IE 312 PRODUCT DESIGN and MANUFACTURING PROCESSES

FALL 2017 (WEB SECTION)

Instructor: Edward C. De Meter

Office: 217 Leonhard
Telephone: 814 863-7291
Email: ecd3@psu.edu
Office Hours: M, W 11:00 am 12:00 pm

Graduate Teaching Assistant: Haochen Xie

Office: 208 Leonhard
Email: hzx5057@psu.edu
Office Hours: To be determined

Graduate Teaching Assistant: Kok Hwang Chow

Office: 208 Leonhard
Email: kzc53@psu.edu
Office Hours: To be determined

Graduate Teaching Assistant: Yuqin Liu

Office: 208 Leonhard
Email: yxl68@psu.edu
Office Hours: To be determined

Graduate Teaching Assistant: Varad Tripathi

Office: 208 Leonhard
Email: vft5018
Office Hours: To be determined

CONTENTS

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1. COURSE OBJECTIVES 3
2. COURSE TOPICS 3
3. COURSE REQUISITES 3
4. COURSE MATERIALS 3
5. GRADING 4
6. LECTURE AND LABORATORY ORGANIZATION 4
7. SUBMITTING GD&T ASSIGNMENTS AND LAB REPORTS 5
8. TEAMWORK IN ASSIGNMENTS 5
9. EVALUATION OF LABORATORY PARTICIPATION 6
10. EXAMS 6
11. LATE SUBMISSIONS AND ABSENCE IN LABS AND EXAMS 6
12. TEAM CONFLICTS 7
13. OFFICE HOURS 7
14. EXAM AND Q&A INFORMATION 7
15. ACADEMIC HONESTY POLICY 7
16. STUDENT DISABILITY POLICY 7
17. COURSE STUDY, ASSIGNMENT, AND EXAM SCHEDULE 9

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1. COURSE OBJECTIVE
The objective of this course is to introduce mechanical engineering students to design and
manufacturing process concepts that are critical to the scalable, i.e. commercial
production of finished goods. The course will focus on design specification and
manufacturing processes, with an emphasis on process selection and its consequences
with regard to process mechanics, capability, cost, and lead times. The course will
comprise lecture and laboratory work on a series of course topics. Grading* will involve
performance and participation in laboratory and three tests.

2. COURSE TOPICS
Course Introduction
Mechanical Product Attributes
Mechanical Properties and Metrology
Geometric Tolerance Specification and Metrology
Surface Texture Specification and Metrology
Manufacturing Process Overview
Machining Processes
Metal Casting Processes
Metal Bulk Deformation Processes
Sheet Metal Processes
Metal Welding Processes
Powdered Metal Processes

3. COURSE REQUISITES

Prerequisites: EMCH 213, EMCH 210 or EMCH 110H

Co-requisites: MATSE 259 or ESC 414M

4. COURSE MATERIALS

Text: Kalpakjian, S. and S. Schmid, Manufacturing Processes for Engineering Materials,

5th Edition, Prentice Hall, NJ, 2001

*It is encouraged that students purchase this book due to its excellent coverage of the
material. Reading assignment will be prescribed from the textbook. However, all material
required for laboratory reports, GD&T assignments and tests will be covered in class or
provided.
Website: Supplementary material required for understanding concepts will be available
via. CANVAS course website. Among others, these will include:
Lecture notes
Lab descriptions

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 Geometric Dimensioning and Tolerancing (GD&T) assignments
Example GD&T homework problems and solutions
Links to course instructional videos (web only)
Select chapters from the 1994 ASME Y14.5M GD&T Standard ASME Y14.5M
GD&T Short Guide

5. GRADING
Team Laboratory Reports & Team Homework Assignments 35%
Midterm Exam 1: 25%
Midterm Exam 2: 25%
Final Exam: 15%

6. LECTURE AND LABORATORY ORGANIZATION

Students will learn through the web via videotaped lectures, videotaped laboratories, and
web based question answer sessions with the course instructor and the course teaching
assistant. They will also learn via reading assignments, team laboratory assignments, and
team homework assignments. All resources necessary to complete this course are
available on CANVAS. A schedule for the completion of assignments is provided at the
end of the syllabus. It is also provided on the course website.

Laboratory assignments pertaining to metrology and manufacturing processes will be

provided to reinforce and add depth to concepts discussed in lecture. Complete
instructions are provided in the laboratory description document. A typical team
laboratory assignment will require students to:
Read a laboratory description document.
Submit a preliminary report pertaining to the lab; this is not required for all labs
Watch a video of the laboratory and record measurement data that is called out by the
lab instructor, and subsequently submit this data electronically to the course website;
this is not required for all labs.
Download engineering data similar to that derived from the laboratory video.
Analyze the data.
Create and submit an engineering report that describes the results of the investigation.
It is important that you review the assignment dates for these laboratories in the lab
assignment schedule. Within the same block as the posted assignment, you will see the
statement "Prelim Report & Lab Data Due." This means that prior to 5 pm of the
assignment date, you are to read the laboratory document, complete the preliminary lab
report, watch the lab video, and fill out the data tables in your lab assignment document
using data called out in the video. You are to electronically submit the preliminary report
and the recorded data to the assignment drop box on the course website by 5 pm of the
assignment date.

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7. SUBMITTING GD&T ASSIGNMENTS AND LAB REPORTS
All GD&T assignments, preliminary lab reports, and final laboratory reports must be
successfully uploaded to the assignment drop box on the CANVAS course website prior
to the deadline posted on the assignment schedule. The schedule may be found on the
course website as well as the course syllabus.

