SAN
JOSE STATE UNIVERSITY
Department
of Technology
| Tech 142 | Product Prototyping and Manufacturing |
| Dr. Samuel C. Obi |
Spring 2003 |
| Office: | IS 105 |
| Office Phone: | 924-3218 |
| Office FAX: | 924-3198 |
| Office Hours: | MW 12:00 -2:30 PM |
| Email: | sobi@email.sjsu.edu |
| Web Address: | WWW.engr.sjsu.edu/sobi/ |
Catalog
Description
Design
and development of prototype products. Traditional and non-traditional processes including chemical,
electrochemical, mechanical, and thermal. Building jigs, fixtures and molds.
Emphasis on manufacturing products by casting and
molding.
Prerequisite:
Tech 46 - Introduction to
Machining Processes
Purpose
of the Course
The
purpose of this course is to provide advanced study in manufacturing
processes. To this end, areas of
study will include: pattern making, jig and fixture design and construction, and
the nontraditional machining processes of chemical, electrochemical, mechanical
and thermal. Modern methods of
rapid prototyping will be covered.
Textbook/Material
Hoffman, Edward G. (1996). Jig and Fixture Design. Delmar
Publishers, San Francisco.
Handout material will be provided for an overview of the processes
discussed in this class. While
research is required on a few of the topics, further research on all the topics
by the student is encouraged.
References:
Current and Related Technical Journal and Magazine
Articles
DeGarmo, E. P., Black, J. T., & Kohser, R. A. (1997) Materials and
Processes in
Manufacturing
(8th. Ed.). Prentice Hall: New Jersey
Fundamentals of Tool Design, Society of Manufacturing
Engineers
Nontraditional Machining Processes, Society of Manufacturing
Engineers, 2nd
edition, 1984.
Olivo, C. Thomas (1987). Machine Tool Technology and Manufacturing
Processes, Thomas Olivo Associates, Albany, New York.
Machinery's Handbook, 22nd Edition
Jig and Fixture Handbook, Carr Lane Manufacturing Co.
General
Course Goals
1.
Develop a general understanding of
rationale for prototype development
2.
Participate in activities involved
in prototype development
3. Understand the relations between product prototyping and jig & fixture
applications
4. Comprehend the principles and practices of nontraditional machining systems
and processes
5. Develop a broader understanding of machines, pattern making, casting,
machining, tooling, teamwork approach, planning, safety, and other
practices employed in prototype
development.
Outline
of Course Content and Unit Objectives
Unit
1.
Product Formulation, Design
and Development
Objectives:
a) Brainstorm and formulate product ideas using team
approach
b) Develop original product concept using team
approach
c) Translate product concept into a design using team
approach
d) Perform related product development research using team
approach
Reading List for Unit
1
1.
Handout materials on product design
and development
2.
Related video presentation
3.
Student research (related technical
articles)
Unit
2.
Pattern Making & Foundry Work
Objectives:
a) Develop an understanding of appropriate types of materials
used in making
patterns.
b) Determine proper adhesives employed in pattern making,
and understand the
correct gluing techniques.
c) Develop an understanding of shrinkage and draft as they
pertain to
casting processes.
d) Become familiar with technical terms associated with
pattern making/foundry.
e) Design and build patterns needed to complete development
of the
selected
team project.
f) Cast samples of work pieces which will be finish
machined.
Reading List for Unit
2
1.
Handout materials on green sand
casting
2.
Related video presentation (TU0
624B)
3.
Student research (related technical
articles)
Unit
3.
Tool Design and Construction
Objectives:
a) Develop an understanding of the need for tooling.
b) Develop an understanding of the purpose of jigs, types of
jigs, and how
they are made.
c) Develop an understanding of the purpose of fixtures, types
of fixtures,
and how they are made.
d) Design and build jigs and fixtures needed to complete
development of the
selected team project.
Reading
List for Unit 3
1.
Basic types and functions of jigs
and fixtures (pp. 1-75)
2.
Considerations of design economy
(pp. 78-122)
3.
Designing and constructing jigs and
fixtures (pp. 125-213)
4.
Tool materials (pp.
309-322)
5.
Student research (related technical
articles)
Unit
4.
