IE 312 Product Design and Manufacturing Processes: Syllabus
(Tentative)
Instructor: Prof. E. C. De Meter
Office: 217 Leonhard Bldg, University Park
Telephone: 814-863-7291
Email: ecd3@psu.edu
Office Hours:
Graduate Teaching Assistant: Kris Doll
Office: 204 Leonhard Bldg, University Park
Email: krd174@psu.edu
Office Hours:
Prerequisites: EMCH 213, EMCH 210 or EMCH 110H
Co-requisites: MATSE 259 or ESC 414M
TEXT
Kalpakjian, S. and S. Schmid, Manufacturing Processes for Engineering
Materials, 5th Edition, Prentice Hall, NJ 2001
Electronic Copies of Lecture Notes, Lab Notes, Lab Assignments, Course
Assignments, Example Homeworks & Solutions will be provided via ANGEL
COURSE OBJECTIVE
A manufacturing process is employed to transform the properties of inputs
(raw materials and/or work-in-progress) in accordance with prescribed
specifications and subject to constraints with regard to product cycle time,
lead time, cost, and quality. The objective of this course is to introduce
mechanical engineering students to design and manufacturing process concepts
that are critical to the production of finished goods on a commercial
basis. The course will focus on design specification and manufacturing
processes, with an emphasis on process selection and its consequences with
regard to process capability, process cost, and process lead time.
COURSE TOPICS
Course Introduction
Mechanical Product Attributes
Mechanical Properties and Metrology
Geometric Tolerance Specification and Metrology
Surface Texture Specification and Metrology
Manufacturing Process Overview
Machining Processes
Metal Casting Processes
Metal Bulk Deformation Processes
Sheet Metal Processes
GRADING
50% Team Laboratory Reports & Team Homework Assignments
25% Midterm Exam 1
25% Final Exam
COURSE CONDUCT
Students will learn through the web via videotaped lectures, videotaped
laboratories and web based question and answer sessions with the course
instructor and the course teaching assistant. They will also learn via
reading assignments, team laboratory assignments and team homework
assignments. All resources necessary to complete this course are available
on ANGEL. A schedule for the completion of assignments is provided on the
ANGEL course schedule.
Student Participation in Team Assignments
Students will work in teams of five students on team laboratory assignments
and team homework assignments. Team members are expected to communicate
electronically to coordinate and exchange data for the purpose of completing
team assignments. Students are highly encouraged to communicate as much as
possible to exchange ideas and help each other learn. Students are expected
to understand all information submitted in lab and team assignments.
Likewise, students are expected to review all feedback on graded
assignments.
Prior to the beginning of the semester, students will have the
opportunity to identify other students that they wish to team with.
Students will also be required to provide contact information (address, cell
phone number, daily schedule when they can be reached, email, etc.). At the
beginning of the semester, team assignments will be made by the course
instructor and posted on ANGEL.
A folder within ANGEL will be created for each team. This folder will
contain a file listing team contact information. The team will submit
laboratory reports, laboratory EXCEL analysis files and homework assignments
to this folder for grading. Lastly, the course TA will use the folder to
provide feedback on graded assignments.
Team Peer Evaluations
At the midpoint and endpoint of the semester, lab team members will rate
each other's performance as well as their own. This rating may be used to
adjust the laboratory and assignment grades of individual team members.
Team Laboratory Assignments
Laboratory assignments pertaining to metrology and manufacturing processes
will be provided to reinforce and add depth to concepts discussed in
lecture.
A team laboratory assignment will require students to:
Note that students will have the option of completing an extra credit
laboratory. Metrology Lab #4: Geometric Error Measurement II. Material
covered in this laboratory will not be covered in the exams.
Team Homework Assignments
Two team homework assignments pertaining to Geometric Dimensioning &
Tolerancing will be given. The assignments will provide a series of
questions regarding the interpretation of GD&T specifications as well as the
use of these specifications to insure design functionality. Students within
a team are expected to work together to submit the answers to the questions.
Exams
A midterm exam and non-cumulative final exam will be given will be given
during the semester at the student's site. The exams will be mailed to an
approved proctor (the student identifies a proctor and submit the paperwork
to be approved-see the Proctor Folder for more information). The proctor
will be responsible for administering the exam and insuring that the student
adhers with the exam regulations. The proctor will also be responsible for
mailing the completed exam back to Penn State.
The student will be responsible for providing the proctor's contact
information to the PSU web course administrator at the beginning of the
semester. Eligibility requirements for the proctor are posted in the
course Angel site.
The exams will have a multiple choice format. The exams will be closed
book and closed notes. However the student will be allowed to bring three
note sheets, hand/typed copied front and back. Each exam will have a two
hour time limit.
Weekly Question and Answer Sessions
Each week during the semester, the course TA will hold a two hour, web based
Q&A session in the evening. Students can log in, ask questions, and listen
to other exchanges between the course TA and students. The sessions will be
held using Skype (with a multi-platform, 25 seat bridge) with video, audio
and file sharing capability. Q&A sessions will also be available to view
via live streaming with email interaction. In addition, the course
instructor will conduct two web based Q&A sessions pertaining to GD&T. The
dates and times of these sessions will be posted in Angel at the beginning
of the semester.
ACADEMIC HONESTY POLICY
All students are expected to adhere to the policies regarding academic
integrity as outlined in section 49-20 of Policies and Rules for Students.
All infractions will be prosecuted to the fullest extent possible. While it
is expected that students will interact with each other outside of the
"classroom", all individual home works and exam solutions handed in must be
your own.
STUDENT DISABILITY POLICY
"Penn State welcomes students with disabilities into the University's
educational programs. If you have a disability-related need for reasonable
academic adjustments in this course, contact the Office for Disability
Services (ODS) at 814-863-1807 (V/TTY). For further information regarding
ODS, please visit the Office for Disability Services Web site at http://equity.psu.edu/ods/
In order to receive consideration for course accommodations, you must
contact ODS and provide documentation (see the documentation guidelines at
http://equity.psu.edu/ods/guidelines/documentation-guidelines). If the
documentation supports the need for academic adjustments, ODS will provide a
letter identifying appropriate academic adjustments. Please share this
letter and discuss the adjustments with your instructor as early in the
course as possible. You must contact ODS and request academic adjustment
letters at the beginning of each semester."
