1

ADVANCED MANUFACTURING
MEC 431
Fall 2014

Dr. Farrokh Sharifi

Ryerson University,
Office EPH 318
email: fsharifi@ryerson.ca

(MEC431)

Course Format
3 Lecture hours: Tues (1:00 pm-2:00 pm) SHE652,
Wed (10 am-12 pm) SHE660
2 hours
h
Lab:
L b Section-1
S ti 1 Thursdays
Th d
(8:00
(8 00 am-10:00
10 00 am),
) S
Sectionti
2 Thursdays (12:00 pm- 2:00 pm) KHE139/EPH331

Textbook

Course notes
Fundamentals
F d
t l off Modern
M d
M
Manufacturing:Processes
f t i P
andd Systems;
S t
Second Edition or Third Edition
Mikell P. Groover, 2002 (2007)
John Wiley & Sons
(MEC431)

Course TAs
Section 1- Lubna Shahid (lubna.shahid@ryerson.ca): Office
EPH335, Office Hours: Thursdays 10:00 am-10:30 am
Section 2- Shahir Hasanzadeh
(shahir.hasanzadeh@ryerson.ca): office EPH 335, Thursdays
2:00 pm 2:30 pm
You can send them an email for appointment.

(MEC431)

Protocol of Communications
Office Hours: you are welcome to see the course professor or
your TA during the office hours. (see my office hours + TAs
office hours)
Office Appointments beyond office hours: Only in
exceptional cases with the previous arrangements
arrangements.
E-mails: are not usually encouraged!
Emergency acceptable: emails to office
office, TA
TA, or professor
professor.
I also encourage only emails for short-answer questions.
Class Rep: Official requests for the whole class must be made
through the class representative.

(MEC431)

Other Info
Class Representative:

Amir Ibrahim
Amir.ibrahim@ryerson.ca

Faculty Course Survey

Monday November 17

My Office Hours
Wednesdays 2:00 pm-4:00 pm in EPH 318
Important
p
Dates:
Due dates of assignments (0-5), midterm test, due
dates for reports (interim and final reports),
competition date, etc. all in the Significant Dates
document
(MEC431)

Important Dates

Due dates of assignments (0-5) including first lab (0)

Midterm test
Due dates for reports (interim and final reports)
Competition date
Facultyy Course Surveyy date

(MEC431)

Important Dates

MasterCAM Lab:
Assignment 1:
Assignment 2:
Assignment 3:
Assignment 4:
Assignment
g
5:
Interim Report:
Midterm test :
Final Report:
Competition :
Awards presentation:
Faculty Course Survey:
Fi l Exam:
Final
E

Sep 11
Sep 17
Oct 1
Oct 22
Nov 5
Nov 12
Oct 8
Oct 22
Nov 26
Nov 19
Nov 26
Nov 17
TBD

(MEC431)

Course Policies
Material presented will not always be in the book.
book
Written examinations will cover material from lectures, textbook
and assigned homework problems.
A penalty of 10% per day applies to late Homework/Reports
submissions
( No homework will be accepted after the solutions are posted on
the web~ 5 days).
days)
All the course assignments or reports must be handed to the
professor by 4 pm of the due week. Late submission must be
stamped by the department office
office.

Mark Distribution

Mid T
Term E
Exam: October
O t b 22 (Room
(R
TBA)
NC Project (due coming pages)
Assignments
Fi l E
Final
Exam (2 h
hours))
(MEC431)

25%
15%
10%
50%

Bonus Marks
Surprise Quizzes
Journal Paper (www.ryerson.ca/sjarmm)

(MEC431)

5%
5%

Awards & Scholarships

Industrial Awards: to the first three team members. Each
year varies and depends on the industrial sponsor.
Other Awards and Scholarships: Open through Ryerson
and SME (Society of Manufacturing Engineers).

(MEC431)

10

Ground Rules

No cell phones.
No distractions: facebook, chatting, eating, etc.
Be on
on-time
time
Be present
Be positive and constructive

(MEC431)

11

Topics to be covered
Numerical Control
4 & 5 Axis CNC
Economics of NC, Manufacturing Economics
Process Planning & Computer Aided Process Planning
Non-traditional Manufacturing Processes (Power
Metallurgy; Electric Discharge Machining, etc.)
Quality Management Techniques, Statistical Process
Control, ISO 9000;
Rapid Prototyping

(MEC431)

12

Lab
MasterCAM KHE 139 (tutorial material posted). Starts next
week
CNC Machining EPH 331
Labs attendance sheet will be collected. Absence from the labs
will be penalized by deductions (upto 100%) from the
labs/projects marks.

