Design for Manufacturing
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056/058:032 Spring 2006 Syllabus
(Subject to Change)
Quick links: Assignments, Course InformationCourse Overview and Objectives, Texts, Supplemental Resources, Basis of Grade,

1. Course Information
Instructor:
URL
E-mail:
Days & Time:
Location:
Labs times:
Lab location:
Credit:
Prerequisites:
Co-requisite
Office:
Office Hours:
Dr. Rick Jerz, Phone 563.333.6183 (http://www.sau.edu/cob/JerzRichard)
RickJerz@cs.com
Monday and Wednesday, Time: 1:30PM - 2:45PM
2217 SC
Thursdays (50 minutes): 9:30, 10:30, or 11:30
3231 Seamans (ALF)  or G435 (for machining)
3 hours
None
057:015 - Materials Science
1139SC
Wednesdays: 10:30AM-1:00PM. Others by appointment.
2. Teaching Assistants

Mr. Alaa Elwany (photo), alaa-elwany@uiowa.edu
Office G435, Office Hours Tuesdays 1:00PM - 2:30PM.  Others by appointment.  Phone: (319) 594 - 0363. 

Mr. Kevin Kaiser (photo), kevin-kaiser@uiowa.edu
Office G435, Office hours: Mondays, 11:30 - 1:20PM.  Others by appointment.  Phone: (563) 349 - 0210.

Mr. Shaun Carr (photo), shaun-carr@uiowa.edu
Office 1433SC, Office Hours: Tuesdays 10:45AM - 12:20PM. Others by appointment.  Phone: 335-5049.


3.
Course Overview and Learning Objectives
This course provides students with the opportunity to develop and demonstrate an understanding of product design, engineering graphics, and manufacturing processes fundamentals.

The learning objectives are:

* Students will gain an understanding of the major manufacturing processes, including machining, casting, forming, assembly, surface treatment, plastics processing, and inspection.

* Students will develop the ability to use 3D computer-aided design (CAD) software and create part models, assemblies, and drawings.  Pro/ENGINEER will be our CAD software.

* Students will understand  computer numerical control, how to write NC programs, and how to create NC programs with CAD/CAM software.

* Students will understand CAD/CAM technologies and create physical parts.

* Students will understand engineering graphics principles and how designs are communicated in industry. They will develop the ability to interpret engineering drawings.

* Students will understand the relationships between customer desires, project materials, product design, and manufacturing process selection. The will develop an appreciation of product design and manufacturing process trade-offs.

* Students will be able to look at products and determine how they were manufactured and why?


4.

Texts
Manufacturing Engineering and Technology, S. Kalpakjian and S.R. Schmid, 5th Edition, Prentice Hall, Upper Saddle River, NJ, Copyright 2005.  
ISBN 0-13-148965-8

Pro/Engineer Wildfire2.0 Tutorial, Roger Toogood and Jack Zecher, SDC Publications, 2004. (This is the red Pro/E book, not the older blue book)
ISBN 1-58503-186-0


5.

Supplemental Readings and Resources
Interpreting Engineering Drawings, 6th Ed., Cecil H. Jensen, Delmar Thompson Learning, United States, 2002, ISBN 0-7668-2897-2.

Additional readings may be provided by the instructor.  These will almost always be available on this website for downloading.  Flash


6.


Basis of Grade

First Written Exam 15% Attendance 5%
Second Written Exam 15% Homework and Labs 30%
Final Written Exam 15% Integrated Design Project 20%

>= 99: A+,  94-98: A, 90-93: A-, 87 - 89: B+, 83 - 86: B, 80-82: B-,  77 - 79: C+, 73 - 76: C, 70 - 72: C-, 67-69: D+, 63-66: D, 60-62: D-, below 60: F. 

As the semester progresses, you will be informed about your assignment grades.
YOU HAVE 2 WEEKS TO DISPUTE YOUR GRADE ON ANY ASSIGNMENT.

You are reminded about the College policy about academic misconduct http://www.engineering.uiowa.edu/current-students/academic-misconduct.html, and plagiarism at http://www.engineering.uiowa.edu/~ctc/docs/ctc_guides/ctc_guide_avoiding_plagiarism.html.

