Northern Kentucky University

Department of Technology

Fall 2005

 

IET-116 Materials and Processes

 

Time:

Tuesdays,   6:15-9:00 pm

Room:

TBA

Text:

Processes of Manufacturing, Thomas Wright, 2005

ISBN: 1-59070-362-6       464 Pages   

                                                 

Instructor:

Dr. S. M. Allameh

Office:

AST 231

Phone:

859-572-5759

E-mail:

allamehs1@nku.edu

Website:

http://www.nku.edu/~allamehs1

Office hours:

M and W: 3-4:30 PM

T, R: 3-6:15 PM or by appointment

 

Book Chapters:

1.       Nature of Manufacturing

2.       Organizational Structure of Manufacturing

3.       Industrial Materials

4.       Introduction to Casting and Molding Processes

5.       Casting Metals- Expendable Mold Techniques

6.       Casting Metals- Permanent-Mold Techniques

7.       Casting and Molding Plastic Materials

8.       Casting Ceramic Materials

9.       Introduction to Forming

10.   Hot Forming Metals

11.   Cold Forming Metals

12.   Forming Plastics

13.   Forming Ceramic Materials

14.   Forming Powdered Metals

15.   Introduction to Separating

16.   Turning and Related Operations

17.   Milling and Related Operations

18.   Sawing, Broaching, and Filing

19.   Shaping and Planing of Metals

20.   Drilling, Boring, Reaming, and Tapping

21.   Abrasive Machining Operations

22.   Thermal and Chemical Machining

23.   Shearing

24.   Introduction to Conditioning

25.   Conditioning Materials

26.   Introduction to Assembling

27.   Welding Processes

28.   Adhesive Bonding

29.   Mechanical Fastening

30.   Introduction to Finishing Processes

31.   Inorganic Coating Processes

32.   Organic Coating Processes

33.   Introduction to Process Planning

34.   Selecting and Sequencing Operations

35.   Automating Processes

36.   Planning for Quality

Course Description

Fundamentals of materials, processing methods, tools, and equipment used to produce metallic and non-metallic products.

Course Objective

Each student will

1. GAIN knowledge on methods of material testing

2. GAIN knowledge on material identification

3. GAIN knowledge on proper material processes

Evaluation and Grading

Attendance and Participation in Discussions

100 pts

A

>899 pts

Quizzes

100 pts

B

=800-899 pts

Labs 8x25

200 pts

C

=700-799 pts

In class Exams (2 x200)

400 pts

D

=600-699 pts

Final Exam

200 pts

F

<600 pts

Total

1000 pts

 

 

 

Quizzes/Reading Assignments:

Students are required to read the assigned study materials before coming to the class. Quizzes on the assigned readings will be administered frequently to determine the level of students’ competency and preparedness. This is a hands-on course and requires regular attendance. Quizzes are usually multiple choice tests consisting of 20 or more questions or short problems about the assigned reading materials.

 

Extra Credit:

Will be given for successful completion of special assignments. These may include preparation of “grade A” class notes (neatly typed and turned in ) or preparation of quality multiple choice tests/questionnaires.

 

Exams:

In-class exams will be given throughout the term. (Please consult the schedule.) Each exam will be designed to take about 60 minutes to complete. Each may consist of multiple choice, true-or-false, matching, fill-in-the-blank, short essay, or problems to be solved through calculations. The latter two will account for the bulk of the points of each exam. The grade of each exam will be based on both completeness and correctness.

A comprehensive final exam will be given at the end of the term.

All quizzes and exams will be closed book, unless informed otherwise. Students will be allowed to use calculators, rulers, and protractors. It is recommended that each be brought to each session.

 

IMPORTANT NOTE: MISSED EXAMS, REORTS OR QUIZZES WILL BE GRADED AS ZERO IF NOT HANDED IN ON TIME OR WITHOUT AN APPROVED WRITTEN PROOF OR REASON OF ABSENCE. NO LAB MAKEUP WILL BE ALLOWED.

 

Absences: Each student is expected to attend each session. Each student is responsible for all reports, quizzes, and exams. Attendance sheets must be signed by the students to earn them credit.

 

Homework:

Follow-up problems to reinforce and enhance the lecture may be assigned at the end of class sessions. Homework must be submitted electronically via Blackboard before due date (Next session, unless stated otherwise). Homework will be graded on completeness and correctness. To receive full credit there must be evidence that a valid attempt, as judged by the instructor, was made to solve each problem. Just writing the answer does not constitute a valid attempt to solve a problem. Work/calculations must accompany the answer to show how it was obtained.

 

Class Comportment:

  1. The use of tobacco products, eating or drinking in classroom is prohibited.
  2. Appropriate instruction on the safe operation of machines, tools and equipment will be provided for all students. However, it is the responsibility of each student to inform the instructor if the student is unsure regarding the safe use of any machine, tools or equipment and to ask for clarification regarding any assignment or work in which there is any perceived safety risk.
  3. Safety glasses must be worn at all times when working in the lab or in the area of operating machines and/or tools.
  4. Turn offal! electronic devices such as cell phones and beeper while in the classroom.
  5. Be courteous of your classmates. Refrain from any activity that may distract them or the instructor.
  6. Consult the Student Honor Code at http://www.nku.edu/~deanstudents/

 

Preliminary Schedule:

The instructor reserves the right to alter the schedule as deemed necessary to adequately address the student’s needs

 

Date    Session           Text Chapters            Topics                                                           .

8/23      1                      Ch. 1                            Introduction to Processes and Manufacturing, Safety 

8/30      2                      Ch. 2-3                         Organization Structure of Manufacturing, Industrial Materials

                                                                        Lab: Measuring tools, Materials Testing

9/6        3                      Ch. 4-5                         Introduction to Casting and Molding Processes

                                                                        Lab: Casting Aluminum

9/13      4                      Ch. 6-7                         Casting Metals: Permanent Mold Techniques, Molding Plastics

                                                                        Lab: Oxy-Acetylene Welding                

9/20      5                      Ch. 8                            Casting Ceramic Materials

                                                                        Lab: Arc Welding

9/27      6                      Exam 1, Ch.9              Introduction to Forming 

10/4      7                      Ch 10-11.                      Hot and Cold Forming

Lab: Turning (lathe)      

10/11    8                      Ch. 12-13                      Forming Plastics and Ceramic Materials

                                                                        Lab: Drilling, Tapping

10/18    9                      Fall Break                     No Class          

10/25    10                     Ch. 14                          Powder Metallurgy

                                                                        Lab: fabrication using powders

11/1      11                     Ch. 15-16                      Introduction to Separating, Turning and Related Operations

11/8     12                    Exam 2                       

                                                                                   

11/15    13                     Ch. 17                          Milling

                                                                        Lab: Project work-II     

11/22    14                     Ch. 19-20                      Shaping, Drilling, Tapping

                                                                        Lab: Project work-III

11/29    15                     Ch. 26-27                      Assembling and Welding

12/6      16                     Web-base Materials      Introduction to Micro/Nano fabrication

12/13    17                     Final Exam