MET 142 – Manufacturing Processes I -- Fall 2001
Text: Materials and Processes in Manufacturing, by Paul E. DeGarmo, Temple J. Black, Ronald A. Kosher; 8th Edition; at book stores. This text is also on reserve at the front desk of the Engineering Library in Potter (behind MGL). You must ask for it by the author’s last name, DeGarmo.
Lab Manual: MET 142 Manufacturing Processes I Lab Manual, Fall 2001, by C. L. Corum, available for purchase at the Copy Center in the Purdue Memorial Union Instructors: Assoc. Professor Christine Corum Knoy 113, 49-47530 Chris Devers (lab instructor) Knoy 287, 49-66092
Office: Email: Office hours: MON & WED 9:30a – 11:30a THU 1:00p – 3:00 p Other times by appointment
Material: You are expected to furnish your own safety glasses for the lab sessions. For welding you are expected to furnish welding gloves, and welding caps. Lab materials can be purchased in MGL 1208 during lab. There is limited locker space in lab. Consider sharing a locker to store your safety equipment in. You can not participate in laboratory activities without wearing required safety equipment! Course Schedule: Your lecture schedule is attached. Students will be divided into two groups for lab sessions. These two lab groups will not work on the same activity at the same time so there are effectively two separate lab syllabi. Be sure you always refer to the lab schedule for your lab group! Course Measurement: Course grades are typically determined as A = 90-100%, B = 80-89%, C = 70-79%, D = 60-69% and F = 59% or below. The course grade will be a weighted average of tests, quizzes, homework and lab exercises in the following manner: 6 Tests (10% each) = 60% Lab Exercises = 30% Quizzes & Homework = 10%** Total = 100% In order to pass this course you must: maintain an average of no less than 55% on all exams, maintain an overall course average of no less than 60%, and complete (score 5 or 10) at least 11 of 13 lab exercises. ** I will remove your lowest homework or quiz score from your “Quizzes & Homework” grade. Laboratory Exercises: While you will not become an accomplished welder or foundry operator in a few weeks, your “product” will be evaluated. The intent is to practice and have your score reflect what you have learned about casting, welding and polymer manufacturing as well as the quality of the product. Each laboratory exercise (there are a total of 13, including lost foam casting) will be graded on the basis of zero (0), five (5), or ten (10) points. Zeroes (0) will be assigned for all missed labs. Tens (10) will be
assigned for each lab attended and fully participated in. A five (5) will be assigned for any labs which a student attends but does not fully participate in, i.e., leaves lab early, does not hand in required paperwork at end of lab, does not take part in lab activities, does not complete all assigned work or answer all assigned questions, etc. A student will not be able to pass this course if he or she misses three (3) or more lab sessions! You will notice that I have included an opportunity for making-up labs in the lab schedule. You must inform your instructor one week in advance if you intend to make-up a lab. You must also let us know which lab activity you will be making up. The only labs that cannot be made up are 1) investment casting and 2) lost foam casting. Exams, quizzes and homework: There will be six tests covering lectures and laboratories between them. The tests will be given during normal lecture time in our regular classroom. The only exception will be the sixth test, which will be administered during Final Exam week, location and time to be announced. There will be no opportunity for making up tests. A missed test will be scored as a zero! There will be a number of short in-class quizzes covering material presented in that lecture and/or previous lecture material. To reward attendance, the minimum score on quizzes will be 50%. For most lecture periods, a number of recommended review questions are listed. These review questions should be used to help you prepare for lectures and exams. Review questions may be collected for homework credit as announced class. Be prepared to hand in homework assignments at the beginning of class. Late homework will not be accepted. Assigned homework can be turned-in in advance. There is a format requirement for homework assignments. Please refer to the homework formatting handout. Homework formatted improperly will earn only partial credit. Attendance: Students are expected to be present for every class meeting (lectures and labs). I will frequently take attendance during lecture. You should not miss labs, since it is difficult to complete the required lab exercises at any other time. Your lowest quiz/homework grade will be dropped, so if you miss one lecture where homework was collected or a quiz was given and receive a zero, that zero would not be included in your quiz/homework grade. Any additional zeroes will be included in your grade. Disabling Conditions: Any student who, because of a disabling condition, may require special arrangements in order to meet course requirements should contact the instructor by the third week of class in order to make necessary accommodations. Students who do not contact the instructor by the third week of class, or as soon as they know they have a disabling condition, forfeit their rights to special accommodations. Students must work with the Dean of Students Office in order to receive special accommodations for this class. Core Learning Objectives - MET 142 Upon successful completion of this course, the student should be able to: 1. 2. 3. 4. 5. Communicate easily with colleagues in their field. Identify basic process variables and predict their general effect on the product quality. Specify adequate processes for their particular manufacturing need. Make basic recommendations related to product design that would allow more efficient manufacturing. Perform quality inspection, analyze basic manufacturing-related defects, and recommend appropriate modification that would be likely to reduce or eliminate the defects.
