ME455 2011

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The design group at Clemson University
160 articles in English

Contents

[edit] Official Syllabus

[edit] Course Contact

[edit] Prerequisites

The student must have passed with a C or better the following courses: ME 301, 306, and 312. Under limited circumstances, the student may be concurrently enrolled in ME 404 based upon professor discretion.

[edit] Special Accommodations

If special accommodations are required for the student, please see the professor so that proper arrangements may be made.

[edit] Textbooks

[edit] Required

Poli, C., (2001), Design for Manufacturing:  A Structured Approach, Butterworth-Heinemann, Boston, MA: ISBN 0-7506-7341-9. online-Google Books

[edit] Suggested

Boothroyd, G., Dewhurst, P., Knight, W., (2002), Product Design for Manufacture and Assembly, CRC Press, : ISBN 082470584X, 9780824705848. (online-Google Books (partial)

[edit] References

See the Library Reserves.

[edit] Course Description

Concepts of product and process design for automated manufacturing are considered. Topics include product design for automated manufacturing, inspection and assembly, using automation, industrial robots, knowledge-based systems and concepts of flexible product manufacture. Preq: ME 301, 306, and 312 (or concurrent enrollment), or consent of instructor. The primary objectives of this course are to develop in the student:

  • To show students the relationships between part design and its manufacturability.
  • To teach students methods of DFM and DFA.
  • To provide students team instruction through project experiences.

[edit] Assignments

This course is structured to build upon the student's experiences, encourage the student to discover new material independently, and foster a habit of self-critique. To do this, assignments are designed to help the student understand the material, not to create busy work.

  • Assignments should be professional quality (clear, concise, correct, and conscientious).
  • Design Rules should be turned online to the following e-mail id: pshanka@clemson.edu and jsummer@clemson.edu
  • The Design Rules should be submitted with a standard (please refer tentative schedule section, lecture 1 for the standard template)
  • Assignments are due at the BEGINNING of class. Late assignments will be given credit after a 10% reduction for each day late, however late work may be submitted for corrections.
  • Ethical behavior and professional standards are expected in this class. All work submitted is to be that of the individual

student unless cooperative effort is authorized in specific instances. The College of Engineering and Sciences Honor Code will be observed.  Refer to your student handbook regarding University policies on academic dishonesty.

[edit] Computer Usage

Word processing, spreadsheet, Internet, and mathematical computation utilities will be used by the students throughout the course.

[edit] Weighting for Grade

Description ME 455 Weighting ME 655 Weighting
In-class Activities 20% 15%
Reverse Engineering Project 25% 20%
Design for Assembly Project 15% 15%
Design for Manufacturing Project 15% 15%
DFX Guidelines 25% 15%
Term Project 20%
Total 100% 100%

[edit] Graduate/Undergraduate

This course will be taught at an accelerated pace, corresponding with a graduate level course. Students are encouraged to work in pairs on the projects. Undergraduates and graduates will be evaluated on separate scales. Additional assignments will be given to the graduate students to test deeper understanding of the material.

[edit] The Engineer's Creed

As a Profession Engineer, I dedicate my professional knowledge and skill to the advancement and betterment of human welfare. I pledge:

  • to give the utmost of performance
  • to participate in none but honest enterprise
  • to live and work according to the laws of man and the highest standards of professional conduct
  • to place service before profit, the honor and standing of the profession before personal advantage, and the public welfare above all other considerations

In humility and with need for Divine Guidance, I make this pledge.

[edit] Engineering Ethics (The Canons)

  • Engineers shall hold paramount the safety, health, and welfare of the public in the performance of their professional duties.
  • Engineers shall perform services only in areas of their competence.
  • Engineers shall continue their professional development throughout their careers, and should provide opportunities for the professional and ethical development of engineers under their supervision.
  • Engineers shall act in professional matters for each employer or client as faithful agents or trustees, and shall avoid conflicts of interest or the appearance of conflicts of interest.
  • Engineers shall build their professional reputation on the merit of their services and shall not compete unfairly with others.
  • Engineers shall associate only with reputable persons or organizations.
  • Engineers shall issue public statements only in an objective and truthful manner.
  • Engineers shall consider environmental impact in the performance of their professional duties.


[edit] Tentative Schedule

This schedule is subject to change. Students are responsible for being aware of such changes.

Lecture Topic Reading
1 Introduction: Course, Design for Manufacturing (large) (small) * Chapter 1 and Chapter 2 of Poli
2 Design for Assembly (large) (small) * Chapter 12 (Poli), Boothroyd
3 Design for Assembly (large)(small) * Chapter 12 (Poli), Boothroyd
4 Design for Assembly (large)(small) * Chapter 12(Poli), Boothroyd
5 Design for Assembly (large) (small) * Chapter 12(Poli), Boothroyd
6 Tooling and Fixturing (large) * Chang (Ch 5)
7 Injection Molding * Chapter 3 (Poli)
8 Injection Molding * Chapter 4 (Poli)
9 Injection Molding Chapter 5 (Poli)
10 Injection Molding Chapter 5 (Poli)
11 Casting Chapter 6 (Poli)
12 Casting Chapter 7 (Poli)
13 Casting Chapter 7 (Poli)
14 Sheet metal forming Chapter 8 (Poli)
15 Sheet metal forming Chapter 9 (Poli)
16 Sheet metal forming Chapter 10 (Poli) Answer to Quiz
17 Other metal process Chapter 11 (Poli)
18 Material selection Chapter 13 (Poli)
19 Reverse Engineering 455 Project 655 Project Otto and Wood
20 Reverse Engineering Otto and Wood
21 Reverse Engineering Otto and Wood
22 Lean Manufacturing Notes Class notes
23 Lean Manufacturing Class notes
24 Design for Environment Class notes
25 Group Technology
26 Presentations Guest lecture Dr. Johnson
27 Presentations
28 Presentations
29 Presentations
30 Presentations

Questions should be directed to the professor: Joshua D. Summers [1]

[edit] Project Images

[edit] Design for Assembly - Prototype Images

Book Binder

Team: Vikrant Rayate

Clip loader

Team: Nick Leland, Matt Sutch

Six Pack Holder Shredder;

Team: Apurva and Liz

Lunar Spring Tweel

Team: Michael Miller, David Griese, Matthew Peterson

Ball Throwing Machine

Team: Timothy Hess,Mark Bowman, David Sitarski

Artificial Respirator

Team: Raghuvansh Ramaswamy, Jared Hazel, and Teal Fenton

Paper Shredder

Team: Austin Smith, Garrett Corwin, Hunter Cestoni

Tailight Fixture

Team: Samantha Thoe

Lunar Tweel(NASA)

Team: Milto Stamatopoulos, Lawrence Smith, Alexander Vitou

[edit] Design for Manufacturing - Prototype Images

Ryobi Molding 1 Ryobi Molding 2 Headlight Casing 1
Headlight Casing 2

Team: Jared Hazel, Teal Fenton, Raghuvansh Ramaswamy

Headlight Casing 3 Headlight Casing 4
Radiator Fan

Team: Austin Smith, Garret Corwin, Hunter Cesstoni

Back Rest 1

Team: Alex Vitou, Lawrence Smith, Milto Stamatopoulos

Back Rest 2
Back Rest 3

Team: Apurva Gokhale, Liz Mathew

Seat frame

Team: Nick Leland, Matt Sutch

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