Course Description
Fundamental science and engineering associated with the manufacturing processes of products made of metals, polymers, ceramics, and composites. Details the physical and quantitative elements of processing, justification of process selection, and the identification of processes used to manufacture existing products.
Additional Requirements for Graduate Students:
Course will include a project for all students. Graduate students will complete a more comprehensive extension to the project where they perform further analysis on the project to determine manufacturing sensitivity and variable optimization. Graduate students will use this additional knowledge when selecting and justifying manufacturing decisions.
Athena Title
Adv Manufacturing Processes
Prerequisite
MCHE 3920 and (ENGR 3150 or ENGR 3150E)
Semester Course Offered
Offered every year.
Grading System
A - F (Traditional)
Course Objectives
Students vary in their competency level on these abilities. You can expect to acquire these abilities only if you honor all course policies, attend classes regularly, complete all assigned work on time, and meet the course expectations. I. Model and analyze a representative set of traditional and fundamental manufacturing processes in use today. Derive expressions for expected process and product characteristics (e.g., forging forces, expected tolerance). a. Understand the terminology of fundamental manufacturing processes. b. Calculate process characteristics based on quantitative analytical models. Use generalized models to predict specific behavior. c. Describe the expected part characteristics based on a qualitative understanding of various processes. II. Prescribe a manufacturing process or combination of processes for producing a given part based on metrics of success such as specific cost and output rate and subject to design constraints such as tolerance, quality, and application-specific needs. a. Derive requirements for part characteristics based on intended application and environment. b. Analyze the costs associated with different manufacturing processes and what factors affect cost. c. Understand and explain the interaction of materials and processes. III. Identify manufacturing process(es) used to make a given part. Suggest improvements to existing part and process designs based on economy and an understanding of the prescribed manufacturing process. a. Identify process-specific part characteristics and differentiate between similar characteristics. b. Understand and describe the effect of product design on manufacturability. c. Evaluate part and tooling design deficiencies and suggest improvement modifications, including material geometry and process changes. Apply “rules of thumb” of manufacturability to part design. IV. Graduate Students: Derive equations necessary to perform optimization analysis for a product, volume, and performance. a. Identify the objective and constraining statements in a manufacturing process. b. Numerically represent the statements in a manner that allows for sensitivity analysis and optimization. c. Evaluate results of optimization analysis to determine optimal manufacturing process, volume, or set-up configuration.
Topical Outline
1. Introduction, Overview and History, Process Identification 2. Casting a. Introduction b. Analysis 3. Bulk Deformation a. Forging Processes and Analysis b. Rolling c. Extrusion d. Drawing 4. Surface Characterization a. Surface Finish b. Surface Roughness 5. Sheet Metal Processing 6. Machining Processes and Equipment a. Relationships and Analysis b. Forces and Power c. Cutting Tools and Fluids and Machining Economics d. Grinding 7. Polymers Processing a. Screw Extrusion b. Injection Molding 8. Additive Manufacturing 9. Composites Manufacturing 10. Statistical Process Control