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Syllabus ME 3450 (10291-001): Manufacturing Processes I (3 CR)

Tue. & Thur. 5:30 p.m. 7:20 p.m., 0128 Manogin Lecture Hall INSTRUCTOR Xin Wu, Associate Professor Office: 2144 Eng. Bldg. Tel: (313) 577-3882; E-mail: xwu@eng.wayne.edu CLASS SCHEDULE AND LOCATIONS Class hours: Tuesday, Thursday: 5:30 p.m. 7:20 p.m. (Including exercise/HW analysis if needed), at 0128 Manogian Hall Office hours: Thursday 4:00-5:20 p.m. or by appointment for additional hours. COURSE DESCRIPTION The first course in ME manufacturing program that describes and analyzes various industrial manufacturing processes, mechanics and mechanisms involved, and their impact to product performances, economics, energy saving and environmental protection. (3 Credits) PREREQUISITES None (ME 2050 cumulative prerequisite) CO-REQUISITES ME 2410 Statics TEXTBOOK AND OTHER REQUIRED MATERIAL S. Kalpakjian, S., Schmid, S. R., Manufacturing Processes for Engineering Materials, 5th Edition, Addison-Wesley, 2008. COURSE OBJECTIVES (Letters in brackets refer to ABET Student Outcomes (a) - (k). Abbreviations in brackets refer to the methods of evaluation, with HW = Homework, QE = Quizzes & Exams, PC = Projects or Competitions, PR = Presentations, and RP = Reports.) Students who successfully complete ME 3450 will be able to: 1. function effectively within engineering work teams; [(d), (f); RP] 2. analyze metal forming methods as casting, forming, machining, and joining; [(b); HW, QE] 3. perform hands-on experiments in various stages of material manufacturing including initial material property testing (tension of wire and sheet), processing (plastic bending and rolling), and post-forming characterization (microhardness testing and microstructure examination); [(b); RP] 4. apply engineering principles in material processing and manufacturing to the product and manufacturing process design. [(b); RP] TOPICS COVERED Introduction of Product and Process Design, and Assignment of Design Project

Mechanical Behavior of Materials Material Structures and Manufacturing Properties Metal-Casting & Heat Treatment Bulk Deformation Processes Sheet-Metal Forming Processes Lab 1. Mechanical test: sheet and wire tensile tests Lab 2. Metal Rolling Lab 3. Sheet metal bending and springback Lab 4. Post-forming properties: micro-hardness and microstructures Material-Removal: Cutting Material-Removal: Abrasive, etc. Polymers and Reinforced Plastics Metal Powders, Ceramics, Composites Joining and Fastening Processes Micro and Nanomanufacturing Surfaces, Tribology, and Quality Design project presentation and discussion CONTRIBUTION TO PROFESSIONAL PROGRAM COMPONENTS This course contributes 3 credits to the Engineering component of the professional program. ABET STUDENT OUTCOMES (as revised on September 18, 2009) It is expected that by the time of graduation, our BSME students will have: (a) an ability to apply knowledge of mathematics, science, and engineering (b) an ability to design and conduct experiments, as well as to analyze and interpret data (c) an ability to design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability (d) an ability to function on multidisciplinary teams (e) an ability to identify, formulate, and solve engineering problems (f) an understanding of professional and ethical responsibility (g) an ability to communicate effectively (h) the broad education necessary to understand the impact of engineering solutions in a global, economic, environmental, and societal context (i) a recognition of the need for, and an ability to engage in life-long learning (j) a knowledge of contemporary issues (k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice.

