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MACHINE TOOL OPERATIONS FOR ENGINEERS

ME 350 Fall 2009

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Syllabus - ME 350

COURSE DATA

Time (Lecture): M 1:00 2:00 PM Place (Lecture): ETC 5.132 Unique #s: 18630/18635 Time (Lab): 18630 TTH 9:00 12:00 Noon

18635 TTH 1:00 4:00 PM Place (Lab): ETC 1.210

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INSTRUCTOR INFORMATION

Instructors name: Don Artieschoufsky Instructors office: ETC 1.214 Instructors phone number: 471-5388 Instructors e-mail:

don.artie@mail.utexas.edu Office hours: TTh During lab or

by appointment

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PREREQUISITES

Admission to an appropriate major sequence in engineering

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TEXTBOOK

Manufacturing Engineering and Technology, Fifth Edition, Serope Kalpakjian and Steven R. Schmid (Pearson Prentice Hall, 2006) ISBN 0-13-148965-8

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GRADING POLICIES

Homework 30% Final Exam 20% Lab Projects:

Vise Project 40% CNC Project 8% Casting Project 2%

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OTHER CLASS POLICIES

Lecture and laboratory attendance is required. Homework is due in class, one week from date

assigned. Late homework is accepted up to one week after due date with 5 point penalty/day (cut-off is 2:00 PM). Two people may work together on homework; no large groups (On joint work both students must acknowledge the cooperation and hand in individual papers.)

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OTHER CLASS POLICIES

Scholastic dishonesty will not be tolerated and any incident of dishonesty will be reported in accordance with University procedures.

The University of Texas at Austin provides, upon request, appropriate academic adjustments for qualified students with disabilities. For more information, contact the Office of the Dean of Students at 471-6259, 471-4241 TDD or the School of Engineering Director of Students with Disabilities at 471-4321.

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Class Web Sites and Student Privacy

Web-based, password-protected class sites will be associated with all academic courses taught at The University. Syllabi, handouts, assignments and other resources are types of information that may be available within these sites. Site activities could include exchanging e-mail, engaging in class discussions and chats, and exchanging files. In addition, electronic class rosters will be a component of the sites. Students who do not want their names included in these electronic class rosters must restrict their directory information in the Office of the Registrar, Main Building, Room 1. For information on restricting directory information see:

http://www.utexas.edu/student/registrar/catalogs/gi00-01/app/appc09.html

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Blackboard https://courses.utexas.edu

Blackboard Learning Portal will be used for ME350 - Announcements Syllabus Handouts under Course Documents Home-Work Assignments

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Add-Drop Period

After the end of the add-drop period you may drop in compliance with the rules for the School of Engineering: An engineering student must have the deans approval to add or drop a course after the fourth class day of the semester or, after the second class day of a summer term. Adds and drops are not approved after the fourth class day except for good cause. Good cause is interpreted to be documented evidence of an extenuating nonacademic circumstance (such as health or personal problems) that did not exist on or before the fourth class day. Applications for approval to drop a course after the fourth class day should be made in the Office of Student Affairs, Ernest Cockrell, Jr. Hall 2.200.

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Course/Instructor Evaluation

Course / Instructor evaluation will be conducted on 11/30/2009 using the Common University Form.

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Final Exam

A Take Home Final Examination will be conducted at the end of the semester.

The exam will be handed out on Monday, November 30 during class and due no later than 5:00 PM on December 11.

The examination will be cumulative and will allow the use of the course text, notes, and handouts.

Individual effort is required for the exam.

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2008-2010 CATALOG DATA

350. Machine Tool Operations for Engineers. Hands-on manual and computer-numerical controlled machine tool operation. Part design and tool selection for production. One lecture hour and six laboratory hours a week for one semester. Offered on the letter-grade basis only. Mechanical Engineering 350 and 379M (Topic 7: Machine Tool Operations for Engineers) may not both be counted. Prerequisite: Admission to an appropriate major sequence in engineering.

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GOALS

Develop the engineering students understanding of the capabilities and limitations of machine tools commonly used in prototype fabrication and model building.

Acquire personal experience operating equipment to gain knowledge of the parameters for part production needed in industry

Learn to write programs for Computer Numerical Control Machinery

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GOALS

Learn terminology used in the manufacturing environment to communicate effectively

Gain exposure to Geometric Dimensioning and Tolerancing

Understand the importance of ethics in engineering practices

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KNOWLEDGE, SKILLS, AND ABILITIES STUDENTS SHOULD HAVE BEFORE ENTERING THIS COURSE

Knowledge of the physical demands required for operation of metal working machinery

Ability to work safely, both independently and with others in a laboratory environment

Ability to follow detailed instructions Ability to quickly absorb and comprehend new

concepts and information

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KNOWLEDGE, SKILLS, AND ABILITIES STUDENTS SHOULD HAVE BEFORE ENTERING THIS COURSE

Ability to manage time resources for the completion of scheduled homework assignments and laboratory projects

Ability to read, write, and speak clearly and effectively in English

Skills of an interpersonal relations nature sufficient to not become a distraction or create unnecessary problems with fellow students or lab assistants

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KNOWLEDGE, SKILLS, AND ABILITIES STUDENTS SHOULD GAIN FROM THIS COURSE

Knowledge of the capabilities and limitations of machine tools.

