Manufacturing Methods



Dr. J. JeswietMcLaughlin Hall 303Ajacob.jeswiet@queensu.cax32577

Course Description

The objective of this course is to achieve a knowledge and understanding of a wide variety of manufacturing processes involving plastics and metals. This course forms the basis for improved product and machine design, and will assist the mechanical engineer to function in the areas of design, manufacturing and general engineering. Training in the use of machine and welding tools found in a modern job shop is a required activity practiced in the machine tool laboratory. (0/0/0/0/48)


Objectives and Outcomes

By the end of this course, learners should be able to:

- Identify, explain and use different methods of manufacturing: turning, milling, drilling, grinding,  waterjet cutting, plasma cutting, welding, tension, compression, bulk forming, sheet metal forming,  rolling, extrusion, hydroforming, deep drawing, bending and punching.  
- Calculate material removal rates and feedrates for machine cutting processes.  
- Explain machining terminology such as DOC, rake angle, shear plane angle, “thou”, and calculate  these for a variety of input parameters.
- Calculate cutting tool life using Taylor’s equation.  
- Calculate force requirements for machining.  
- Calculate force requirements in metal forming: extrusion, rolling, punching.  
- Identify and explain the differences between tension and compression in metal forming.  
- Estimate the power and energy needed for machining and forming.  
- Explain rudimentary aspects of stress in metal forming and how yield stress changes with strain  hardening.  
- Use sheet metal forming tests such as the limiting dome height (LDH) and bulge tests. Calculate  major and minor strains with LDH data.  
- Use basic welding techniques.  
- Be able to decide which metals are appropriate in manufacturing a part  
- Apply surface roughness data in part tolerance problems including Ra, Rt, Rz,Rmax, Kurtosis and  Skewness.  
- Manufacture and assemble parts in the laboratories.  
- Make proposals for course projects.  
- Research and report on a specific manufacturing process. 

Relevance to the Program

Course Structure and Activities

3 lecture hours + 1 tutorial hour + 2 shop hours per week.  Please refer to SOLUS for times and locations.


Required Textbook: Manufacturing Engineering & Technology (7th ed.) - Serope Kalpakjian & Steven R. Schmid