GRADING POLICIES: Attendance 7% (based on signup sheets record) Homework 8% Exam 1 15% Exam 2 15% Lab reports 7.5% x 4 Design 25% At the end of the course the summarized scores will be curved to WSU letter grades. A TENTATIVE conversion is given below for reference: 90+% 86+% 82+% 78+% 74+% 70+% 66+% 62+% 58+% Below A AB+ B BC+ C CD+ F

There will be NO makeup labs. A make-up examination is only possible with sufficient written proof of medical or emergency situation that prevents you from participating an exam. ALL OTHER POLICIES: To follow university, college and department policies STUDENT DISABILITY SERVICES: If you have a documented disability that requires accommodations, you will need to register with Student Disability Services for coordination of your academic accommodations. The Student Disability Services (SDS) office is located at 1600 David Adamany Undergraduate Library in the Student Academic Success Services department. SDS telephone number is 313-577-1851 or 313-577-3365
STUDENT CONDUCT It is the responsibility of each student to adhere to the principles of academic integrity. Academic integrity means that a student is honest with him/herself, fellow students, instructors, and the University in matters concerning his or her educational endeavors. Thus, a student should not falsely claim the work of another as his/her own, or misrepresent him/herself so that the measures of his/her academic performance do not reflect his/her own work or personal knowledge. In this regard, cheating will not be tolerated. Cheating includes (but is not limited to) any communication (written or oral) during examinations and sharing of work, such as using the same processed lab results or copying work. All homework and projects must be an individual effort unless specifically noted. STUDENTS WHO CHEAT ON ANY ASSIGNMENT, LAB REPORTS, OR DURING ANY EXAMINATION WILL BE ASSIGNED A FAILING GRADE FOR THE COURSE. Therefore avoid all appearance of improper behavior! Students who witness cheating should report the incident to the instructor as soon as possible. Students are also welcome to discuss with Department chair on any concerns related to cheating.

The actual schedule may vary based on interactive learning progress and lab preparation readiness.
Class 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Date Text (Ch.) Ch01 Content Introduction Product and process design (continue) Mechanical Behavior of Materials Structure and Manuf. Properties Metal-Casting & Heat Treatment Bulk Deformation Processes Sheet-Metal Forming Processes Open issues Instruction on labs, MatLab Review and discussion Exam 1 (Ch. 1-3, 5-7) Lab 1-1. Tensile test of sheets Lab 2. Rolling Lab 4. Microhardness & microstructures Lab 3&1-2. Plastic bending & wire tension Lab 3&1-2. Plastic bending & wire tension Material-Removal: Cutting Material-Removal: Abrasive, etc. Joining and Fastening Processes Polymers and Reinforced Plastics Metal Powders, Ceramics, Composites Surfaces, Tribology, Quality Micro and Nanomanufacturing* Thanksgiving holiday Exam 2 (lab problems and Ch 8,9,12) TBD Design group meeting Design group meeting Study day (no class) Final Presentation HW or Location Read text Ch01 Web/patent search[1,2], 2.47,48,51,58,67,72 3.39, 40, 43, 44 5.73, 75 6.62, 4, 98,100,101 7.65,66,77,86 Due or notice

9/1 9/6 9/8 9/13 Ch02 9/15 03 9/20 05 9/22 06 9/27 07 9/29 10/4 10/6 10/11 10/13 handout 10/18 handout 10/20 handout 10/25
handout handout 08 09 12 10 11 04 13

HW02 HW03, 05 HW06, 07

1353 ENG MEB Hall 2025 MEB 1353 ENG 1353 ENG

Grp1 Grp2 Grp3 Grp1+G2-1 Grp2-2+G3

10/27 11/1 11/3 11/8 11/10 11/15 11/17 11/22 11/24 11/29 12/1 12/6 12/8 12/13 12/15

TBD for the rest Lab 1 Rpt

All lab Rpts

Design Rpt*

DESIGN PROJECT Design Project will be conducted in team, targeted in a group of 4 selected by the instructor.
1 2

