ISE316Fall2010

ISE316ManufacturingEngineeringIProcesses
Fall2010
ClassTime: Tu,Th.10:1511:15AM.(DAN218)
Instructor:
Office:

LabTime:Th.1:304:20PM.(DAN118)
Fri.9:1011:55AM.(DAN118)
Phone:5151549
Email:rawysk@ncsu.edu

ProfessorRichardA.Wysk,Ph.D..
DanielsHall414A

OfficeHours: Tu.,Th.11:30AM12:30PM,(oranytimeIaminmyoffice)
TeachingAssistants:

LiYang
TAOffice:DAN416

OfficeHrs:Mon.,4:005:00PM
Wed.,4:005:00PM

TA1'sEmail:lyang5@ncsu.edu

LabManager: Mr.DanielLeonard(drl@ncsu.edu)
RoomDAN100A
Prerequisites:

ISE216(Mfg.Eng.Practicum),MAT200,IE/GC210

TextBook:

FundamentalsofModernManufacturingMaterials,ProcessesandSystems,
MikellP.Groover,4th.Edition,ISBN9780470467002,PrenticeHall,2010.
Lecturenotesandsupplementnotesdistributedinclass.

Goals:
Tolearnthefundamentalsofmanufacturingprocesses.
Tounderstandhowmodernmanufacturingsystemswork.
Toknowhowtotransformamechanicaldesignfromadrawingtothefinishedpart.
CourseObjectives:
Attheconclusionofthiscourse,youshouldbe:
1.Familiarwithengineeringmaterialsandtheirmechanicalproperties,
2. Able to understand, analyze and apply the fundamentals of basic forming and
machiningprocesses,toolingandmachinetoolsformanufacturingproducts,
3.Abletounderstandtolerancesanddimensional,andinspectionmethods,
4. Able to understand the modern manufacturing techniques, nontraditional

manufacturing processes, plastic forming manufacturing and micromanufacturing

technology,

5. Able to design, select and apply the product development, machining operations, the
manufacturingcostanalysistechniquesforproductdesign,planning,andmanufacturing,and.
1

ISE316Fall2010

6.Showyourexperienceofmachiningprocessesondifferentmachinetools.

ISE316Fall2010

Week
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Date
Th.

8/20

Topic

Textbook

Lab(Th/Fr)

Introductionofmanufacturing

LectureNotes

(NoLab)

TheNatureofMaterials

Chapt.1

Tu.

8/24

MechanicalPropertiesofMaterials

Chapt.2

LabI

Th.

8/26

MeasurementandInspection(1)

Chapt.2suppl.

Intro&Safety

Tu.

8/31

MeasurementandInspection(2)

Chapt.2suppl.

LabII

Th.

9/2

MeasurementandInspection(3)

Chapt.2suppl

Metrology

Tu.

9/7

Theory of Metal Machining Machining: Process

Chapt.21

LabIII

Th.

9/9

Mechanics

Chapt.22

Casting

Tu.

9/14

Machining:TurningandRelatedProcesses

Chapt.22

LabIV

Th.

9/16

Machining:MillingandHolemakingProcesses

Chapt.23

Forming

Tu.

9/23

CuttingToolTechnology

Chapt.23

LabV

Th.

9/25

GrindingandOtherAbrasiveProcesses

Chapt.25

Milling

Tu.

9/28

GrindingandOtherAbrasiveProcesses

Chapt.25

LabVI

Th.

9/30

Exam1(inclassexam)

Tu.

10/5

Metals

Chapt.6

LabVII

Th.

10/7

Fallbreak

Chapt.10

Machining

Tu.

10/9

Casting:FundamentalsandSolidification

Chapt.11

LabVIII

Th.

10/11

Casting:Sand,PermanentMoldandDieCasting

Chapt.19

Welding

Tu.

10/12

SheetMetalForming

Th.

10/14

Tu.

10/19

Forming:Bulk

Chapt.20

Product

Th.

10/21

Forming:Sheet

Chapt.21

Manufacturing

Tu.

10/26

ShapingProcessesforPlastics

Chapt.13

g
(NoLab)

Th.

10/28

(NoclassSpringHoliday)

Tu.

11/2

ShapingProcessesforPlastics

Chapt.13

Product

Th.

11/4

Exam2(inclassexam)

Tu.

11/9

Joining:WeldingProcesses

Chapt.31

Product

Th.

11/11

PowderMetallurgy

Chapt.16

Manufacturing

Turning

(NoLab)

Manufacturing

Tu.

11/16

GrindingandOtherAbrasiveProcesses
NonTraditionalMachiningandThermalCutting

Chapt.26

gProduct

Th.

11/18

NonTraditionalMachiningandThermalCutting

Chapt.26

Manufacturing

Tu.

