ME/ISE 110 Manufacturing Processes

Semester

Fall 2009

Credit Units

3 units, Lecture + Lab

Prerequisites

ME 20 (Design Graphics), MatE 25 (Introduction to Materials)

Class Hours & Catalog Details

Description

Fundamentals of manufacturing processes such as machining, forming, cutting, welding and casting. Selection of materials. Production facility practices and metrology. Geometric dimensioning and tolerancing. MATE 25, ME 20. Misc/Lab: Lecture 2 hours/lab 3 hours.

Instructor

Prof. Samuel Obi  |  IS 105  |  408-924-3218  | sobi@email.sjsu.edu

Office Hours tentatively Thursday 12:00-5:00 PM.

http://www.engr.sjsu.edu/sobi/

Course Website

General Information: http://www.engr.sjsu.edu/sobi/

Required Textbook

& Other Materials

1. S. Kalpakjian & S. Schmid, Manufacturing Engineering and Technology, 6th ed.,     New Jersey: Prentice Hall, 2010 (ISBN 0-13-148965-8).

3         2. Scientific hand calculator with trig and square root functions

4         3. Safety goggles

5         4. Digital calipers

6         5. Rags

7         6. Flash drive

8         7. Term Project Raw Materials

Graded Work

& Associated Weights

15% for Spot Quizzes: (6-1 X 15/5 = 15%)

15% for Mid-Term Exam: (60/4 = 15%)

25% for Final Exam, scheduled Monday May 18, 9:45-12:00: (100/4 = 25%)

10% for each of two Prescribed Lab Projects: (50/5 X 2 = 20%)

5% for Lab Citizenship & Participation: (25/5 = 5%)

20% for Term Project: (100/5 = 20%)

Total = 100%

Course Goals and Learning Objectives

Course Goals

§         Acquire familiarity with a wide variety of manufacturing processes

§         Understand material properties and basic physics behind various methods of material transformation.

§         Build the knowledge to match design requirements with the most suitable manufacturing processes and materials.

§         Gain direct experience with common manufacturing tools and machinery.

§         Promote interactive learning through teamwork and technical communication.

Student Learning Objectives

Upon successful completion of this course, the student should be able to:

§         Identify candidate materials and processes appropriate for given design requirements.

§         Make relative comparisons among a wide variety of engineering materials in terms of mechanical properties and workability.

§         Describe capabilities and limits for several manufacturing processes in terms of size, accuracy, precision, surface quality, and production rate.

§         Use common manufacturing tools, machinery, and metrology instruments safely and properly.

§         Communicate manufacturing considerations throughout the design cycle, not only in terms of the physical process but also in terms of cost, volume, and automation.

§         Propose reasonable strategies for fabricating new engineering components that have no pre-existing standard production method.

Instructor's Policies, Expectations, and Tendencies

These points discuss a few important issues that may arise in an instructor-student relationship during a course.   My intent is to communicate expectations as clearly and as early as possible, and to do my sincere best in being consistent throughout this course.

1.       Both student and instructor share the responsibility of verifying that the syllabus (greensheet) is sufficiently clear and thoroughly understood.

2.       Any grade-related dialog (request for re-evaluation, etc.) must be in writing.  Verbal discussion is welcome for preliminary inquiry, but will not be considered binding.  Email messages for which both sender and receiver keep copies are usually sufficient.

3.       Students are responsible for staying aware of assigned work, deadlines and announcements.  These are often stated at the very beginning of a class period, and even if tardy or absent the individual has personal responsibility to keep track of course requirements (by contacting a classmate, checking online postings, visiting office hours, etc.).

4.       I do not give credit for late work (unless specifically allowed in particular assignment instructions), nor am I open to discussing verbally.  I strongly believe that "lenient to one is unfair to all others."  Any appeals for extenuating circumstances must be addressed strictly in writing.

5.       The SJSU Academic Integrity Policy S07-2 defines roles and obligations for both students and faculty, with severe consequences.  I have in the past caught instances of academic dishonesty and do report them.  All work submitted for grading is expected to be original and (except for explicit group assignments) strictly individual.

6.       I respond to class-related email strictly within the class-specific email system, and thus require students to keep a current email address up-to-date.  Messages to me may be sent to my general university account (sobi@sjsu.edu).

7.       At least one week's notice will be given of announcements and/or changes in forthcoming exams.

8.       No make-up of examinations shall be given, except if an emergency arises.  Such situations must be documented immediately.

9.       All assignments are due as scheduled and must be typewritten or they will not be accepted.

10.    NO PAPERS WILL BE ACCEPTED LATE UNLESS PROPER AND APPROVED WRITTEN PERMISSION HAS BEEN OBTAINED BEFORE THE DUE DATE.

11.    Assignments are due at the BEGINNING of the class period on the designated due date.

12.    Students are expected to have read specific reading assignments before they are discussed in class. Some of the spot quizzes will be given from these assignments.

This is an evolving document that incorporates feedback from students across several semesters.  If you have helpful suggestions, especially of the type "I wish he would have said so at the beginning of the course!", please do consider sharing for the benefit of future students.  Thanks.

Course-Related Costs

Textbook

The course textbook is indeed required and reading is essential.  All references to textbook sections and page numbers will be based on the official (6th) edition.

S. Kalpakjian & S. Schmid, Manufacturing Engineering and Technology, 6th ed., New Jersey: Prentice Hall, 2010 (ISBN 0-13-148965-8).

