FACULTY OF MECHANICAL ENGINEERING UNIVERSITI TEKNOLOGI MALAYSIA MANUFACTURING PROCESS (SME 2713) DIS 2011/2012

Week/Date

TOPICS INTRODUCTION TO MANUFACTURING General Introduction Manufacturing system, manufacturing industries, examples of manufacturers Importance of manufacturing, manufacturing trends Methods of production, plant layout, manufacturing capability Materials in manufacturing engineering materials, material properties, material selection Manufacturing processes classification brief overview, process selection

REFERENCE

REMARKS

Week 1 20/02/12 ~ 24/02/12

Kalpakjian ch 1, Groover,ch 1, DeGarmo, ch 1, 9

Week 2 27/02/12 ~ -2/03/12

INTRODUCTION TO MANUFACTURING Basic stages in product manufacture Research and development, Manufacturing planning and equipment, Manufacturing and production, and Marketing. Concurrent engineering Manufacturing costs Manufacturing Organization organization structure, coordination of manufacturing functions.

Kalpakjian ch 1, Groover,ch 1, Lecture note

Group Case study

Week 3 05/03/12 ~ 09/03/12

MANUFACTURING ASPECTS Specification and standardization for production Introduction Specification Standardization Manufacturing of mating parts Make to suit Selective assembly Interchangeable manufacture
SME 2713 (MANUFACTURING PROCESSES)

Lecture note

RMS/20-FEB-12

DEC - 2011/2012

 MANUFACTURING ASPECTS Week 4 12/03/12 ~ 16/03/12 Tolerancing Limits and fits METAL CASTING PROCESSES= Introduction Why choose casting process, common term. Pattern Pattern material, types of pattern. Mold Riser, Gating system, core. METAL CASTING PROCESSES Heating and pouring Solidification & cooling Casting processes Criteria, advantages and disadvantages, application. Non permanent mold casting processes Green sand casting, baked sand casting, CO2, shell, plaster, etc TEST 1 (31/03/2012 - SAT) (9:00AM ~ 11:00AM) DK8 N24 Introduction to Manufacturing And Manufacturing Aspects Kalpakjian, ch 13, 14, 15, 16 Groover ch 18, 19, 20 Lecture note Kalpakjian, ch 10, 11, 12 Groover ch 10, 11

Week 5 19/03/12 ~ 23/03/12

Week 6 26/03/12 ~ 30/03/12

METAL CASTING PROCESSES Permanent mold casting processes Die, pressure, gravity. Casting design Basic principles. Casting defects Defects, caused of defects, avoid or reduction of defects.

Week 7 02/04/12 ~ 06/04/12

METAL FORMING PROCESSES Introduction Definition of metal forming, competing factor comparing to other alternative of processes, Hot working and cold working, heat treatment, re-crystallization, Classification of metal forming. Rolling process Aspects of rolling processes, types of roller, application of rollers, various rolling operation. Criteria, advantages and disadvantages and application, flat rolling, shape, ring, and gear. Forging process Criteria, advantages and disadvantages and application, open die forging, close die forging, impression die forging, drop forging, press forging, upset forging, etc.
SME 2713 (MANUFACTURING PROCESSES)

RMS/20-FEB-12

DEC - 2011/2012

Week 8 07/04/12 ~ 15/04/12

MID-SEMESTER 11 BREAK (1 WEEK) METAL FORMING PROCESSES Extrusion process - Criteria, advantages and disadvantages and application, direct extrusion, indirect extrusion, hydrostatic extrusion, impact extrusion. Rod and wire drawing, thread forming - Criteria, advantages and disadvantages and application. Sheet metal forming shearing process, blanking, punching, cut-off, slotting, perforating, notching, trimming, shaving, bending, flanging, hemming, seaming, curling, deep drawing, ironing, corning & embossing, lancing, roll forming, spin forming, tube forming, high energy forming

Week 9 16/04/12 ~ 20/04/12

Week 10 23/04/12 ~ 27/04/12

JOINING PROCESSES Introduction and classification Why joining is important and the factor for its selection. Soldering and Brazing Filler metal, soldering and brazing, capillary action Welding processes Meaning, classification, gas, arc, resistance

Kalpakjian, ch 30, 31, 32 Groover ch 30, 31, 32, 33

Week 11 30/04/12 ~ 04/05/12

JOINING PROCESSES Joint quality and weld joint test type of join, quality and defects of welding, weld joint test. Mechanical joining process Joining with the use of mechanical forces

