Wentworth Institute of Technology
Mechanical Engineering and Technology Department

Course:

MANF1000 Manufacturing Processes

Instructor:

Peter Rourke, CMfgE

Semester:

Spring, 2016

Catalog
Description:

This course is designed to provide a basic understanding of present-day manufacturing processes. Through lectures, demonstrations, and practical applications the student will be introduced to various manufacturing processes. Topics will include machine tools, welding, casting, sheet metal, and an introduction to numerical control programming.

Course
Goals:

This course is intended to both introduce students to basic manufacturing processes, and prepare them for future required project fabrications, including senior design.

Course
Objectives:

1	Learn and demonstrate safe shop practices.
2	Correctly use various precision measuring devices such as dial calipers, micrometers, and Vernier height gauges.
3	Demonstrate proficiency in the operation of basic machine tools including: drill press, engine lathe, and vertical milling machine.
4	Program and fabricate a part on a computer numerical controlled milling machine.
5	Develop a flat pattern, then cut, form, and fasten the part in sheet metal.
6	See and understand various rapid prototyping technologies, and know their applications.
7	Sand cast an aluminum part
8	Understand the application of various welding techniques. Each student will weld and tensile test a coupon using gas-metal arc welding processes
9	For both a practical application of GD&T as well as to emphasize the need for tolerances each student will build and evaluate a pneumatic engine. Images of some completed Wobblers.

Required
Text:

Kalpakjian, Serope and Schmid, Steven R., Manufacturing Engineering and Technology, 7^th ed., Pearson, Boston, 2014,
ISBN-13: 978-0-13-312874-1

Suggested
Reference:

Machinery's Handbook (28th Edition) Electronic ISBN: 978-1-59124-118-8

Grading:

· Homework and Quizzes 35%

· Laboratory 50%

· Course Participation 15% Wentworth Grading Policy

Manufacturing
Minor

If you intend to graduate with a minor in manufacturing it is important that you submit the Minor Declaration Form as soon as possible. By declaring the minor the departments are aware of the number of students that require courses, and will run sufficient sections to match the demand. Simply saying that you are working on the minor is not enough. You must declare the minor.

The following is a guideline for the course, rather than a weekly schedule. The order of events will actually depend on availability of the various laboratories, and the coordination of facilities amongst all the courses using them. The homework assignments will reflect the reading and lecture materials, as well as information presented during laboratory demonstrations. There will be a written quiz for each of the reading assignments.
	Topic	Description	Laboratory
1	Shop Safety	Introduction and Overview of Manufacturing: pages 1-33	ProtoTRAK SMX panel
2	Milling Processes	Chapter 24: Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing	Wobbler Prints Cylinder-plate Program
3	Metrology	Chapter 35: Engineering Metrology and Instrumentation. How to read a micrometer	Wobbler Prints
4	Turning Processes	Chapter 23: Turning and Hole Making Threading Operations	Tap Drill Chart
5	Foundry (AFS) 02/18	Chapter 10: Fundamentals of Metal Casting Chvorinov Chvorinov-2	Wobbler Base
6	Metal Casting 02/18	Chapter 11: Metal-casting Processes, Chapter 12: Casting Design
7	Welding Processes 03/17	Chapter 30: Fusion Welding Processes Design of Welded Joints	Welding Lab
8	Brazing and Soldering 03/17	Chapter 31: Solid-State Welding Processes Chapter 32: Brazing, Soldering, Adhesive-bonding
9	Metal Fabrication 03/24	Chapter 13: Metal Rolling Processes Chapter 14: Forging Processes	Layout
10	Forming and Drawing 03/24	Chapter 15: Metal Extrusion and Drawing Chapter 16: Sheet Metal Forming Processes
11	Numerical Control 03/31	Chapter 25: Machining Centers Computer Aided Manufacturing introduction	Conversational Programming
12	Final exam	Speed Week

Course Notes:

1. Please do not ask me when a quiz is due: check the site. Also, adequate time is always given for a quiz: usually a week. Please do not ask to re-open quizzes. Anticipate network difficulties by taking the quiz well before the due date. If you wait until the last day to take the quiz, and there are network problems, or problems with your computer, there is nothing I can do.

2. While the previous section contains the planned order of material presentation, lab scheduling conflicts may require syllabus changes

3. If you arrive to class or lab and do not see the electronic attendance sheet I use, it means you arrived late. You will be marked absent unless you stay at the end of the session and have me change the spreadsheet to mark you late.

4. ALWAYS have your safety glasses when attending any lecture or lab

5. A significant portion of the laboratory time will be the demonstration of correct use of the equipment, with an emphasis on safe operation.  The laboratory grade will reflect your prompt and consistent attendance to see these, and all other presentations. Please note the Institute's attendance policy.

Learning and Competency Objectives

Engineering and Engineering Technology programs must demonstrate that their students attain the following outcomes listed. Those that are shown in bold are areas most applicable to this course:

(a) an ability to apply knowledge of mathematics, science, and engineering

(b) an ability to design and conduct experiments, as well as to analyze and interpret data

(c) an ability to design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability

(d) an ability to function on multidisciplinary teams

(e) an ability to identify, formulate, and solve engineering problems

(f) an understanding of professional and ethical responsibility

(g) an ability to communicate effectively

(h) the broad education necessary to understand the impact of engineering solutions in a global, economic, environmental, and societal context

(i) a recognition of the need for, and an ability to engage in life-long learning

(j) a knowledge of contemporary issues

(k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice

The first and last activities of the course will include the instructor and students discussing how the course addresses the Institute learning and competency objectives through the goals and objectives specifically set out for the course.

DISABILITY SERVICES STATEMENT:
Any student who thinks s/he may require a disability-related accommodation for this course should contact Disability Services in the Counseling Center privately to discuss your specific needs.  Disability Services coordinates reasonable accommodations for students with documented disabilities.  They are located in Watson Hall 003 (the Counseling Center) and can be contacted at 617-989-4390 or counseling@wit.edu. For more information on acceptable documentation and the Disability Services process, visit the Disability Services website at www.wit.edu/disabilityservices

Helpful Links

1	Should you feel the need for divine intervention with some of the material presented in this course the patron saint of metal workers, machinists and smelters is Saint Hubert of Liege
2	If you need help from the Greek gods, Hephaestus, picture on the right, is our guy. Check out his work at http://www.kusadasi.tv/greek-gods-hephaestus.html
3	To "force" the network drives on: click the windows key then in the search box type: \\wit.private\netlogon A list of batch files will appear. Double click on the students file. The drives will come on in a moment.
4	Exceptional Links: · www.dump.com/2011/07/15/fascinating-1936-footage-of-car-assembly-line-video/ · Virtual Machine Shop
5	To map the network drive that serves the Manufacturing Center open a file browser, right click on Computer or This PC and click as shown below. Add the drive by typing \\drive.wit.edu\manufacturing When completed you will see all the information on the drive.