Knowledge of time and tooling requirements for part production with various machining processes

Ability to communicate effectively in a manufacturing environment

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KNOWLEDGE, SKILLS, AND ABILITIES STUDENTS SHOULD GAIN FROM THIS COURSE

Understanding of G-code and M-code programming for Computer Numerical Control Machines

Ability to recognize, apply, and understand Geometric Dimensioning and Tolerancing (at a basic level)

Understand the steps necessary in part production to produce finished parts from rough stock

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IMPACT ON SUBSEQUENT COURSES IN CORRICULUM

The knowledge and skills gained in ME 350 may be utilized in ME 266K Senior Design Projects for theoretical or applied use in presentation materials and/or prototype fabrication.

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ABET EC2000 PROGRAM OUTCOMES ACHIEVED:

This course contributes to the following ME Program Outcomes for ME () Outcome Outcome 1. Knowledge of and ability to apply engineering and science fundamentals to real problems.

6. Ability to communicate in written, oral, And graphical forms.

2. Ability to formulate and solve open-

ended problems. 7. Ability to work in teams and apply

interpersonal skills in engineering contexts. 3. Ability to design mechanical components, systems, and processes.

8. Ability and desire to lay afoundation for continued learning beyond the baccalaureate degree.

4. Ability to set up and conduct experiments, and to present the results in

a professional manner.

9. Awareness of professional issues in engineering practice, including ethical responsibility, safety, the creative enterprise, and loyalty and commitment to the profession.

5. Ability to use modern computer tools in

mechanical engineering. 10. Awareness of contemporary issues in engineering practice, including economic,

social, political, and environmental issues

and global impact.

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ASME PROGRAM CRITERIA OUTCOMES ACHIEVED:

Mechanical Engineering Criteria a. Knowledge of chemistry and calculus-based physics with in-depth knowledge of at least one. b. The ability to apply advanced mathematics through multivariate calculus and differential equations. c. Familiarity with statistics and linear algebra. d. Ability to work professionally in both the thermal and mechanical systems areas including the design and realization of such systems.

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DESIGN ASSIGNMENTS Casting Project:

Each student will be provided a 3 cube of extruded foam. The student requirement will be to design and cut the foam into a decorative or functional pattern for lost foam casting. The design must allow room for attaching a 1.0 square sprue on one of the faces. The pattern must have sufficient strength to withstand compaction in a sand mold without deforming.

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LABORATORY ASSIGNMENTS Practice Parts:

Mill Assignment: Aluminum block requiring milling, facing, grooving, drilling, tapping, and boring to print specifications using a vertical milling machine with digital readout.

Lathe Assignment: Steel shaft-requiring center drilling, facing, turning, knurling, threading, and chamfering to print specifications using an engine lathe.

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LABORATORY ASSIGNMENTS Vise Project:

Work from Lab Manual to machine rough-cut steel and brass parts into a working vise using band saws, vertical mills, engine lathes, pedestal and surface grinders, surface plate, height gage, and optical comparator.

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LABORATORY ASSIGNMENTS CNC (Computer Numerical Control) Project:

Use of CAD/CAM software for converting 2-D or 3-D graphics (students original design) into G code and M code program to machine initials in raised-relief on an aluminum block with machining operations performed on a 3-axis Vertical Computer Numerical Control Machining Center. CAD/CAM software will be used to simulate Tool-Path after the program is created. CAD/CAM software (BobCad-Cam V21 - available on 10 stations in METER Lab, ETC 2.126).

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PROFESSIONALISM TOPICS

Topic 1 will deal with shop safety and some of the tooling terminology used in a manufacturing environment.

All topics will include terminology necessary to communicate effectively in a manufacturing environment.

Topic 7 relates directly to engineering ethics and the guest lecturer will discuss and answer questions on the steps necessary to becoming a professional engineer.

Topic 10 on geometric dimensioning and tolerancing will introduce students to a concise method of conveying design intent using an engineering standard.

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COURSE SCHEDULE Topic Hours Dates

1) Safety/Certification/Terminology 1 8/31 2) Machine Tools and Tooling Development +

12) Set-up and Inspection 1 9/14

3) Threading and Thread Forms 1 9/21 7) Guest Lecturer- David Howell, PE Director of Licensing Texas Board of Professional Engineers Engineering Ethics and Steps to Becoming a Professional Engineer

1 9/28

6) CNC Programming & CAD/CAM 2 10/5 10/12

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COURSE SCHEDULE Topic Hours Dates

5) Material Selection/Tooling Materials 1 10/19 8) Coatings/Surface Treatments/Heat Treatment 1 10/26

9) Casting Demonstration 1 11/2 10) Guest Lecturer- Don Titel Manufacturing Engineer - AMAT

Geometric Dimensioning and Tolerancing

2 11/9 11/16

11) Advanced Machining Processes/Powder Metallurgy (P/M)

1 11/23

Review/Course Instructor Evaluations/Take Home Final 1 11/30

Final Exam 3 Take home due 5:00 PM on Dec. 11

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TOPIC TEXTBOOK REFERENCE

1) Pgs. 1-45, Chapters 21, 23, 24, 25 Class handouts 2) Chapters 21, 23, 24, 26

3) Chapters 13, 23, 26 (pp. 362, 676, 691, 700, 716, 702, 812)

4) Part VI, Chapters 30, 31, 32 welding/no lecture

5) Chapters 5, 6, 7, 8, 22, 40

6) Chapter 37. 38

7) Chapter 1

8) Chapters 34, 4

9) Chapter 10, 11, 12 10) Chapter 35 11) Chapters 17, 25, 26, 27 12) Chapter 35