Mr. Alaa Elwany (photo), alaa-elwany@uiowa.edu. 
Office G435, Office Hours Tuesdays 1:00PM - 2:30PM.  Others by appointment.  Phone: (319) 594 - 0363. 

Mr. Kevin Kaiser (photo), kevin-kaiser@uiowa.edu
Office G435, Office hours: Mondays, 11:30 - 1:20PM.  Others by appointment.  Phone: (563) ­ 349 - 0210.

Mr. Shaun Carr (photo), shaun-carr@uiowa.edu
Office 1433SC, Office Hours: Tuesdays 10:45AM - 12:20PM. Others by appointment.  Phone: 335-5049.

The learning objectives are:

* Students will gain an understanding of the major manufacturing processes, including machining, casting, forming, assembly, surface treatment, plastics processing, and inspection.

* Students will develop the ability to use 3D computer-aided design (CAD) software and create part models, assemblies, and drawings.  Pro/ENGINEER will be our CAD software.

* Students will understand  computer numerical control, how to write NC programs, and how to create NC programs with CAD/CAM software.

* Students will understand CAD/CAM technologies and create physical parts.

* Students will understand engineering graphics principles and how designs are communicated in industry. They will develop the ability to interpret engineering drawings.

* Students will understand the relationships between customer desires, project materials, product design, and manufacturing process selection. The will develop an appreciation of product design and manufacturing process trade-offs.

* Students will be able to look at products and determine how they were manufactured and why?

Pro/Engineer Wildfire2.0 Tutorial, Roger Toogood and Jack Zecher, SDC Publications, 2004. (This is the red Pro/E book, not the older blue book)
ISBN 1-58503-186-0

Additional readings may be provided by the instructor.  These will almost always be available on this website for downloading.  Flash

As the semester progresses, you will be informed about your assignment grades.
YOU HAVE 2 WEEKS TO DISPUTE YOUR GRADE ON ANY ASSIGNMENT.

You are reminded about the College policy about academic misconduct http://www.engineering.uiowa.edu/current-students/academic-misconduct.html, and plagiarism at http://www.engineering.uiowa.edu/~ctc/docs/ctc_guides/ctc_guide_avoiding_plagiarism.html.

This course is given by the College of Engineering. This means that class policies on matters such as requirements, grading, and sanctions for academic dishonesty are governed by the College of Engineering. Students wishing to add or drop this course after the official deadline must receive the approval of the Dean of the College of Engineering. Details of the University policy of cross enrollments may be found at: http://www.uiowa.edu/~provost/deos/crossenroll.doc

Attendance and Class Participation: Attendance is very important, especially to get information not covered in the text.  You are expected to come prepared to class by completing homework and readings, and to participate in meaningful discussions in class.  Attendance will be taken randomly.  Do not sign other student's names for them.

Homework: There will be variety of homework assignments throughout the semester.  Some expect exact answers and some will be "open ended" meaning that there may be several correct responses, but that there must be some logic to your response.  Some homework is collected, some is put into ICON, and some will be submitted electronically.  The homework link provides the method and due date.

Complete the assignments individually (i.e., put the answers into your own words) although discussion with other students is allowed and encouraged.  Students are expected to complete the assignments by the due date which will always be shown on this website (by midnight).  Some assignments may have different weights assigned to them to reflect their difficulty.  The grade will be based on approach to the problem, effort, and answer quality.  If you copy someone else's homework or let someone copy yours, you can expect to get a zero for the entire day's assignment and possibly face more serious disciplinary action. Be a professional; do your own work.

Homework handed in one class period late will be given a maximum grade of 1/2 its full value. No credit will be given for homework two periods late.   Also, when handing in multiple pages, please staple these together.

Integrated Design Project: This semester long project challenges you to apply your knowledge to a product design and manufacturing scenario.  This is a team project, and you will be assigned to a manufacturing team (team members).  Click here for project details.

Bonus Assignments: Throughout the semester, bonus exercises may be provided.  These are optional and they can only help your manufacturing processes understanding and your grade.