This course is given by the College of Engineering. This means that class policies on matters such as requirements, grading, and sanctions for academic dishonesty are governed by the College of Engineering. Students wishing to add or drop this course after the official deadline must receive the approval of the Dean of the College of Engineering. Details of the University policy of cross enrollments may be found at: http://www.uiowa.edu/~provost/deos/crossenroll.doc

Examinations: There will be three examinations that may contain problem solving, fill in the blank, multiple choice and true/false questions.   Exams are not comprehensive.  Please let the instructor know if you cannot make the exam date and time.  These exams are difficult and the student is expected to read and study the assignments, attend lectures, and ask questions.

Attendance and Class Participation: Attendance is very important, especially to get information not covered in the text.  You are expected to come prepared to class by completing homework and readings, and to participate in meaningful discussions in class.  Attendance will be taken randomly.  Do not sign other student's names for them.

Homework: There will be variety of homework assignments throughout the semester.  Some expect exact answers and some will be "open ended" meaning that there may be several correct responses, but that there must be some logic to your response.  Some homework is collected, some is put into ICON, and some will be submitted electronically.  The homework link provides the method and due date.

Complete the assignments individually (i.e., put the answers into your own words) although discussion with other students is allowed and encouraged.  Students are expected to complete the assignments by the due date which will always be shown on this website (by midnight).  Some assignments may have different weights assigned to them to reflect their difficulty.  The grade will be based on approach to the problem, effort, and answer quality.  If you copy someone else's homework or let someone copy yours, you can expect to get a zero for the entire day's assignment and possibly face more serious disciplinary action. Be a professional; do your own work.

Homework handed in one class period late will be given a maximum grade of 1/2 its full value. No credit will be given for homework two periods late.   Also, when handing in multiple pages, please staple these together.

Integrated Design Project: This semester long project challenges you to apply your knowledge to a product design and manufacturing scenario.  This is a team project, and you will be assigned to a manufacturing team (team members).  Click here for project details.

Bonus Assignments: Throughout the semester, bonus exercises may be provided.  These are optional and they can only help your manufacturing processes understanding and your grade.

Depending on how the semester goes, a couple low homework scores may be dropped.


7.

Assignments
(week of)

EG = Engineering Graphics topics, LAB = Lab Assignments
1. January 18 Course Overview
Video - Manufacturing Engineers

Introduction to Manufacturing Engineering (read pages 1-42)

LAB01: Orientation: (Yes, there is a lab the first Thursday!)

2. January 23 Materials in Manufacturing:  Chapters 1-9.  Read: Introductions and summaries for each chapter, and also read the following sections:
1.7,  2.2.1,  2.6,  3.8,  4.7,  4.8,  5.6,  6.15,  7.3(only pg 202), 7.4,  8.4,  8.6,  8.7,  9.2.

Homework #01 (due 1/30): 1.18; 2.20; 3.18; 4.17; 5.16; 7.63; 8.29; 9.65 (3 examples).

Introduction to Computer-Aided Design (CAD): Optional reading 38.4.

LAB02: Pro/E - Introduction and Creating a Simple Part (Lessons 1 and 2, due 2/3)

Homework #02 (due 2/3): Product Cost - Chocolate Chip Cookies

3. January 30 Cambridge Engineering Selector (CES) Overview (no reading required)Homework #03 Selecting material or process with CES  (due 2/6 2/8)

Manufacturing Economics (Optional reference reading)
Excel Model

EG: Bases for interpreting drawings, sketching, orthographic and Isometric Views, Hidden Lines

This group of assignments are due on 2/13, bring to class.
Homework #04-A1, Homework #05-A2, Homework #06-A3
Homework #07-A8, Homework #08-A10
Homework #09 - Determining Material Cost

LAB03: Pro/E - Creating a Simple Part, Part II (due 2/10)

4. February 6 Fundamentals of Machining: Chapter 21. Read pgs. 603-610; 21.2.1; 21.3 (only power and cutting force); 21.5 (to top of 630); 21.6; 21.7 (only to 21.7.1); and Summary.

Homework #10 (due 2/13) 21.16, 21.18, 21.40 (hard, use eq. 21.20a).

Cutting Tools: Chapter 22.  Read 22.1; 22.2; 22.4.3; 22.12 (to bottom of page 666); and Summary.

Homework #11 (due 2/13) 22.25, 22.40.

Lecture notes for both chapters

EG: , Working Drawing & Dimensioning (full slides)
CAD Analysis and Dimensions (by Shaun Carr)
HW#12 - A4 (include dimensions) (due 2/20)

LAB04: Pro/E - Revolved Features, Mirrors, Rounds, and Chamfers (Lesson 4) (due 2/17)

5. February 13 Milling: Chapter 24 (full slides).  Read 24.1, 24.2

Homework #13 (due 2/20): Ch 24.36, 24.37, 24.39.