http://www.uspto.gov/ http://www.google.com/patents 4

Each team will select a component or assembly, conduct a survey on existing products and manufacturing processes, and provide an alternative product/process design for the products with equivalent or better functions, with a justification of your new design. Each student in the team will contribute one portion or one element of the project, and perform oral presentation for that portion. This will requires team members to actively collaborate and interaction to meet due date for the team design report. Each team will submit one combined/complete report that include (1) survey of existing products/processes of selected topics with citations containing all required information for verification, and (2) new designs of product/manufacturing process with detailed engineering calculations as a foundation of the design. The report must be typed (including equation typing), with graphical demonstration and engineering drawing. The evaluation will be based on both intellectual merit and quality of technical writing.
* Required final submission of Design Project: 1. Design Technical Report in Word document (this is the most important document for evaluation), but make one pdf file from it and check if it comes correct. The report contains: Cover page with title, group members and individual responsibility, and inserted Table of Content from MS Word and with page numbers. Design objective/targeted specification/constraint, and any special requirement for the design; Current state of art review, with all references cited and sources provided at the end of References section. Use EngNote software for reference managing - available at WSU free software site. In case your topic related to a particular detailed reference that needs to be included in this document for reader to understand what your work is about, but that will make the report page set not balanced, put it into appendix at very end. Product/process design, (not limited but include) process description and all detailed engineering calculation, a feasibility study for a new process, also to address: environmental concerns, sustainability of the manufacturing, economical justification etc. and very briefly on how a teamwork and work management helps in this project. Summary

(The only difference of this design project to your future design is in the fact that we have no time to put your design in reality at this time - all other aspects are treated as real, so you try to do something useful, but also do not make too big scope of your design). 2. Presentation ppt file, 3. EndNote reference file/folder including course information/patents/papers as attachments embedded/linked in your EndNote file. All submissions are in electronic form for my review. Due to ABET need I will later make hard prints from your pdf file (a single file containing all report elements required), so you must check to assure all page setting is correct when make pdf. (The software EndNote is available and free for registered WSU students at:

LABORATORY Lab sessions are designed to include 5 parts, to be performed in 3 lab sites in parallel, Lab 1-1 (ENG 1353) Material properties from uniaxial tension of sheets Lab 1-2 (ENG 1353) Temperature and strain rate effect of material properties: tension of wires Lab 2 (MEB Hall) Cold rolling Lab 3 (ENG 1353) Plastic bending and spring back Lab 4 (MEB 2025)Micro-hardness measurement and microstructure observation All experiments are performed by students in group except operating Instron machine by a graduate student. It is allowed to share some raw testing data with others, but each student must independently perform data processing, result plotting, and develop individual lab reports that covers all aspects of experiments in one report, for each lab report. Handout of lab instructions (also serves as report template for formatting) will be provided. MatLab software is to be used for data processing and figure plotting. MS Excel may have limitations to handle the amount of data we obtained. An instruction lecture of using it will be provided. You need to install MatLab in your computer. For the software installation see: Ms. Lidia Nedeltcheva, IT Support (by appointment) lid@eng.wayne.edu, 313-577-5788 Engineering 1325 The group rotation is in the following order: Location ENG 1353 MEB Hall MEB 2025 Day 1 Group 1 Group 2 Group 3 Day 2 G3 G1 G2 G2 G3 G1 Day 3 Day 4 G1 + G2-1 Open use Open use Day 5 G2-2+G3 Open use Open use

Grouping for lab and design project:

Total of 3 lab groups and 6 design groups (and lab sub-groups), e.g. G3-2 means Lab group 3 (for the designated lab site and run test in second subgroup), and design group 3-2. See table below.


Last Name

First Name


1 2 3 4 5

Alojipan Alzameli Badaoui Carter Dabrowski Davidson Fahs Figliomeni Forthoffer Harper Ismail Lenczewski Makkiya Mateas Palac Petro Pierzynski Price Shammas Siewert Spencer Sukkarieh Virk Visconti Viviano Ware Fahs Lenczewski Makkiya Viviano

Albert Murtada Ali Steven Eryk Alexander Mohamad Jonathan Daniel Joshua Majid Adrian Hussam Daniel Derek Kirsten David Maxwell Michael William Winston Mohaned Nauman Alexander Matteo Malik Mohamad Adrian Hussam Matteo


6 7 8 9 10


11 12 13 14 15 16


17 18 19 20


21 22 23 24 25 26


7 8 9 25