The University of Michigan

Department of Mechanical Engineering 

Fall 2004

ME 481 - Manufacturing Processes

Course Outline

Week	Topic	Reading	Assignment
1	Introduction
2	Material Removal Processes	Ch. 8	8.98, 8.104, 8.108, 8.111, 8.121 You may use Table 8.3
3	Material Removal Processes	Ch. 9	9.45, 9.48, 9.49, 9.53 You may use Table 9.4
4	Computer Numerical Control	Notes	Programming
5	Casting Processes	Ch. 5	5.4, 5.8, 5.20, 5.32, 5.40
6	Casting Processes	Ch. 5	5.52, 5.53, 5.54, 5.55 Elliptical surface area ~187,208 mm^2
7	Metal Forming	Ch. 6	6.9, 6.11, 6.33, 6.39, 7.25, 7.27, 7.41
8	Metal Forming	Ch. 7	Handout
9	Polymer Processing Powder Metallurgy	Ch. 10 Ch. 11	10.8, 10.40, 10.63 11.45, 11.46, 11.49, 11.52, 11.53 May use Table 3.2 and Fig. 11.6a
10	Welding Processes	Ch. 12	12.4, 12.7, 12.66
11	Welding Processes	Ch. 12	Handout
12	Rapid Prototyping	Notes
13	Reconfigurable Manufacturing	Notes
14	Review

Textbook: Manufacturing Processes for Engineering Materials,
          by Serope Kalpakjian and Steven Schmid, Prentice Hall, 4th Edition.

References:  Manufacturing Engineering and Technology,
by Serope Kalpakjian and Steven R. Schmid, Prentice Hall, 4th Edition
            Chapters 19 and 34.

Manufacturing Processes and Equipment,

by George Tlusty

Prentice Hall

Manufacturing Engineering, Economics and Processes,

by Ludema, Caddell, and Atkins,

Prentice Hall

Chapters 8 and 11

21st Century Manufacturing,
by Paul Wright, Prentice Hall
            Chapters 4 and 5.

Course Grade:

Homework 10 %

Class Participation 10 %

Term Project 20 %

Exam 1 30 %

Exam 2 30 %

Lectures: Tu, Th 8:30-10:00 a.m.

Instructor: Prof. Kannatey-Asibu, Jr.

Teaching Assistant: Peter Adamczyk

Instructor Office Hours:

Tu, Th 3:00 - 4:00 p.m.

W       1:00p.m. - 2:00 p.m.

Or by appointment

Office: 3134 GGBrown. Phone: 936-0408

E-mail: asibu@umich.edu

All reading assignments must be completed ahead of time.

No make-up exams.

Do not hesitate to come and see me if you have any questions or problems.

Or you can call if that will be more convenient.

ME 481 - MANUFACTURING PROCESSES

Module 1 - Machining
The machining module will provide the students with insight into secondary operations and how they are influenced by primary 
processes such as casting. The basic mechanics of the metal cutting process will be discussed, using orthogonal cutting to illustrate 
the basic concepts. The principles of chip formation, tool wear, surface finish, machinability, cutting fluids, chatter, and machining 
economics will be discussed. Specific processes will then be introduced. These will include multip-point operations such as drilling and milling; abrasive processes such as grinding; and non-traditional processes such as laser machining, electrical-discharge machining, and electrochemical machining.

Module 2 - Casting
The module on casting will provide the students with breadth in primary manufacturing processes and how they influence secondary operations such as machining. The principles of sand, shell mold, permanent mold, die, plaster mold, precision investment, continuous, and centrifugal casting will be discussed. The advantages and disadvantages of each process will be outlined to provide a framework for deciding what process needs to be used for a given product. Students will be expected to specify what casting processes were used for select components, and to suggest alternate casting methods. This will be augmented with example casting product lines from local industry.

Module 3 - Metal Forming Processes
This module will enable the students to acquire basic insight into bulk deformation and sheet forming processes, and how they can 
augment machining processes. Forging, rolling, extrusion, drawing, swaging, shearing, bending, stretch forming, bulging, deep drawing, and spinning will be discussed, and illustrated using videotapes. Examples will be drawn from local industry product lines to illustrate some of the forming operations some components undergo before machining, and how they influence the subsequent machining operations. Students will be expected to specify what forming processes were used for select components, and to suggest alternate forming methods. This will be augmented with examples from local industry. Various forming processes will be simulated using computers.

Module 4 - Polymer Processing
This module will provide the students with a background on different types of polymers and how they are processed. Differences 
in the properties of thermoplastic and thermosetting materials will be discussed. Basic processing techniques such as compression, transfer, and injection molding will be discussed, along with extrusion, lamination, and filament winding, and illustrated using 
videotapes. Examples will be drawn from local industry to illustrate the various processes.