Nontraditional Machining Processes: Mechanical
Energy
Objectives:
Become familiar with, and develop, an understanding of the
operating
principles, equipment, and applications of:
a) Abrasive Jet Machining
b) Ultrasonic Machining
c) Abrasive Flow Machining
d) Water Jet and Abrasive Water Jet Cutting
Reading
List for Unit 4
1.
Handout materials on Mechanical
Energy NTM
2.
Video on Abrasive Flow Machining
(XS1007)
3.
Student research (related technical
articles)
Unit
5.
Nontraditional Machining Processes: Thermal
Objectives:
Become familiar with and develop an understanding of the operating
principles, equipment, and applications of:
a) Electron Beam Machining
b) Laser Beam Machining
c) Electrical Discharge Machining/Cutting/Grinding
d) Plasma Arc Machining
e) Thermal Deburring
Reading
List for Unit 5
1.
Handout materials on Thermal NTM
2.
Video on EDM
(XS1005)
3.
Student research (related technical
articles)
Unit
6.
Nontraditional Machining Processes: Electrical Energy and
Chemical
Objectives:
Become familiar with and develop an understanding of the
operating principles, equipment, and applications of:
a) Electrochemical Machining
b) Electrochemical Grinding
c) Electrochemical Discharge Grinding
d) Electrochemical Deburring
e) Shaped Tube Electrolytic Machining
f) Chemical Material Removal
g) Chemical Milling
h) Chemical Blanking
i) Chemical Engraving
Reading
List for Unit 6
1.
Handout materials on Electrical
Energy and Chemical NTM
2.
Video on Electrochemical Milling
(XS1009)
3.
Video on Chemical Milling
(XS1008)
4.
Student research (related technical
articles)
Unit
7.
Rapid Prototyping Methods (to
be Incorporated in Term Research Paper)
Objectives:
Become familiar with and develop an understanding of the
operating
principles, equipment, and applications of:
a) Stereolithography
b) Optical Fabrication
c) Fused Deposition Modeling
d) Solid Base Curing
e) Other methods of rapid prototyping
Reading
for Unit 7
1.
Library research material for term
research paper (required)
2.
Related video on rapid
prototyping
Instructional
Methodologies
1.
Lectures/Discussions/Presentations
2. Demonstrations
3. Laboratory Activities
4. Video/Film Presentations
5. Outside Readings and Research Assignments
6. Field Trips/Tours (contingent upon time)
Course
Policies
Attendance: In
order to benefit from the lecture and laboratory activities and to complete
assignments on time, students are encouraged to attend every class meeting. Attendance is encouraged and could affect
the number of points earned on some class/laboratory
activities.
Written
Assignments: All
assignments are due as scheduled, and must be typewritten or no points will be
awarded. No late papers will be
accepted unless specific prior
permission has been obtained.
Assignments are due at the beginning of the class period on the
designated due date. Outside reading assignments should be typed double spaced
on the sheet format provided. (Obtain a copy from
instructor)
Laboratory
Assignments: All
laboratory assignments are to be completed in the laboratories in the Industrial
Studies Building. Failure to attend
scheduled laboratory times will not provide sufficient time to complete
assignments. Make-up lab time will not be granted at the
end of the semester.
Examinations/Quizzes: There
will be one (1) 50-point midterm exam, three (3) 20-point quizzes, and one final
exam that is worth 100 points. The final exam is mandatory and must be taken
together at the scheduled time during the final's week. No make-up exams/quizzes
will be given unless prior permission
was obtained from the instructor. No exams will be rescheduled due to student perceived overloads (e.g. two
mid-terms, finals back-to-back).
NOTE: Refer to the SJSU General Catalog, Undergraduate Studies, for policies
on
absences,
Lab
Cleanup/Tool Control
Each
student is responsible for cleaning the machine and/or area where they have been
working. You are expected to put
forth 100% in the cleanup effort in order to keep the lab and equipment clean
and to prevent unsafe working conditions. All tools used must be returned and
properly stored in the crib. Every group will be responsible for tool management
for about two weeks. (See schedule)
Safety
It is
imperative that each student working in the lab, exercise extreme care and use
caution in setting up and operating equipment. If you are uncertain how to operate the
equipment, ask for assistance from your instructor. Rooms 122 and 124 are to be
used in a safe and organized manner. Therefore, all tools, equipment, utensils,
etc. used should be properly returned and stored in their normal places at all
times.
