MFE 230 MANUFACTURING PROCESSES II FORMING, CASTING AND

JOINING

David Berdahl
Office Hours: T 5-6; Th5-6 or by appointment. Please email ahead of time if you are
planning on coming to an office hour (students questions often take me out of the
office to labs, if I know you are coming I will make sure to be there).
E-mail: dlberdahl@cpp.edu

Note: The instructor reserves the right to make changes as necessary to this information.

COURSE OBJECTIVES: To know and understand the practical details (Geometric

capabilities and limitations, tolerances and surface finish, materials producible and
properties attained, necessary tooling, production process details) of metal casting,
powder metal, forming, rapid prototyping, welding, ceramics, polymers and composites.

Prerequisite:
MFE 217 or equivalent.

Grading:
Lecture and lab are integrated. Thus, the same grade will be given to both sections.
Midterm Exams (2) 25% ea.
Final 25%
Laboratories 25% (Quizzes, reports, attendance and participation). Note that the safety
quiz must be passed with an 80% grade prior to start accumulating laboratory credit.
A straight scale will be used for the class: 95%=A, 85%=B, 75%=C, 65%=D and +/-
grading will be used in intermediate brackets.

Extra credit possible:

Item Date Description

Professional Due Final Day Student membership in any of the following:
Memberships AFS, SPE, AWS with the review of an article
from a magazine of the respective society.
Attendance to Schedules and AFS, AWS, SPE senior chapter meetings.
Professional information at: Bring proof of attendance to instructor.
Meetings AFS:
www.afssocal.org
SPE:
www.socalspe.org
Open House TBD Demonstrate foundry, machining and/or sheet
 metal processes. 8 AM to 1:30 PM.
How its The student will turn in a legible one page
made handwritten report of the segment including:
segments on Title, time and date it was seen, summary of the
TV (Discovery processes described highlighting which
or Science processes have been or are to be covered in
channels). class, and a listing of what subchapters are
applicable (ie chapter 10.2, 11.5, 11.6, 15.8).
The write ups must be turned in the class
session following the episode airing. Each
segment will be worth between to percent
(to be determined). A maximum of 5% of total
grade will be given in extra credit.
Scholarships, Conference Trips, Internships: For students with interest in metal casting, or
plastics processing, these are available.
Each extra credit item counts independently, maximum of 20% of grade, and will be
applied only to students earning a C in the class.

Make ups and late work:

Make ups for exams and late work will only be allowed in cases of emergency and as
approved by the instructor.

To ensure fairness, regrading will be done at the written students request to ensure
fairness. Requests must be received within one week of assignment return and the entire
assignment will be regraded.

Announcements and communication:

Announcements will be broadcast using Blackboards messaging system. All
announcements are effective within 24 working hours of sending the email. Note that the
emails will be sent to your csupomona email account, so make sure the mailbox is not
full and that you can receive the messages sent there. When sending the instructor an
email (DONT use Blackboards messaging system) make sure it is from your csupomona
account as well as emails from other sources will frequently be blocked by spam filters.

Supplies:
Safety Equipment: During all laboratories the following will be mandatory: Safety
glasses/goggles (ANSI rated), closed shoes (in welding and casting labs they must be
leather), long pants, over the ankle socks, shirts (tank tops not acceptable), dangling items
(such as loose clothing, long necklaces or earings) will not be allowed and long hair must
be kept bundled in a safe manner. It is likely that you will get dirty during labs, so bring
appropriate work clothing or a lab coat.

Safety Procedures:
Appropriate behavior in the labs is expected. No eating, drinking, horseplaying, running
is allowed. In addition, be mindful of your neighbors, and watch out for everybodys
safety. The safety procedures for the laboratories are detailed in a separate section of the
syllabus and also in the lab manual. It is the students responsibility to become fully
acquainted with these procedures prior to the laboratories.
SAFETY VIOLATIONS WILL NOT BE TOLERATED AND WILL RESULT IN
EXPULSION FROM THE CLASS WITH A FAILING GRADE.

Feedback on class:
Feedback on the class is always accepted. Particularly if there is something about the
class that you dont like and have ideas on how to improve it, please let the instructor
know so the class can be improved. The preferred (though not exclusive) method is an
anonymous note delivered either in class or office.

DSS students:
The intent is to make all accommodations that are helpful to the student. Please identify
yourself to the instructor to have a conversation on how your needs can best be met.

Textbook Policy:
Manufacturing Engineering and Technology, Kalpakjian and Schmid, current edition. is
the required text for this course.

Class time required:

This class is anticipated to take approximately six hours/week in addition to the two hour
lecture and additional laboratory attendance and assignments. This time is an estimate
that you should adjust based on your reading speed and studying efficiency. If you have
not allotted this amount of time for the class you are in danger of failing. It is
recommended that you adjust your schedule to allow the time or drop the class.