Project raw Material

Raw materials for the two prescribed lab projects will be provided.  However, students are responsible for raw materials needed for the Term Project.  Therefore it is very important to discuss project ideas with your instructors, so that they can help you choose one that does not demand costly expenses.  Another option is to work on a service-related project for a sponsor who would be willing to compensate project expenses.

Machine Tools

Essential tools for the class-wide prescribed projects will be provided.   However, for the Term Project, individuals are responsible for any unique tools (e.g. custom bit sizes or cutter shapes, etc.) that individual projects may require beyond what is routinely available.  Again it is very important to discuss project ideas with your instructors, so that they can help you choose an affordable plan.

 Measuring Tools

Each student is required to have his/her own set of calipers for lab.   Prices vary from less than $20 to well over $100, so it is advisable to solicit suggestions from instructors based on your constraints and long-term plans for engineering activity even beyond this class.  Do ask your instructors and peers for information regarding different styles and brands, as well as vendor options.  In cases of financial hardship, work-around strategies such as sharing with a designated classmate may be worth exploring.

Grading Scales

San José State University uses a 4.0 scale for computing Grade Point Average with 4.0 = A, 3.0 = B, 2.0 = C, and 1.0 = D, adjusted by 0.3 for "+" and "-" modifiers.   I interpret "C" as "adequate", "A" as "excellent",  and "B" as generally good performance in between "C" and "A". Grades will be computed from the ratio of total points achieved to total points possible, as follows: 

97+% = A+, 93-96 = A, 90-92 = A-; 87+% = B+, 83-86 = B, 80-82 = B-; etcetera.

University, College, and Department Policies

This page provides mandatory policy information in partial fulfillment of requirements established by Academic Senate policy F06-2 regarding course greensheets (syllabi).  The full text of F06-2 may be found at http://www.sjsu.edu/senate/F06-2.htm.

  Academic Integrity Statement from the Office of Student Conduct and Ethical Development (Quoted from F06-2):

“Your own commitment to learning, as evidenced by your enrollment at San José State University, and the University’s Academic Integrity Policy requires you to be honest in all your academic course work. Faculty members are required to report all infractions to the Office of Student Conduct and Ethical Development. The policy on academic integrity can be found at http://sa.sjsu.edu/student_conduct."

Campus Policy in Compliance with the Americans with Disabilities Act (Quoted text from F06-2):

“If you need course adaptations or accommodations because of a disability, or if you need special arrangements in case the building must be evacuated, please make an appointment with me as soon as possible, or see me during office hours. Presidential Directive 97-03 requires that students with disabilities requesting accommodations must register with DRC to establish a record of their disability.”

Information for the Disability Resource Center (DRC) can be found at:

http://www.drc.sjsu.edu/

Presidential Directive 97-03 for Accommodations for Students with Disabilities can be found at:

http://www.sjsu.edu/president/directives/

Policies or information required by the Department of Mechanical and Aerospace Engineering

The department enforces strict sanctions regarding prerequisites.  One specific sanction is that any student enrolled in a course without satisfactory completion of the official prerequisites will receive a letter grade of "F".

Spot Quizzes

 Spot Quizzes are used as a tool for formative assessment of learning on a relatively frequent basis throughout a course.  The content of a Spot Quiz is normally be based on recently covered lecture material, recently assigned reading, and/or recently completed homework.  More specific information for a particular Spot Quiz would be announced in class.  Emphasis is placed on the most basic knowledge and skills covered in recent past, as opposed to advanced skills or more complex synthesis of knowledge over a more comprehensive period.

In a given semester there would be typically six (6) Spot Quizzes.  A Spot Quiz may be administered on any class day and at any portion of the class (i.e. a "pop" quiz).  However, more typically the exact day will be pre-announced at least one class prior to any given Spot Quiz.  So it is very important to keep up with class announcements even when absent from class (by contacting a classmate, checking online announcements, etc.). 

Spot Quizzes are intended to be completed in a time window typically between 5 and 15 minutes except in a few cases.  The actual time limit will be based on the class-wide start time, and there will be no extra time allowed for anyone who arrives or starts late. Furthermore, it will be up to the discretion of the instructor whether or not a late-comer is allowed to begin a Spot Quiz after it has officially started for the rest of the class.  So being on time for class is important, especially for Spot Quizzes that may be conducted at the very beginning of a class period.

To accommodate any missed Spot Quizzes because of unavoidable absences or tardiness, one (1) of each student's lowest scores (which includes any missed  quizzes scored as zero) will be dropped when computing average scores.  Reasons for absence or tardiness encompass almost all conceivable situations including illness, travel, job obligations, non-emergency medical/dental appointments, commute delays, etc.  Accordingly there are no make-up options nor petitions for missed Spot Quizzes.

Projects
There will be three lab projects in this course. The first is a sheet metal project. The second will involve machining activities. The third will be a team project. Details on these will be provided in class.

Course Examinations
There will be one midterm and one comprehensive final examination, covering reading assignments, lectures, classroom discussions, field trips, and laboratory exercises. The midterm and final will be announced at least one week in advance, and will occur close to the dates scheduled for the course.                 

Reading Assignments
All textbook reading assignments must be completed according to the activity schedule, and students must be prepared for discussion of weekly reading topics in class.