Date Tu 8/21 Th 8/23 Tu 8/28 Th 8/30 Tu 9/4 Th 9/6 Tu 9/11 Th 9/13 Tu 9/18 Th 9/20 Tu 9/25
Lab TA's Joel & Brandon Orientation to Welding & Order Welding Equipment Demonstration of SMAW SMAW 1: Equipment assemply and use, striking and controlling an arc, run beads, fillet weld Group A students use first 55 minutes (begin @ 11:30) Group B students use last 55 minutes (begin @ 12:25) SMAW 2: Lap joint, GMAW, PAC, RW Soldering and Cutting SMAW 1: Equipment assemply and use, striking and controlling an arc, run beads, fillet weld Soldering and Cutting SMAW 2: Lap joint, GMAW, PAC, RW
Graduate Instructor Chris Devers Orientation to Manufacturing Lab
Polymers 1: Rotational molding, blow molding, chemical foam molding, expanding bead molding, injection molding (screwdriver handles)
Polymers 2: Compression molding, vacuum molding, extrusion, hot dipping Orientation to Welding & Order Welding Equipment Demonstration of SMAW Polymers 1: Rotational molding, blow molding, chemical foam molding, expanding bead molding, injection molding (screwdriver handles)
Polymers 2: Compression molding, vacuum molding, extrusion, hot dipping
Metal Casting: Sand Testing Th 9/27 Tu 10/2 Metal Casting: Orientation, demonstration and cast hand & wheel Th 10/4 Tu 10/9 No labs will meet this week for OCTOBER BREAK! Th 10/11 Tu 10/16 Metal Casting: Sand Testing Th 10/18 Tu 10/23 Metal Casting: Orientation, demonstration and cast hand & wheel Th 10/25 Tu 10/30 Th 11/1 Tu 11/6 Th 11/8 Tu 11/13 Th 11/15 Tu 11/20 No labs will meet this week for THANKSGIVING BREAK! Th 11/22 Tu 11/27 Th 11/29 Tu 12/4 Th 12/6 Metal Casting: 2-Blade propeller with core Lost Foam mugs Metal Casting: CO2 process Lost Foam mugs Metal Casting: CO2 process Lost Foam mugs
Investment Casting Week 1 of 2
Investment Casting Week 2 of 2
No labs will meet this week for OCTOBER BREAK!
Metal Casting: 2-Blade propeller with core Lost Foam mugs
Investment Casting Week 1 of 2
Investment Casting Week 2 of 2
Metal Casting: Pulley split pattern Lost Foam mugs Metal Casting: Squeeze press medallions, spin casting, permanent mold casting Lost Foam mugs
No labs will meet this week for THANKSGIVING BREAK!
Metal Casting: Squeeze press medallions, spin casting, permanent Metal Casting: Pulley split pattern mold casting Lost Foam mugs Lost Foam mugs Opportunity for lab make-up See comments on course syllabus Opportunity for lab make-up See comments on course syllabus Green = Group 1 students
Yellow = Group 2 students