11/23

MicroFabricationTechnologies

Chapt.37

gProject

Th.

11/25

Thanksgivingnoclass

Chapt.38

Reportdue

Tu.

11/30

Nanomanufacturing

12/02

Review

ISE316Fall2010
Exam3(08:00AMscheduledbytheUniversity)

ISE316Fall2010

COURSE STRUCTURE:
I. KNOWLEDGE BUILD PHASE

Lecture Outline:

1. Introductionofmanufacturing
2. Materialremovalprocesses
3. Metalformingandsheetmetalworking
4. Castingandmolding
5. Grindingandabrasiveprocesses
6. Plasticformingprocesses
7. Nontraditionalprocesses
8. Joiningandweldingprocesses
9. Powdermetallurgyprocesses
10. Microfabricationtechnologies
II.HANDSONEXPERIENCEManufacturingLabs:
1. Introductiontolabsafetyandreviewofmachines
2. ProductdesignandMetrology
3. CastingExperiment
4. MetalForming:SheetSpringback
5. CNCMachining:MachiningCenters
6. CNCMachining:TurningCenters
7. Machining:SurfaceFinishandLubricantAssessmentExperiment
8. WeldingandWeldJointStrengthExperiment
9. InjectionMoldingExperiment
10. SemesterLabProjectproductdevelopment,design,planningandmanufacturing
COURSEORGANIZATION:
Thiscourseconsistsofthefollowing:
1. LecturesAttendanceisrequiredinthisclass.
2. Homeworks*andInclassAssignments*Several*homeworkorinclassassignments*willbegiven
fromtimetotime.Thepurposeofassignmentsistogiveyouachancetopracticewhatyoulearned
fromtheclass. Trytosolvethehomeworkproblemsbyyourself. Ifyoustillcannotsolvethem,
cometoseemeorTAs.Inclassassignmentswillbegivenduringclassdiscussion.Nomissingin
classassignmentwillbeacceptedafterclass.
3. Labs*Aboutfivelabassignmentswillbegiveninthesemester.Labassignmentsareprovidedon
theIE316Webpage.
(*:Theexactnumberofhomeworks,labsandinclassassignmentswillbedeterminedthroughoutthe
courseofthesemester.)
4. Semester Project a semester project of product design and manufacturing is assigned and the
semesterprojectalongwiththecompletedproductneedtobecompletedandpresentedattheendof
thesemester.
5. TestsThreeinclasstests(includingfinals)willbegiven.
SEMESTERPROJECT:
5

ISE316Fall2010

November23
December2

Physicalproductdue(4:00PM)
Finalreportdue(4:00PM)

GRADING:
Homeworks
10%(youareallowedtomissonehomework)
InclassAssignmentsandQuiz
15%(youareallowedtomissoneinclassassignment)
Labs
10%
SemesterLabProject
10%
Participation
5%

Tests(3)

50%(16.7%+16.7%+16.7%offinal)

Total

100%
ADMINISTRATIVEPOLICIES

1. Attendance is expected at all lectures and is required for laboratory. Missing more than one lab will
results in failure for the course.
2. All homework and lab reports must be turned in on-time for credit.
3. Individual and group assignments should be solely the work of the individual or group handing it in.
While I encourage you to ask questions for clarification the work should be your own or your groups.
4. Proper attire as defined in the Laboratory Safety Sheet is required to participate in lab and you must
be present to receive credit.
5. No after-fact excuse on missing assignment or test will be accepted. If you shall have a job
interview you must inform me at least a week ahead of time. After-fact excuse is not acceptable.
6. You must show all calculations or procedures in your test paper/report in order to get full score.
7. This is an engineering course, you are expected to actasaresponsibleengineer. Everydocument
handedinmustbeneatlyprepared.Sloppyworkmaycostyoupoints.
8. Academic Integrity: It is understood and expected that all work turned in under your name is your
own work or, if a group assignment, the work of you and your group members, and that you have
neither given nor received unauthorized aid. The University policy on academic integrity can be
found in the Code of Student Conduct (see Appendix L of the Handbook for Advising and Teaching:
www.fis.ncsu.edu/ncsulegal/41.03-codeof.htm).
9. Incomplete Grades and Late Assignments: If requested by a student, the grade of Incomplete will
be given for work not completed because of a serious, documented interruption in the students work
not caused by their own negligence. Only regular Projects and the Final Project will be accepted late,
with a reduction of 10% in the assignments grade for each day it is late. In-class assignments cannot
be accepted late.
10. Absences and Scheduling Make-up Work: A make-up exam will be scheduled if a student has an
excused absence (see http://www.ncsu.edu/provost/academic_regulations/attend/reg.htm for NC
States policy on excused absences). There are no make-up in-class assignments or quizzes; the
lowest one in-class assignments and the lowest quiz will be dropped in lieu of any absence.