TECH 048: PRODUCT PROTOTYPING AND NON-TRADITIONAL MANUFACTURING
UNIT 1:
The following terms and phrases have
been selected from outside and unit materials. Students are expected to have
read related sections before class discussions.
The development of a product involves several major steps which must be carefully planned and executed. This unit introduces these steps, and prepares the student for subsequent activities.
1. Planning Manufacturing Systems:
Product Determination
a)
What is manufacturing?
b) Identify
potential product using brainstorming technique
c)
Function
d)
Parts or components (at least 3)
e)
Material(s) (aluminum recommended)
f)
Manufacturing properties of the material(s)
g)
Machines and tools (check for availability)
h)
Processes (check for availability and skill requirement)
i)
Cost factor (affordability; must be shared by group members)
j)
Manufacturability
2. Planning Manufacturing Systems:
Planning and Scheduling
a)
Materials (costing, ordering, properties, availability, processes etc.)
b)
Machines, tools and tooling (availability and/or ordering)
c)
Other resources (availability, hiring, implementation and/or ordering)
d)
Task identification
i.
Design of parts
ii.
Pattern making
iii.
Mold making
iv.
Casting
v.
Jig and fixture design
vi.
Jig and fixture fabrication
vii.
Bill of materials preparation
viii.
Purchase of other parts and sources
ix.
Machining
x.
Applying the jig and fixture
xi.
Modifications and finishing
xii.
Assembling and touch up
xiii.
Reporting and presentation
e)
Task analysis
f)
Meeting time
g)
Lab and tool management
h)
Reports
i)
Presentations
j)
Demonstrations
k)
Developing a comprehensive schedule
3. Planning Manufacturing Systems:
Product Design
a)
Part design by each student
b)
CAD systems available
c)
System resources and locations
d)
Complete views and/or 3-D required
e)
Complete dimensions required
f)
Full information must be provided
g)
Each drawing relates to other drawings (assembly)
h)
Design for manufacture, assembly, disassembly & service
i)
Modifications
j)
The design process and concurrent engineering
4. Planning Manufacturing Systems: Pattern
Making
a)
Pattern materials
b)
Pattern allowances
c)
Available machines and tools
d)
Pattern fabrication (skill, rules, and safety)
e)
Finishing
f)
Assembly
g)
Lab safety
5. Planning Manufacturing Systems:
Casting
a)
Available materials
b)
Available tools and implements
c)
Procedure
d)
Green sand molding technique
e)
Furnace and melting
f)
Pouring
g)
Cooling and breaking
h)
Deburring and cleaning
i)
Foundry management
j)
Foundry safety practices
6. Planning Manufacturing Systems: Jig
and Fixture
a)
Purpose of Jig and Fixture
b)
Selection and design of jig and fixture (one per student)
c)
Jig and fixture materials
d)
Fabrication of jig and fixture
e)
Finishing and testing jig and fixture
7. Planning Manufacturing Systems:
Machining of Parts (Castings)
a)
Available machines and tools
b)
Availability of jig and fixture
c)
Functionality of jig and fixture
8. Planning Manufacturing Systems:
Reporting and Presenting
a)
See group project instructions on reports, format and attachments
b)
See group project instructions on group presentation date and format
c)
See semester schedule for due dates