(Wed) NC Programming (full slides), Ch37, Read 37.3, 37.4.

Discuss Exam (Study notes)

Lab 05: NC Programming Introduction (due 2/24)

6. February 20 Various Shapes Processes: Chapter 24.  Read 24.3, 24.4, 24.5, and 24.7.

Homework #14: (due 2/27): Ch 24.16, 24.25

Discuss Project

Exam #1: Wednesday, February 22, in class. All material through and including February 15, but no NC Programming.
Study Notes

LAB06: Pro/E - Sketcher Tools and Datum Planes (Lesson 6) (due 3/3)

7. February 27 Machining Processes used to Produce Round Shapes: Chapter 23.  Read 23 (all). (full slides)

Turning Equations (full slides)

Homework #15: Ch 23.17, 23.30, 23.34, 23.38. (due 3/6)
Homework #16: Ch 23.43, 23.44, 23.45. (due 3/10)

LAB07: Pro/E - Engineering Drawings (Lesson 8) (due 3/10)

8. March  6 EG - Inclined Surfaces and Rotational Surfaces (full)
EG - Isometric Projections (full)

Homework #17: A12, A14, A16, A17, A18 (due 3/22)

Forming and Shaping Processes: Chapters 13-16. Read: 13 (all); 14.1,2,3,4, 8,9;  15.1,2;  16.1,2,5,13.
Lecture Notes: (full)

Homework #18: 13.25, 13.32, 14.35, 15.49, 16.60. (due 3/22).

LAB08: Pro/E - Patterns and Copies (Lesson 7) (due 3/24)

March 13 Spring Break - no classes
9. March 20 Forming and Shaping (continued)
Sheet metal and bending (in class notes)

Metal Casting Processes and Equipment: (Wednesday, Mr. Elwany): Read Chapters 10 and 11 (all)
Lecture Notes (full)

Homework #19: 10.35, 10.49, 11.2, 11.13, 11.38 (due 4/3)
Extra Bonus: Problem: Pick a product from your choice, sketch it NEATLY, and sketch the pattern you would use to sand cast this product.

LAB09: Pro/E - Assembly Fundamentals (Lesson 9) (due 3/31)

10. March 27 Metal Casting (full)
Casting Research and Casting Design (full), Guest Speaker

Exam #2 (Wednesday) - All material through and including March 17 (no Pro/E assembly).

Exam 2 Study Notes

Lab 10 - Pro/E - Sweeps and Blends (Lesson 11) (due 4/7)

11. April 3 Surface Treatment - Chapter 34: Read 34.1 to 34.6, 34.9, 34.12, 34.15.
Homework #20: 34.15, 34.27. (due 4/17)

Surface Finish and Machining Symbols (full): Chapter 33. Read 33.3.

Rapid Prototype - Chapter 20: Review the chapter materials.
Lab 11 (below) is part of this chapter.

EG: Primary and Secondary Auxiliary Views (full)
Homework #21: Aux-1, Aux-4 (due 4/17)

Exchanging model geometry between CAD products.

Lab11: Machine Shop Tour and Producing Rapid Prototype Parts (due 4/14)  Note: You should attend lab this Thursday in G450.

12. April 10

(Online week)

NOTE: We will not meet in class this week.

CLICK HERE FOR YOUR ON-LINE ASSIGNMENTS

Topics for the online week:
    Plastics and Composites:
    Computer-aided machining
    EG: Sectional views, removed sections.
    Work on Team Projects

Lab12: CAM - Milling Parts with Pro/E (due 4/26 4/28

13. April 17 Welding, Joining, and Assembly Processes: (full)
Chapter 30: Read all except 30.5
Chapter 31: Read 31.1, 31.3, 31.4, 31.5, 31.8
Chapter 32: Read 32.1, 32.2, 32.3, 32.4, 32.5

Homework #25: 30.15, 30.19, 30.34, 31.21, 31.22, 31.35, 32.16, 32.18, 32.22 (due 4/26)

Lab13: Inspection Lab (due 4/28)

14. April 24

Inspection and Quality Assurance (full)- Chapters 35 and 36.

(Wednesday)
Integrated Design Project, report due today, April 26
Project Presentations (see link for presentation order).

15. May 1 Project Presentations Continued

Exam 3, Wednesday, May 3 (Study Notes)

16. May 8 University Finals Week - we do not meet this week.