Module 5 - Powder Metallurgy
This module will emphasize the circumstances under which powder metallurgy becomes a viable alternative to conventional processes. Powder production, and their characteristics that affect the end product properties will be discussed. Mixing (blending), pressing, and sintering of powders will be discussed and illustrated using videotapes. Wherever possible, examples will be drawn from Focus: HOPE product lines to illustrate how parts may initially be produced by powder metallurgy and subsequently machined.

Module 6 - Joining Processes
The module on joining processes will provide the background necessary for specifying appropriate for assembling individual machined components together for form an integral unit. Mechanical fastening, welding, and adhesive bonding will be discussed and illustrated using videotapes. Wherever possible, examples will be drawn from local industry product lines to illustrate how machined components will subsequently be joined. The effect of the welding process on the properties and geometry of machined components will be emphasized. Computers will be used to analyze the heat flow and associated cooling rates that occur during welding, and their impact on the final product properties.

Module 7 – Computer Numerical Control (CNC)
This module will introduce students to the basic concepts on numerical control programming, focusing on manual programming. Different forms of instruction format, the g-code, specific examples to illustrate the concepts. Inverse time code, magic three code.

Module 8 - Rapid Prototyping
Students will learn about the basic steps associated with rapid prototyping: computer-aided design, part building (processing), and 
post-processing. The concepts of constructive solid geometry, boundary representation, and faceted approximation in CAD will be introduced. Common rapid prototyping formats such as the STL and IGES formats will also be presented. Part-building techniques involving liquid-based, powder-based, and solid-based systems. Major areas of application of rapid prototyping.

Module 9 - Reconfigurable Manufacturing Systems (RMS)
Students will be introduced to the basic characteristics of Reconfigurable Manufacturing Systems. The concepts of Modularity, 
Integrability, Customization, Convertibility, and Diagnosability will be illustrated. RMS systems will be contrasted with the more 
traditional production concepts such as mass production (transfer lines), lean manufacturing, and flexible manufacturing systems.
The concepts of system-level and machine level configuration will be discussed. Economic, design, control, and monitoring and 
diagnostics issues.

Module 10 - Semiconductor Manufacturing
This module will outline the basic characteristics of semiconductors. Processing of silicon wafers. n-type and p-type semiconductors. Characteristics of the p-n junction. The diode, transistor, field effect transistor, metal-oxide semiconductor. Processing of integrated circuits. Example NMOS manufacturing. Masking, photolithography, etching, doping, ion implantation, chemical vapor deposition. Packaging.

CATALOG DESCRIPTION:

Simple modeling and quantitative analysis of the processes used to manufacture mechanical systems; process costs and limits; 
influence of processes on the final mechanical properties of the product.

COURSE TOPICS:

1.Manufacturing systems.

2.Overview of manufacturing processes of use in industry.

3.Machining processes.

4.Deformation processes.

5.Welding processes.

6.Assembly processes.

7.Surface treatment processes with a focus on heat treating.

8.Solidification processes with a focus on metal casting.

COURSE OBJECTIVES* (numbers shown in brackets are links to department educational outcomes):

1.To teach the process-level dependence of manufacturing systems through tolerances [5, 11, 13].

2.To expose the students to a variety of manufacturing processes including their typical use and capabilities [5].

3.To teach the important effects that manufacturing processes may have on the material properties of the processed part with 
a focus on the most common processes [1, 5].

4.To teach the thermal and mechanical aspects, such as force, stress, strain, and temperature, of the most common 
processes [1, 5, 12].

5.To provide a technical understanding of common processes to aid in appropriate process selection for the material and required 
tolerances [1, 5].

6.To provide a technical understanding of common processes to aid in appropriate material selection for a predetermined 
process [1, 5].

COURSE OUTCOMES* (numbers shown in brackets are links to course objectives):

1.Document system, measurement and tolerance issues driven by process selection [1].

2.Given a part to be manufactured, identify candidate processes that are capable of creating the parts features [2].

3.Weigh tradeoffs between similar processes based on general pros and cons in terms of heuristic guidelines [2].

4.Compute force components of interest that are associated with processes that are performed by mechanical means [4].

5.Compute stresses and strains, both in-process and residual, for mechanical, thermal and thermo-mechanical processes [3, 4].

6.Compute temperatures and cooling trends in thermal processes [3, 4].

7.Evaluate process selections for a predetermined material [3, 4, 5].

8.Evaluate process selections for prescribed tolerances [2, 4, 5].

9.Evaluate material selection for a predetermined process [3, 4, 6].

ASSESSMENT TOOLS:

1.Regular homework problems.

2.Exams.