EMAE 160 Syllabus

EMAE 160 – INTRODUCTION to MECHANICAL DESIGN and

MANUFACTURING MECHANICAL AND AEROSPACE ENGINEERING DEPT.

COURSE SYLLABUS FOR: 2015-2016 (1st and 2ND SEMESTER)

CREDIT and CONTACT HOURS: 3 Credit Hrs.

(2) 75 Min. Lectures, (1) 110 min. Mach/CAD Lab /wk

INSTRUCTORS: Jim Drake 216-368-2956 [email protected]

Office: Olin Bldg. Room 201

Office Hours: Please e-mail to set-up an appointment, Mon-Fri 8:30-5:00

CAD Jason Bradshaw 216-368-5171 [email protected]

Office: Glennan 820

Office Hours: Please e-mail to set-up an appointment, Mon-Fri 8:30-5:00

TEXTBOOKS: 1) Manuf Lecture Outline Notes (on Black Board)

2) Manual Drafting Worksheets (handed out in class)

3) CAD Tutorials (within the SolidWorks software)

4) Lecture Slides on BlackBoard

COURSE DESCRIPTION: The course is taught in two sections - Graphics & Manufacturing.

Manufacturing

To introduce manufacturing processes and materials and their

relationships to mechanical design engineering. Course includes

hands-on machining and metal fabrication lab.

Graphics

Development of mechanical engineering drawings in orthographic,

sectional, and pictorial views using manual drafting and computer-

aided drafting. (CAD software) Dimensioning, tolerancing, geometric

dimensioning and tolerancing and assembly drawings will also be covered.

All students are paired up to create and present a Manufacturing Design

Presentation MDP; demonstrating the course material.

-NO COURSE PRE-REQUISITES-

-COURSE REQUIRED FOR MAE MAJORS-

COURSE OUTCOMES: At the completion of the course, students should:

1. Understand the basic manufacturing processes required for metals,

plastics, and composites.

2. Be able to create manual and CAD generated drawings using

orthographic, sectional, and pictorial principles.

3. Understand the basic principles and applications for Geometric

Dimensioning and Tolerancing. (per ANSI/ASME Y-14)

4. Complete machining/fab projects in the lab to see the relationship

between mechanical engineering and manufacturing engineering.

5. Work as a group to complete a Manuf Design Presentation MDP.

MANUF/GRAPHICS LECTURE: Tuesday and Thursday, 2:45-4:00, Bingham 103

MACHINING LAB: Bingham Student Workshop, Bingham 3

CAD LAB: Glennan 821 Reinberger Design Studio RDS

LAB TIMES:

LAB 1 MON 12:30 – 2:20 LAB 2 MON 3:00 – 4:50

LAB 3 TUE 9:30 – 11:20 LAB 4 TUE 12:30 – 2:20

LAB 5 WED 12:30 – 2:20 LAB 6 WED 3:00 – 4:50

LAB 7 THUR 9:30 – 11:20

Please Note: Each Lab will be split into (2) groups. One week at the B-Shop for machining and

following week at RDS for CAD. All to be explained at the first lecture.

CAD ADMINISTRATOR: Jason Bradshaw, [email protected]

GRADING: (Out of 100% Possible)

25% - CAD Qualifier (Mid-Term Exam)

10% - Machining Lab *

10% - Manual Drawings

20% - Final Exam

35% - Manufacturing Design Project

Quizzes: BPR (5 Total Pts) and GD&T (5 Total Pts)

with Jason Bradshaw @ RDS

Note: Quiz grades will affect Final Exam grade.

( to be explained)

GRADE SCALE: A= 90-100 B= 80-89 C= 70-79 D= 60-69 F= 0-59

LATE POLICY: NO LATE ASSIGNMENTS EXCEPTED.

(Allowances for pre-approved reasons – ONLY)

* All machining projects to be completed on or before the last lab.

(NOTE: NO extra labs)

EMAE 160 Fall Calendar Week 1 - Tues – 8/25 Introduction to the Course Thurs – 8/27 Lines, Paper, Scale, Lettering, Orthographic Lecture Week 2 - Tues – 9/1 Machining Lecture Thurs – 9/3 Surface Finish, Casting Lecture Week 3 - Tues – 9/8 Sectional and Aux Views Lecture Thurs – 9/10 Metal Forming Lecture Week 4 - Tues – 9/15 Pictorials Lecture Thur – 9/17 Dimensioning, Threads, and Weld Symbols Lecture Week 5 - Tues – 9/22 Tolerancing and Working Dwgs. Lecture MDP LABS 1A,B 2A,B Round I Thurs – 9/24 MDP LABS 3A,B 4A,B 5A,B 6A,B Round I Week 6 Tues – 9/29 Matl. Properties, PM, Non-Trad Lecture MDP LABS 7A,B 1C,D Round I Thurs – 10/1 Welding, Brazing, Soldering, Adhesive Lecture MDP LABS 2 C,D 5 C,D Round I Week 7 - Tues – 10/6 Metals, Heat Treating Lecture MDP LABS 6 C,D Round I Thurs – 10/8 Fasteners, Cleaning, Coatings Lecture