(Public Holiday for Labour Day 01/05/12

Week 12 07/05/12 ~ 11/05/12

MACHINING PROCESSES Introduction Classification of machining processes. Advantages and disadvantages of machining process. Mechanic of cutting Common principles, tool life, wear and failure mode, chips formation, types of chips, cutting fluid, cutting geometry

Kalpakjian, ch 21, 22, 23, 24, 25 Groover ch 21, 22, 23

RMS/20-FEB-12

SME 2713 (MANUFACTURING PROCESSES)

DEC - 2011/2012

Week 13 14/05/12 ~ 18/05/12

MACHINING PROCESSES Tool life Definition of tool life, factors affecting tool life, Taylors tool life equation, determining the index C and n. Cutting tool Cutting tool geometry, important criteria, selection factors, materials, application, cutting fluid.

Week 14 21/05/12 ~ 25/05/12

Machining Processes Turning operation Turning process, turning machine, turning cutting tool, working material handling. Milling operation Milling process, types of milling, milling tool

TEST 2 (26/05/2012 - SAT) (9:00AM ~ 11:00AM) DK8 N24 Metal Casting Processes And Metal Forming Processes

Week 15 28/05/12 ~ 06/06/12

Polymer & polymer Processing Introduction Development history, definition of polymer, plastic and polymerization. Classification of polymer thermoplastic, thermosetting, polymer structures Criteria of plastic selection. Advantages and disadvantages of plastic compared to metal. Additives in plastic major purposes of additives. Plastic processing processing condition, advantages and disadvantages, product type, extrusion, sheet and film extrusion, blow molding, injection molding, heat forming, compression molding, calendaring

Kalpakjian, ch 7, 19 Groover ch 13

Submission of Group case study

Week 16 07/06/12 ~ 10/06/12 Week 17 - 19 11/06/12 01/07/12

REVISION WEEK

FINAL EXAMINATION FOR SEMESTER II 2011/2012 (3 WEEKS)

RMS/20-FEB-12

SME 2713 (MANUFACTURING PROCESSES)

DEC - 2011/2012

LECTURERS :

a) Assoc Prof Zainal Abidin Ahmad (Seksyen 01) b) Dr. Norizah Redzuan (Seksyen 02) c) Mr Rozaimi Mohd Saad (Seksyen 03) d) Mr Khidzir Zakaria (Seksyen 04)

Room: C25-336 4742 Room: C23-416 4680 Room: C25-330 4731 Room: C23-418 4639

TEL: 07-553 TEL: 07-553 TEL: 07-553 TEL: 07-553

EVALUATIO N:

a) Course work i) Test (2X) 1 Hours ii) Case Study / Assignment iii) Peer And Self-Assessment Of Group b) Final Examination TOTAL 40% 15% 5%

60%

40% 100%

TEXT : REFERENCE S:

a)

Kalpakjian, S., "Manufacturing Engineering and Technology", 5th Edition, 2007, Prentice Hall.

a) b) c) d) e) f)
RMS/20-FEB-12

Groover, M. P., Fundamentals of Modern Manufacturing, 3rd edition, John Wiley, 2007 DeGarmo, E.P., "Materials and Processes in Manufacturing", 10th edition, John Wiley, 2008. Ahmad, Z.A., "Proses Pembuatan - Jilid II", Penerbit UTM, 1997. Ahmad, Z.A., "Proses Pembuatan - Jilid II", Penerbit UTM, 1997. Lecture notes SME 2713 at http://elearning.utm.my or http://www.fkm.utm.my/~zulkepli/ Ostwald, F.P. and Munoz, J. (1997), Manufacturing Processes and Systems, 9th Edition, John Wiley
SME 2713 (MANUFACTURING PROCESSES) DEC - 2011/2012

g) Schey, J.A. (2000), Introduction to Manufacturing Processes, 3rd Edition, McGraw Hill h) Lindberg, R.A. (1990), Processes and Materials of Manufacture, 4th Edition, Prentice Hall i) Amstead, B.H. (1987), Manufacturing Processes, 8th Edition, John Wiley & Sons

RMS/20-FEB-12

SME 2713 (MANUFACTURING PROCESSES)

DEC - 2011/2012