(MEC431)

13

Course Website
https://my.ryerson.ca/
https://my ryerson ca/

(MEC431)

14

Course Project:
Toggle-Rope Competition of
M
R il Cars
C
Mono-Rail

Objective:
To construct a self-contained mono-rail cars powered by a
single motor
Winning car must keep the flag in its own field.
Restrict yourself to the material given (to be posted).
web
Project description and details on the course web.
Each group could design its own car.
Each group does not need to give a presentation but needs to
submit design in the interim report.
report
Machining constraints:
Cutter 0.125 end mill- Rapid prototyping is also available
Suggested feed rate 8 in/min,
in/min Suggested plung 8 in/min,
in/min
Suggested retract 8 in/min. 1000 rpm.
Use only given boards
Use 2 ppasses for safety
y reasons
(MEC431)

15

More on Project
Milestones and Deadlines

Interim Report- Deadline: October 8, 2014

Manufacturing/CNC machining of the car: Weeks of Oct 6,
6 13,
13 20,
20 27,
27
Nov 3, 10.
Race day and location (TBA): November 19
Project Report Due: Friday November 26

Marking Scheme (15%)

Interim Report (3%)

Completion of the machining and the report (8%)
Competition result (4%)

(MEC431)

16

17

More on Project

10 in x in dia bar that could

be used for pulling or attacking
Length of car < 8 in

W=3/8 in
H= 5 in
t = 3/16 in

rope
flag
W=3/8 in
H= 1 in

+
_
Independent power
source for left rail

l = 1 ft

+
_

L = 3 ft
Independent power
source for right rail

(MEC431)

Comp ter Numerical

Computer
N merical Control

Introduction

(MEC431)

CNC Machining

(MEC431)

19

Why CNC?
Increase production
g p
throughput
Programmable
Automation

(MEC431)

20

Production Quantity & Variety

Annual production quantities can be classified into three ranges:
Production range
Annual Quantity Q
Low production
1 to 100 units
Medium production
100 to 10,000 units
High production
10,000 to millions of units

What is the future of Manufacturing?

g

(MEC431)

21

22

Automation in Manufacturing

(MEC431)

Fixed Automation
the sequence off processing
th
i operations
ti
is
i fixed
fi d by
b the
th
equipment configuration.
Typical features :
high initial investment for custom-engineered equipment
high production rates
relatively inflexible in accommodating product variety

(MEC431)

23

Flexible Automation
C
Capable
bl off producing
d i a variety
i t off parts
t with
ith virtually
i t ll no time
ti lost
l t for
f
changeovers from one part to the next. (minimal differences between parts)
Flexible automation characterized by these features:
high
hi h investment
i
t
t for
f a custom-engineered
t
i
d system
t
continuous production of variable mixtures of products
medium production rates
fl ibilit to
t deal
d l with
ith product
d t design
d i variations
i ti
flexibility

(MEC431)

24

Programmable Automation

25

Production equipment is designed with the capability to change the sequence

of operations to accommodate different product configurations
high investment in general purpose equipment
lower production rates than fixed automation
flexibility to deal with variations and changes in product configuration
most suitable for batch production

(MEC431)

Why CNC?
Machining operations:
Generating geometry of work is
determined by feed
trajectory
Formingg - shape
p of
part is created by the
geometry of cutting
tool

When
Wh iis using
i a
forming tool
economical?
(MEC431)

26

Why CNC?

Manufacture
f
complex
l or otherwise
h i
impossible jobs, 2D and 3D contours.

Improve the quality and accuracy of

manufactured parts

Stabilize manufacturing costs

(MEC431)

27

CNC History
Early 1800s - first programmable machine created Weaving
machine controlled by holes punched in metal cards.
1955 - John Parsons, Parsons Corporation, Michigan, Developed
a control system that directed a spindle to many points in
succession
i
1959 - MIT announces Automatic Programmed Tools (APT)
programming language
1960 - Direct
Di
Numerical
N
i l Control
C
l (DNC).
(DNC) This
Thi eliminates
li i
paper
tape punch programs and allows programmers to send files
directly to machine tools
1968 - Kearney
K
&T
Trecker
k machine
hi ttooll bbuilders
ild market
k t first
fi t
machining center
1970s - CNC machine tools & Distributed Numerical Control
1980s
1980 - Graphics
G hi based
b d CAM systems
t
iintroduced.
t d d Unix
U i andd
PC based systems available
1990s - Price drop in CNC technology
1997 - PCPC Windows/NT
Windo s/NT based Open Mod
Modular
lar Architect
Architecture
re
Control (OMAC) systems introduced to replace firmware
controllers.
(MEC431)

28

Next Lab (KHE139)

PLEASE DOWN LOAD Mastercam material from the website
and review it before coming to the lab on coming week. You
learn Mastercam by yourself.
yourself Tutorial available on the web.
web

(MEC431)

29