Week 8 - Tues – 10/13 Polymers Lecture Thurs – 10/15 GD&T Lecture

Week 9 - Tues – 10/20 FALL BREAK Thur – 10/22 MDP LABS 1A,B 2A Round II Week 10 - Tues – 10/27 MDP LABS 2B 3A,B Round II Thurs – 10/29 MDP LABS 4A,B 5A Round II Week 11 - Tues – 11/3 MDP LABS 5B 6A,B Round II Thurs – 11/5 MDP LABS 7A,B 1C Round II Week 12 - Tues – 11/10 MDP LABS 1D 2C,D 5C Round II Thurs – 11/12 MDP LABS 5D 6C,D Round II

Week 13 - Tues – 11/17 MDP LABS 1,2,3 A,B Round III Class Time: 2:45-5:30

Thurs – 11/19 MDP LABS 4,5,6 A,B Round III Class Time: 2:45-5:30

Week 14 - Tues – 11/24 MDP LABS 7A,B 1C,D Round III Class Time: 2:45-5:30

Thurs – 11/26 Thanksgiving

Week 15 - Tues – 12/1 MDP LABS 2C,D 5,6 C,D Round III Class Time: 2:45-5:30

Thurs – 12/3 Review for Manufacturing Final Exam

FINAL EXAM: 12/8/2015 - Tuesday - 12:30-3:30 - Bingham 103

HOW TO GET AN “A” IN EMAE 160

Please keep in mind this a FUNDAMENTAL class in Manufacturing and Design. I do not

expect you to know anything about the topic, but I do expect you to do the upfront

work to get the A. This is an easy course geared around nothing more than time

management. This course should give you a “nice base upon which to build”. Again it is

all fundamentals, nothing too in depth, and we are only scratching the surface in

regards to what the course information presents – so much more to learn after the

course is over! Regardless of your major this course can only help with your career –

whatever that might be.

So……

- Come to every class and sit as close to the front as possible.

- For the Manuf Lectures, utilize the Manuf Outline notes posted on B-Board. Tie

the outline notes to the Manuf PowerPoint slides. Look at the notes and slides

prior to each Manuf Lecture.

- Posted on B-Board are questions for each Manuf Lecture - make sure you have all

the answers.

The questions posted will be on the Final Exam (or very close to them)

Note: Final Exam will be manuf questions only.

- The Graphics portion does not have outline notes, but there are P-Point slides –

so review the slides prior to each Graphics Lecture.

- Turn in your assigned Manual Sketches on time!

- The Mid-Term exam will be the SolidWorks CAD qualifier -plan ahead and destroy

this test.

To be able to say you are somewhat proficient in SW will help you land a co-

op/summer internship spot.

- You will have a BPR and GD&T quiz. The grades for the two will count against

your Final Exam grade.

- The MDP (Manuf Design Presentation) is the focus of the course and everything

we cover and discuss is tied to the MDP. We will spend a lot of time in the

lectures talking and preparing for the MDP. (so be in class, as well as your CAD

Labs) At the end of the course you will all have a set of detail dwgs and an assy

dwg to take with you and possibly show to someone at an interview. Anyone

looking at your work should say: “Not bad for an Intro course”.

We will cover all of this on Day One so please be ready with questions.

Drake

WK DATE MDP # @ RDS MDP # @ B-SHOP WK DATE MDP # @ RDS MDP # @ B-SHOP

1 NO LAB WK 1 NO LAB WK 1

2 8/31 1AB 2AB 1CD 2CD 10 10/26 1CD 2CD 1AB 2AB

9/1 3AB 4AB 10/27 3AB 4AB

9/2 5AB 6AB 5CD 6CD 10/28 5AB 6AB 5CD 6CD

9/3 7AB 10/29 7AB

3 9/7 LABOR DAY LABOR DAY 11 11/2 1AB 2AB 1CD 2CD

9/8 3AB 4AB 11/3 3AB 4AB

9/9 5CD 6CD 5AB 6AB 11/4 5CD 6CD 5AB 6AB

9/10 7AB 11/5 7AB

4 9/14 1CD 2CD 1AB 2AB 12 11/9 1CD 2CD 1AB 2AB

9/15 3AB 4AB 11/10 3AB 4AB


9/17 7AB 11/13 7AB

5 9/21 1AB 2AB 1CD 2CD 13 11/16 1AB 2AB 1CD 2CD

9/22 3AB 4AB 11/17 3AB 4AB


9/24 7AB 11/19 7AB

6 9/28 1CD 2CD 1AB 2AB 14 11/23 1CD 2CD 1AB 2AB

9/29 3AB 4AB 11/24 3AB 4AB


10/1 7AB 11/26 T-DAY T-DAY

7 10/5 1AB 2AB 1CD 2CD 15 11/30 1AB 2AB 1CD 2CD

10/6 3AB 4AB 12/1 3AB 4AB


10/8 7AB 12/3 7AB

8 10/12 1CD 2CD 1AB 2AB

10/13 3AB 4AB

10/14 5AB 6AB 5CD 6CD

10/15 7AB

9 10/19 FALL BREAK FALL BREAK

10/20 FALL BREAK FALL BREAK

10/21 5CD 6CD 5AB 6AB

10/22 7AB

EMAE 160 MANUFACTURING DESIGN PRESENTATION – MDP Purpose: An introduction to engineering and design of a product and to have a design package to show prospective employers. (I.E. Co-op, summer internship, etc.) Also, this exercise will be re-visited in EMAE 260 and EMAE 360.

