• Read Materials Handbook section on Estimating Power and Speed
  • https://youtu.be/CBjGDjjyrpU
• Use slides reference at:
  • http://me1800.com/equations and
  • chip Formation Geometry
• Read Chip Formation and Machining of Metals – prof Christopher A. Brown
• Watch:
  • A Level Physics – Stress, Strain and Young’s Modulus
  • A Level Physics – Stress-Strain Curves in Detail

• Study: CNC Quick Guide for Haas Mills Pages 1-3
• Read: “The Winding Path from Art to Part” The Art of Manufacturing pages 14-30
• Watch: “Converting from RPM to Surface Speed In CNC Milling and Turning”
• Monday: Homework 2 Due (canvas.wpi.edu)
• Review lab instructions: http://me1800.com/mill/initial-engraving/
• Tuesday Lecture: Art to Part in Prototype Manufacture
• Wednesday Lecture: Process Variables and NC Code
• Thursday Lecture: Monday Schedule — NO LECTURE —
• Friday:
  • CAM1 Assignment Due Friday 11:59PM (canvas.wpi.edu)
  • Group Assignment 1 Due Friday 11:59PM (canvas.wpi.edu)

• Review the Syllabus
• Read: “Manufacturing – the worlds oldest profession“
• Read: “Quality – Giving customers what they need when they need it“
• Research manufacturing processes on line (start with google)
• Review: https://youtu.be/0eXPn4uNRI4
• Review: The Metrology Handbook , Bucher, Jay L.., ASQ Quality Press, 2004. Pages 149-156.https://youtu.be/ABLHyyOHem8
• Review the NIST Technical Note TN1297
• Complete the Monday Quiz (http://canvas.wpi.edu)
• Tuesday: Lecture — SL104 Quality and Metrology
• Wednesday: Lecture — Prototyping and Before your first lab
• Thursday: Lecture — Metrology and Measurement Uncertainty
• Thursday: Lab (If you are in Section 2, 3, or 4)

This week we will talk about Manufacturing, Lean Manufacturing, and the Process of taking a concept from Art to Part.

We will have lectures on Tuesday, Wednesday, and Thursday:

• Tue – Lean Manufacturing
• Wed – Art to Part 1
• Thur – Art to Part 2

In Labs you will begin to use the CNC Machines and start learning about CNC Programming

 

Objective

• Be able to discuss standards and their purpose.
• Understand how to specify tolerances and fits for common situations in manufacturing assembly.
• Be able to design a manufacturing process to hit a specified tolerance.
• Understand common pitfalls in DFM.
• List common techniques for designing for assembly.

Lecture

• Tuesday – GD&T
• Wednesday – Design for Manufacture

Reading

Hand In On Canvas

Wk5	Tuesday	2/13/18	23:59	Canvas	Week 5 Survey	1
Wk5	Wednesday	2/14/18	23:59	Canvas	Week 3 Quiz	4
Wk5	Friday	2/16/18	23:59	Canvas	CAM 5.1	4
Wk5	Monday	2/19/18	23:59	Canvas	Week 4/5 Quiz	8

This week you are finishing up group assignment 2 and we start talking about design. On Tuesday we look at what we need to know to design fixtures and we explore some possible solutions. Wednesday there is no lecture and on Thursday we will introduce the critical concepts of functional design from the perspective of the manufacturing engineer.

Objective

• Understand how to estimate cutting forces that need to be considered when designing fixtures.
• Understand basic principles of fixturing both kinetic and kinematic.
• Be able to describe the fundamentals of design.
• Discuss design methods and tools.

Lectures

• Tuesday – Fixture Design
• Thursday – Functional Design

Reading

Required

For Reference

• The first secret of great design | Tony Fadell

Hand in on Canvas

Wk4	Monday	2/5/18	23:59	Canvas	Week 4 Survey	1
Wk4	Wednesday	2/7/18	14:00	Canvas	Group Assignment 2	5
Wk4	Friday	2/9/18	23:59	Canvas	CAM 4	4

The Week 3 Quiz is moved to next Week.

Objectives

• Understand why engineers use models to better understand manufacturing processes.
• Be able to develop a model for a simple manufacturing process.
• Use reference materials to find and use models to predict forces, power consumption, and deflection in machining processes.

Lectures

• Tuesday – Energy and Power
• Wednesday – Power force and Chips
• Thursday – Stress and Strain

Homework

Reading

• Oberg, Erik Jones, Franklin D. Horton, Holbrook L. Ryffel, Henry H.. (2016). Machinery’s Handbook (30th Edition) – 44.8 Estimating Machining Power. (pp. 1119-1127). Industrial Press. (https://youtu.be/TrzbrDQCFtM)
•  Chip Formation and Machining of Metals – prof Christopher A. Brown
• A Level Physics – Stress, Strain and Young’s Modulus
• A Level Physics – Stress-Strain Curves in Detail

Submit on Canvas

Wk3	Monday	1/29/18	23:59	Canvas	Week 2 Quiz	5
Wk3	Monday	1/29/18	23:59	Canvas	Week 3 Survey	1
Wk3	Friday	2/2/18	23:59	Canvas	CAM 3	4
Wk4	Monday	2/5/18	23:59	Canvas	Week 4 Survey	1

Objectives

• Be able to explain the importance of Quality in Manufacturing
• Understand the difference between QC and Process Control
• Be able to discuss and calculate Cp, CPk and Process Performance Variables
• Understand and discuss Measurement Uncertainty and how it impacts manufacturing
• Be able to calculate and discuss how PVs in Machining impact Surface Roughness and other DPs

Lectures

• Tuesday — Quality Metrology
• Wednesday — Quality Metrology
• Thursday — No Lecture —

Homework / Assignments

Reading

• Cpk explained by Professor Cleary
• Six Sigma In Plain English
• Evaluation of measurement data (pp 1-15)

For Reference:

• Machine Tool Metrology: An Industrial Handbook (Smith, Graham T)
• The Metrology Handbook (Bucher, Jay L)
• Juran’s Quality Handbook 7e (Defeo, Joseph)

Submit on Canvas

Wk2	Monday	1/22/18	23:59	Canvas	Week 1 Quiz	4
Wk2	Monday	1/22/18	23:59	Canvas	Week 2 Survey	1
Wk2	Wednesday	1/24/18	14:00	Canvas	CAM 2.1	4
Wk2	Friday	1/26/18	23:59	Canvas	CAM 2.2	4
Wk3	Monday	1/29/18	23:59	Canvas	Week 2 Quiz	5
Wk3	Monday	1/29/18	23:59	Canvas	Week 3 Survey	1