Depending on how the semester goes, a couple low homework scores may be dropped.

Introduction to Manufacturing Engineering (read pages 1-42)

LAB01: Orientation: (Yes, there is a lab the first Thursday!)

Homework #01 (due 1/30): 1.18; 2.20; 3.18; 4.17; 5.16; 7.63; 8.29; 9.65 (3 examples).

Introduction to Computer-Aided Design (CAD): Optional reading 38.4.

LAB02: Pro/E - Introduction and Creating a Simple Part (Lessons 1 and 2, due 2/3)

Homework #02 (due 2/3): Product Cost - Chocolate Chip Cookies

Manufacturing Economics (Optional reference reading)
Excel Model

EG: Bases for interpreting drawings, sketching, orthographic and Isometric Views, Hidden Lines

This group of assignments are due on 2/13, bring to class.
Homework #04-A1, Homework #05-A2, Homework #06-A3
Homework #07-A8, Homework #08-A10
Homework #09 - Determining Material Cost

LAB03: Pro/E - Creating a Simple Part, Part II (due 2/10)

Homework #10 (due 2/13) 21.16, 21.18, 21.40 (hard, use eq. 21.20a).

Cutting Tools: Chapter 22.  Read 22.1; 22.2; 22.4.3; 22.12 (to bottom of page 666); and Summary.

Homework #11 (due 2/13) 22.25, 22.40.

Lecture notes for both chapters

EG: , Working Drawing & Dimensioning (full slides)
CAD Analysis and Dimensions (by Shaun Carr)
HW#12 - A4 (include dimensions) (due 2/20)

LAB04: Pro/E - Revolved Features, Mirrors, Rounds, and Chamfers (Lesson 4) (due 2/17)

Homework #13 (due 2/20): Ch 24.36, 24.37, 24.39.

(Wed) NC Programming (full slides), Ch37, Read 37.3, 37.4.

Discuss Exam (Study notes)

Lab 05: NC Programming Introduction (due 2/24)

Homework #14: (due 2/27): Ch 24.16, 24.25

Discuss Project

Exam #1: Wednesday, February 22, in class. All material through and including February 15, but no NC Programming.
Study Notes

LAB06: Pro/E - Sketcher Tools and Datum Planes (Lesson 6) (due 3/3)

Turning Equations (full slides)

Homework #15: Ch 23.17, 23.30, 23.34, 23.38. (due 3/6)
Homework #16: Ch 23.43, 23.44, 23.45. (due 3/10)

LAB07: Pro/E - Engineering Drawings (Lesson 8) (due 3/10)

Forming and Shaping Processes: Chapters 13-16. Read: 13 (all); 14.1,2,3,4, 8,9;  15.1,2;  16.1,2,5,13.
Lecture Notes: (full)

Homework #18: 13.25, 13.32, 14.35, 15.49, 16.60. (due 3/22).

Metal Casting Processes and Equipment: (Wednesday, Mr. Elwany): Read Chapters 10 and 11 (all)
Lecture Notes (full)

Homework #19: 10.35, 10.49, 11.2, 11.13, 11.38 (due 4/3)
Extra Bonus: Problem: Pick a product from your choice, sketch it NEATLY, and sketch the pattern you would use to sand cast this product.

Exam #2 (Wednesday) - All material through and including March 17 (no Pro/E assembly).

Exam 2 Study Notes

CLICK HERE FOR YOUR ON-LINE ASSIGNMENTS

Topics for the online week:
    Plastics and Composites:
    Computer-aided machining
    EG: Sectional views, removed sections.
    Work on Team Projects

Lab12: CAM - Milling Parts with Pro/E (due 4/26 4/28) 

Homework #25: 30.15, 30.19, 30.34, 31.21, 31.22, 31.35, 32.16, 32.18, 32.22 (due 4/26)

Lab13: Inspection Lab (due 4/28)

Inspection and Quality Assurance (full)- Chapters 35 and 36.

(Wednesday)
Integrated Design Project, report due today, April 26
Project Presentations (see link for presentation order).

Exam 3, Wednesday, May 3 (Study Notes)