350 ME Lecture 1 Chapter 1 & 2
ME 350 Design for Manufacturability
Instructor:
email:
office hours:
office:
Keng Hsu,
[e-mail]
Wed: 10-11:30am, Frid: 10-11:30am
4225 MEL
Lab TA s:
Ming Huo;
Cheng Wang;
Apoorv Kalyankar;
Young Min Ahn
Scott Daigle
Tristan Herman;
Sohan Kale;
Labs will meet in 1227 MEL starting next week
Textbooks & References
Groover, M. P., Fundamentals of Modern
Manufacturing, 4th Edition, John Wiley (Available at
IUB and Folletts)
Make sure you have the DVD with the book.
References (available at engineering library):
1) Kalpakjian, S., and Schmid, S.R., Manufacturing Processes
for Engineering Materials, Addison Wesley, 4th edition, 2003
2) Callister, W. D, Materials Science and Engineering, Wiley,
2003
3) Devor, Statistical Quality Design & Control, 2006
Grading and Homework Policy
Grading:
Homework
Hour Exams
Labs
Final Exam
25%
25%
20%
30%
Grade Distribution:
A to A-:
B+ to B-:
C+ to C-:
D to F:
25-35%,
35-45%
20-30%,
< 5%
Homework Policy:
Late penalty 20%, and not accepted after 1 week
Posted on class website Thursdays by midnight and due the
next Thursday in class
(http://mechse.illinois.edu/content/courses/web_sites.php)
Download and print out the assignment and write directly on it
Three Hour-Exams and Final:
In class, close book and notes. Only pencil(s),
an eraser, and a calculator are allowed at your
desk. Dates: Feb 15th, Mar 15th, & Apr 19th.
Typical problems: true/false, short answer, and
quantitative analysis (equation sheet provided).
No phone calls or writing after time called
Makeup exams: with medical excuse only.
Lab Schedule
Week
Lab
What to hand in
What to get back
1
Jan 17-23
No Lab
2
Jan 24-30
ProE
3
Jan 31-Feb 6
Rapid Prototyping
4
Feb 7-13
CAD/CAM
5
Feb 14-20
CAD/CAM
Rapid Prototype
6
Feb 21-27
Sand Casting
CAD/CAM
Rapid Prototype
7
Feb 28-Mar 6
Injection Molding
Sand Casting
CAD/CAM
8
Mar 7-13
Injection Molding
9
Mar 14-20
No Lab
10
Mar 21-27
No Lab
Spring Break
11
Mar 28-Apr 3
No Lab
12
Apr 4-10
Design of Experiment
13
Apr 11-17
Design for Assembly
Design of Experiment
14
Apr 18-24
Design to Cost
Design for Assembly
15
Apr 25-May 1
No Lab
16
May 2-4
No Lab
Exams
RP parts
HE 1
Sand Casting
Injection Molding
HE 2
Injection Molding
Design of Experiment
Design for Assembly
HE 3
Lab Participation & Reports
Lab Attendance and Participation
Each student is expected to attend and actively participate in every two-hour laboratory, read the
lab handout, prepare for the in lab quiz, and/or complete the pre-lab assignment for the
experiment before coming to their lab section. Each student should also bring a calculator, pens
and pencils, notepaper, and the lab handout to each laboratory session.
Students may be allowed to attend a different laboratory session with written notification from the
emergency dean due to a medical emergency. Other requests must be considered by the
instructor. The penalty for an unexcused absence from a laboratory session or tardiness in excess
of ten minutes is 10% off the lab report grade for that experiment.
Lab Reports & Grading
The laboratory portion of the course grades is based on prelab assignments, in lab quizzes, and
the lab reports. Completed computer generated paper reports are to be submitted to your TA at
the beginning of lab on the designated due date. The reports are due immediately at the start of
the lab period. The penalty for late submission is 10% for 1 minute to 1 hour late, and 20% for 1
hour to 24 hours. No credit will be given reports for turned in after 24 hours after your lab. Limited
extensions to written report deadlines will be considered only in cases of extended illness or
personal emergencies of a serious nature.
Although students typically perform laboratory work and preliminary data reduction in groups of
two or more, each student is responsible for the preparation of his or her own independent report,
and each student is graded individually. Confirmed cases of plagiarism, including copying all or
portions of reports of present or former students, submitting reports completed in part or in entirety
by others, using data from other lab sections, or using fabricated data, will automatically result in
any or all of the following actions: a zero grade being recorded for that report; failure of the course;
and referral to officers of the College of Engineering or University
What is Manufacturing and Why
Steel
Aluminum
Polypropylene
Copper
Rubber
Silicon
Manufacturing
segwayofthehudsonvalley.com
Course Objectives
Acquire a general overview of modern manufacturing
processes and knowledge of state-of-the- art process
technologies.
Conduct basic analysis of manufacturing processes as a tool
for understanding the physical process capabilities, tolerances
and limitations.
Develop ideas and guidelines to evaluate design and
manufacturing trade-offs.
Hands-on exposure to manufacturing processes, CAD/CAM,
rapid prototype, metal sand casting, injection molding, designfor-assembly (DFA), Design to Cost (DTC), and design-ofexperiments (DOE) methodologies through lab sessions.
Topics Covered (~30 chapters):
Rapid prototyping
Machining CNC/Abrasive/Nontraditional
Molding
Casting
Composite manufacturing
Welding/Soldering/Joining
DFA
MEMS
Design to Cost (DTC)
Manufacturable Materials
1. Metals
Steel, iron, nonferrous metals and alloys.
2. Polymers
Three catagories: thermoplastics,
thermosets, and elastomers
3. Ceramics
Glasses (i.e. that melt), and crystalline
ceramics.
4. Composites
Mixtures of the other three types
Figure 1.4 Classification of Manufacturing Processes
Processing Operations
Increases workpart s value by
altering:
shape,
physical property,
appearance
Three categories:
Shaping operations (e.g. casting,
forging, machining, etc.)
Property-enhancing operations
(e.g. heat treatment)
Surface processing operations
(e.g. clean, surface coating, etc.)
Assembly Operations
Two or more separate parts are
joined to form a new entity
Types of assembly operations:
1. Joining processes
create a permanent joint
Welding, brazing,
soldering, and
adhesive bonding
2. Mechanical assembly
fastening by mechanical
methods
Threaded fasteners
(screws, bolts and
nuts); press fitting,
expansion fits
What is DFM?
Design for Manufacturability (DFM): By
understanding and analyzing the fundamental
manufacturing processes, reduce the cost of
production while achieving optimal product quality
Quality and lifetime of the products should not be
left until the test stage, but actively brought into
consideration by design, manufacture and
assembly
Rule of 10: order of magnitude increase on the
cost when changes are made at later stages (from
part design subassembly assembly
manufacturing final product to market
customer)
Summary
Attend lectures, be on time, read
chapters, and participate.
We are going to cover a lot of
manufacturing processes their
strengths and weaknesses.
We are going to cover the tools to
understand and optimize manufacturing.
This class is to help you be able to better
design a product for manufacturing.