- Each Lab will be divided into groups of approx. (4). - Design something to benefit the human race, something with a real

purpose. - Your design is to have 6 min. – 8 max. parts. Hardware and O.E.M.

(original equipment manufacturer) parts are exempt. - Create detail drawings, sub assembly drawings (if applicable), and an

assembly drawing. Please follow the EMAE 160 MDP Dwg # Format – shown below.

MDP will consist of (3) Rounds

Round I starts 2/10 Present (3) ideas to me at Bingham 103. I will give you the specifics of what I am looking for. Be creative, challenge yourselves to come up with (3) ideas. Round I is only worth 10% of the MDP Grade, but the effort you put in Round I will have a direct impact on Round II and III.

Round II starts 3/17 You will be creating a prototype version of your design - design only, you will not be building a prototype. Your prototype design will be composed of standard materials. I.E. standard bar stock, structural shapes, sheet and plate, plastic, ferrous and non-ferrous materials, and of course ‘off the shelf’ hardware and O.E.M parts. No Rapid Prototyped parts. Each group has 15 mins. to present and then my critique and comments from the audience. Each group to have a ‘scribe’ to take notes of my critique. (write fast) Within 24 hrs. after the presentation, have a hard copy of my critique in my mailbox. (door of Glennan 820) Type the critique as a word .doc in block form to allow me to check- off the RD II improvements at the RD III presentation.

Each group member to speak – including the scribe. To demonstrate everyone has contributed to the project, each group member to discuss and explain the dwgs. they created. The last group of the day should be prepared to stay later than 4:00. (if needed) For the first day of MDP RD II I will try to go easy, but afterwards you should have a better idea of what I am looking for. Do the best you can, pay attention to detail, be succinct and to the point, study the sample MDP on B-Board, pay attention to the detail dwg./assembly dwg. format. Also, I highly recommend you provide a SW animation. For Round III starts 4/9 Re-present your Round II dwgs. to allow me to see that you have made all the necessary corrections from the Round II critique. Also, for Round III you are to present a model of the mass produced design (jazz it up) and state your recommendations on what manufacturing processes would be required to mass produce this design and why. Make sure your design includes at least three different manufacturing processes AND be prepared to defend your manufacturing choices. To reiterate: RD III will be your opportunity to show you have improved RD II material and to also present and defend your final mass-produced version of your design. The MDP is the focus of the course; an opportunity to tie it all together and to learn and apply the Fundamentals of Manuf. and Design. I encourage 100% attendance to all presentations. Please note: “The Unforgiven Sins of MDP” will be strictly enforced!

MDP Dwg # Format A = ASSEMBLY

SA = SUB-ASSEMBLY

M = MANUFACTURED PART

P = PURCHASED PART

R = RAPID PROTOTYPE PART

F = FIXTURE PART

FA = FIXTURE ASSEMBLY

FSA = FIXTURE SUB-ASSEMBLY

___ - 160 Lab # A,B,C,D – XXX SAMPLE: A – 160L1A- 001

Grading Criteria Round I 10 pts. Round II 55 pts. Detail and Assy DWG format 30pts. Description of design and purpose 15pts. Organization and flow of the PowerPoint presentation 10pts. Round III 35 pts.

Show and explain that you have corrected errors on the detail and assembly dwgs. Show and explain that you have improved the design from RD II. Present the model of the “mass produced’” design and describe the manufacturing processes (3 minimum) required for the mass production.

“The Unforgiven Sins of MDP”

- NO TANGENT LINES

- NO SCREEN SHOTS

- NO ISO DIMENSIONING

- ALWAYS SHOW HIDDEN LINES IN EVERY ORTHO VIEW

B I N G H A M

S T U D E N T

W O R K S H O P

“SAFETY POLICY”

NOTICE TO ALL PERSONS USING THE BINGHAM WORKSHOP:

IT IS REQUIRED THAT YOU SUCCESSFULLY COMPLETE EMAE 160 (OR EQUIV.) BEFORE USING THE EQUIPMENT

WHEN WORKING IN THE SHOP AND OPERATING EQUIPMENT

PROPER ATTIRE IS REQUIRED:

WEAR SAFETY GLASSES

NO JEWELRY, RINGS, WATCHES

NO LONG SLEEVES

NO SHORTS

NO SANDALS

NO TANK TOPS

TIE BACK LONG HAIR

HEALTH

IF YOU ARE SICK AND LACK THE ATTENTION REQUIRED TO WORK SAFELY, DO NOT USE THE SHOP

EMAE 160 Syllabus

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