Handouts 0 14 Nature of knowledge Analysis is done in a quantitative manner, i.e., an equation is available; but synthesis/selection/design is done in a qualitative manner, i.e., no equation is available. In our previous study, such as design project ME 229, there are usually many solutions for a problem, which we call open-ended problems. Solution options are generated empirically or qualitatively. In this class, we also select processes to make a thing better, and this is an open-ended problem. Process options are generated empirically or qualitatively.
Handouts 0 15 Nature of knowledge Therefore, we learn how to make a selection or decision on a process Our general approach to conduct such a selection activity is based on the understanding of expected functions (of a process), constraints (on a process)
Handouts 0 16 Nature of knowledge However, the process we are dealing with in this class is to make a product. That is to say, a process will act on material to make a product which has been designed. Given a process, there may be an issue: the best product that can be made by the process. So, it makes sense to learn how a product should be (i.e. design) to make a process easily act on a material to make the product. This is called “Design For Making or Manufacturing”, DFM for short.
Handouts 0 18 Nature of knowledge In summary, 1.Knowledge about making a thing. 2.Knowledge about the behavior of each process. 3.Knowledge about selection of processes. 4.DFM. 5.Our focus is on a. Principle of a process b. Characteristics of a process – helping us to do selection c. DFM 6. Equipment is not our focus, as the knowledge about it is memory intensive and keeps changing.