Academic integrity:
Cheating is property theft and will be treated accordingly. Dont do the crime if you cant
do the time. Academic integrity will be enforced strictly according to university policy as
described in the university catalog. This can include statements in your transcript that
employers typically review prior to hiring.

Reference policy:
NOTE: INTERNET REFERENCES WILL NOT BE ACCEPTED FOR THE
ASSIGNMENTS. Internet tools and sites, such as Wikipedia, can be used to guide an
information search, however, the actual information needs to be from a reviewed source
such as a textbook, handbook, research papers, etc. It is important to note that reviewed
published material is made available through the web, for instance, ASM Handbooks that
are available through our library. These are still reviewed sources. In most websites,
unfortunately, much of the information is NOT reviewed, and some is factually wrong
and there is little way of verifying except for looking at reviewed sources.

Study Guide:
A study guide for the class is available at the Blackboard site under Course Documents.
The student should study for this class by examining the items in the guide as they are the
most important to the class first. Then, the student should complement the information
with the material in the book, as the student is responsible for all this information.
Learning the material in the study guide items should be approached in a broad sense,
meaning learning roughly a paragraph worth of information using the modules, videos,
class and text book. Once the student has met the study guide, he/she should continue to
the rest of the material in the book. You should be able to recognize, understand, define
and apply each concept covered. For instance, if an item were to read The student will
know and understand how to use the turn signals in a car, the intent is that the student
will know how to actuate the turn signals, what information they provide to other drivers
and pedestrians, what are the laws regulating the use of turn signals, etc. Not simply how
to push the lever up or down. Vocabulary terms and questions listed in the back of the
chapters are other useful guides to check understanding.

Sample exam questions have also been placed in this section of Bb.

Laboratory Instructions:
The pertinent laboratory instructions have been posted on Bb under resources.
Students are responsible to have the proper instructions read and printed for the
laboratories. Also watch any videos assigned. Note: The green sand casting video series
takes about one hour.

Schedule (Tentative):
Week Date Lecture Topic to be read prior to lecture (Thurs) that week. Lab
1 3/30 Intro to course/ Casting Ch 10 Safety
2 4/6 Casting Ch 11, 12 MC1/MC2
3 4/13 Forming Ch 13 MC1/MC2
4 4/20 Forming Ch 14, 15 SM1
5 4/27 Exam I (Ch 10-12), Forming Ch 16 P2
6 5/4 Forming Ch 16 P1/P3
7 5/11 Powder Metal Ch 17, Ceramics Ch 18, W1
8 5/18 Exam II (Ch 13-16), Plastics, Composites Ch 19, Joining Ch 30, W2
9 5/25 Joining Ch 30, 31 MC3
10 6/1 Joining Ch 32, Surface Treatments 34 D2
Final Thursday 6/10 6:00-8:00 PM
(Ch 17-19, 20-32, 34), Comprehensive.
Note that online assignments have already been posted on Blackboard and they are to be
watched prior to the assigned classes.

Laboratories:
1. Introduction/Safety (Intro):
a. Laboratory Locations
b. Overview of laboratory exercises/objectives
c. Safety: NOTE: ANY DISREGARD FROM SAFETY GUIDELINES
WILL RESULT IN EXPULSION FROM THE COURSE WITH A
FAILING GRADE.
 d. There will be a laboratory safety exam that will be taken during lab in the
second week. An 80% pass is required to begin accumulating laboratory
credit.
e. Daily lab schedule: 2 hours. Introduction/demo/safety briefing (10-30
minutes), Lab (up to 2 hrs, 20 minutes), clean up (2:20-2:30). This allows
for contingency plans if labs run longer.
2. Metal Casting 1: (MC1). Location: 17-1307 (Foundry) Green Sand, Truck body,
Sand Testing
3. Metal Casting 2: (MC2). Location: 17-1307 (Foundry) Lost Foam
4. Metal Casting 3: (MC3). Location: Computer lab. Casting Simulation
5. Metal Casting 4: (MC4). Location 17-1307 (Foundry) Gating and fluidity
experiments.
6. Sheet Metal 1: (SM 1). Location: 17-1540 (Machining Lab) Truck Bed
7. Sheet Metal 2: (SM 2). Location: Tour
8. Welding 1: (W1). Location: 17-1544 (Welding Lab) Oxyfuel
9. Welding 2: (W2). Location: 17-1544 (Welding Lab) Electric, Truck Stand
10. Adhesives: (A1). Location: 17-1544 (Welding lab)
11. Plastics 1: Tooling (P1). Location: 17-1307 (Foundry)
12. Plastics 2: Injection (P2). Location: 17-1307 (Foundry)
13. Plastics 3: Thermoforming (P3). Location: 17-1307 (Foundry)
14. Process/Part Design 1: (D1) Casting. Location: 17-1540 (Machining Lab)
15. Process/Part Design 2: (D2) Forming/Welding. Location: 17-1540 (Machining
Lab)