During
the casting process it is recommended that you use ear plugs to protect against
possible hearing problems. Ear
plugs may be purchased in the bookstore or at many locations off campus. Also, protective clothing must be worn
during casting. NO OPEN TOED SHOES OR SANDALS WILL BE
PERMITTED IN THE LAB.
Required
Projects/Assignments
This
course has been carefully planned to provide the opportunity for students to
develop an understanding of advanced machining planning and
processes.
Outside
Readings (45 points)
There
will be three outside reading assignments each worth 15 points.
Their sources must not be older than 3 years, and must be from materials
other than those used/required in the courses, and must be undertaken in any of
the seven unit areas of product prototyping and manufacturing covered in the
course syllabus. The format and schedule for the outside reading report will be
provided by the instructor. Duplication of work by students will not be
tolerated.
Term
Project (small groups) (110 points)
This
is the primary laboratory assignment of the course and will require design,
planning, and production of a student selected project. The completed product will be composed
of at least two machined parts, at least one of which is from an aluminum
casting. A hand-out explaining
detailed requirements will be provided.
Term
Paper
This
assignment is to select one of the nontraditional machining processes and
undertake an in-depth study of the process, its related applications and trends
etc. Students must describe how they
would integrate the selected NTM process with any one of the Rapid Prototyping
Methods available. The paper should be from 3 to 5 pages in length citing 5
or more references. The paper must
be typewritten, double spaced, and free of errors. Drawings or photocopies of
drawings/pictures (not part of the 3-5 pages) may be included to show a unique
feature of a process. Be sure to
cite your references in a reference list on the last page of the paper, using
APA format. A format for grading this paper will be
provided.
Grading
YOU,
THE STUDENT, will
have a major role in determining the final grade you receive for this
course. To be taken into
consideration will be objective and
subjective evaluations. Objective evaluations will include
quizzes, unit exams, and a final exam. Subjective evaluations will
include a term paper and a term project.
A numerical breakdown for grading is as follows:
Criteria
Possible Points
Outside Reading #1
15
Outside Reading #2 15
Outside Reading #3
15
Quiz #1 20
Quiz #2 20
Quiz #3 20
Oral Presentation
Term Paper 30
Term Project (see criteria) 110
Mid-Term Exam 50
Final Exam (Comp) 100
Total
405
Total/405 = % for final grade
90-100% = A
80-89% = B
70-79% = C
60-69% = D
Below 60% = F
Percentages will be adjusted to
accommodate + and - grades
Assignments
Note: Reference material has been placed in the
reserve book room in the library.
Outside
Reading reports will be due at the beginning of the period on Tuesday of the
week they are assigned. Blank forms
will be provided for the reports.
| Week of: | Topic to be Discussed | Assignments | Due |
| Jan. 22 | Course Orientation | ||
| Jan. 27, 29 | Product Development etc | Small Teams, Drawings, Schedules | |
| Feb. 3, 5 | Pattern making & Foundry Works | Lab Work | O.R. #1 |
| Feb. 10, 12 | Pattern making & Foundry Works | Lab Work |
| Feb. 17, 19 | Jig & Fixture Design/Quiz 1 | Lab Work | Quiz 1 |
| Feb. 24, 26 | Jig & Fixture Design | Lab Work | |
| Mar. 3, 5 | Jig & Fixture Design | Lab Work | |
| Mar. 10, 12 | Review of Class Work | Lab Work | O.R. #2 |
| Mar. 17, 19 | Mid-Term (Mar. 20)/Quiz 2 | Overview of NTM | |
| Mar. 24*-26* | SPRING BREAK | SPRING BREAK | |
| Mar. 31*, April 2 | Abrasive Jet/Flow Machining | Lab Work | Quiz 2 |
| Apr. 7, 9 | Orbital Grinding/Water Jet | Lab Work |
| Apr. 14,16 | Electron/laser beam/EDM | Lab Work | |
| Apr. 21, 23 | Plasma machining/Thermal Deburring | Lab Work | O.R. #3 |
| Apr. 28, 30 | Electrochemical/Chemical Processes/Quiz 3 | Lab Work | Quiz 3 |
| May 5, 7 | Rapid Prototyping/Course Review | Report Presentation/Lab Work | Term Report |
| May 12 | Group Presentations/Lab Cleanup | Group Project |