056/058:032 Spring 2006 Syllabus
Days & Time:
Rick Jerz, Phone 563.333.6183 (http://www.sau.edu/cob/JerzRichard)
Monday and Wednesday, Time: 1:30PM - 2:45PM
Thursdays (50 minutes): 9:30, 10:30, or 11:30
3231 Seamans (ALF) or G435 (for machining)
057:015 - Materials Science
Wednesdays: 10:30AM-1:00PM. Others by appointment.
Mr. Kevin Kaiser (photo),
|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:
|Manufacturing Engineering and
Technology, S. Kalpakjian and S.R. Schmid, 5th Edition, Prentice Hall,
Upper Saddle River, NJ, Copyright 2005.
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)
Supplemental Readings and Resources
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
|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 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
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
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
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.
EG = Engineering Graphics topics, LAB = Lab Assignments
Video - Manufacturing Engineers
Introduction to Manufacturing Engineering (read pages 1-42)
LAB01: Orientation: (Yes, there is a lab the first Thursday!)
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
Selector (CES) Overview
(no reading required)Homework #03
material or process with CES (due
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.
LAB04: Pro/E - Revolved Features, Mirrors, Rounds, and Chamfers (Lesson 4) (due 2/17)
Chapter 24 (full
slides). Read 24.1, 24.2
Homework #13 (due 2/20): Ch 24.36, 24.37, 24.39.
Discuss Exam (Study notes)
Lab 05: NC Programming Introduction (due 2/24)
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
Machining Processes used to Produce
Round Shapes: Chapter 23.
Read 23 (all).
Homework #15: Ch 23.17,
23.38. (due 3/6)
LAB07: Pro/E - Engineering Drawings (Lesson 8) (due 3/10)
Surfaces and Rotational Surfaces (full)
EG - Isometric Projections (full)
Homework #17: A12, A14, A16, A17, A18 (due 3/22)
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|
Forming and Shaping (continued)
Sheet metal and bending (in class notes)
Homework #19: 10.35,
10.49, 11.2, 11.13,
11.38 (due 4/3)
LAB09: Pro/E - Assembly Fundamentals (Lesson 9) (due 3/31)
Casting Research and Casting Design (full), Guest Speaker
Exam #2 (Wednesday) - All material through and including March 17 (no Pro/E assembly).
Lab 10 - Pro/E - Sweeps and Blends (Lesson 11) (due 4/7)
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)
Rapid Prototype - Chapter
20: Review the chapter materials.
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.
|NOTE: We will not meet in class
Topics for the online week:
Lab12: CAM - Milling Parts with
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)
|15.||May 1||Project Presentations
Exam 3, Wednesday, May 3 (Study Notes)
|16.||May 8||University Finals Week - we do not meet this week.|