All reports must be submitted for grading as MS-WORD documents that are created
using MS-WORD software. This includes tables containing recorded data from the lab
videos, preliminary lab reports, final lab reports, and assignment solutions. It is
acceptable for students to use cloud software such as GoogleDocs to create a draft of
their document. However material created within this document must be copied and
pasted into a new MS-WORD document created using MS-WORD software.

For many laboratories you will be given data in an EXCEL le, and you will be required to
analyze this data using EXCEL. Before analyzing this data, you are to copy and paste it
into a new EXCEL le of your own creation. Your EXCEL analysis le must be submitted
along with your lab report.

GD&T assignments must be submitted electronically to the course website prior to 5:00
PM of the posted due dates. Preliminary lab reports and final lab reports must be
submitted electronically to the course website prior to the starting time of your lab period
on the dates listed. Data recorded in a laboratory typically must be submitted to the
instructor at the end of the laboratory (see lab write up).

If a team fails to successfully submit an assignment to the drop box before the drop box
closes, they must email the course TAs and formally request an extension. A first time
overdue submission will receive a 10% grading penalty. A second time overdue
submission will receive a 50% grading penalty. A third time overdue submission will not
be accepted. These penalties will apply to the entire team, not just the team member
attempting to upload it. Consequently when uploading your assignment to the drop box, it
is important that you double check to make sure that it has uploaded successfully into the
right folder. Also see section on Late submissions and Absence in Labs and Exams.

8. TEAMWORK IN ASSIGNMENTS
Students will work in teams of four students on team laboratory assignments and team
homework assignments. Team members are expected to communicate electronically to
coordinate and exchange data for the purpose of completing team assignments. Students
within a team are highly encouraged to communicate as much as possible to exchange
ideas and help each other learn. Students are expected to understand all information
submitted in lab and team assignments. Likewise students are expected to review all
feedback on graded assignments.
At the beginning of the semester, team assignments will be made by the course
instructor and posted on CANVAS. Students will be required to provide their team mates
their contact information (address, cell phone number, daily schedule of when they can
be reached, etc.). A folder within CANVAS will be created for each team. The course TA

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will use the folder to provide feedback on graded assignments. Also see section on
Teamwork and Laboratory Conflicts.

9. EVALUATION OF LABORAOTRY PARTICIPATION

At the midpoint and endpoint of the semester, lab team members will rate each others
performance as well as their own. To do so, you will download the peer evaluation form
from ANGEL, fill it out, and submit an electronic copy to your team peer evaluation drop
box. This rating may be used to adjust the laboratory and assignment grades of
individual team members. The time windows for filling out these evaluations are posted
in the COURSE STUDY, ASSIGNMENT, AND EXAM SCHEDULE. Submission of
this peer evaluation form is mandatory and will count toward your lab grade.

10. EXAMS
Two midterm exams and a non-cumulative final exam will be given during the semester.
Students at the University Park campus are required to take the exams on-campus at a
pre-designated time and location. Students who are not on campus, can either take the
exams on-campus (highly encouraged) or at the students home site. If the latter, the
exams will be mailed to a proctor of the students choosing.

The proctor will be responsible for administering the exam and insuring that the student
adheres with the exam regulations. The proctor will also be responsible for mailing the
completed exam back to Penn State. The student will be responsible for providing the
proctors contact information to the PSU web course administrator at the beginning of the
semester. Eligibility requirements for the proctor will be posted on the course website.
The exams will be closed book and closed note. However the student will be allowed to
bring three note sheets, hand/type copied front and back. Each exam will have a two hour
duration.

11. LATE SUBMISSIONS AND ABSENCE IN LABS AND EXAMS

Participation in labs and exams is mandatory. All assigned work is to be turned in at the
beginning of lab the day that it is due. No unexcused late work will be accepted. Work
can only be turned in late upon prior approval of the course instructor. An unexcused
absence will lead to a zero grade for the lab report, or exam. No absences will be excused
without prior approval of the course instructor.

In order to receive prior approval for absence or late submittal, the student must contact
the instructor in person, by email, or by phone prior to the class in question. Valid
reasons for absence include serious illness (FLU, strep throat, etc.) significant injury, or
death or serious injury of family members. Non-valid reasons include: taking your
roommate to a physician, missing the bus, over sleeping, regardless of whether or not
your alarm clock works, or minor illness (i.e. colds). In the case of an excused lab
absence, students can still earn full credit if they participate in the lab report write up. If
this is not possible, then the student can work with the instructor to remediate the

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problem. If a student cannot make a regularly scheduled exam, a conflict exam will be
scheduled.

12. TEAM CONFLICTS

If during the semester, a team has a problem with a noncontributing member or team
dynamics, they are to first resolve it as a team. If the problem cannot be resolved, they are
to contact the course instructor immediately. Efforts will be made to resolve the problem
as quickly as possible. This may including moving members out of a team and placing
them in another team or having them work independently.

13. OFFICE HOURS

Each week during the semester, the course instructor and teaching assistants will hold
office hours. During this period, on-campus students may visit to ask questions in person.
Off-campus students can call/email the course instructor or teaching assistants to ask
questions.

In addition, the course instructor will conduct two on-campus Q & A sessions pertaining
to GD&T. The dates and times of these sessions will be posted at the beginning of the
semester. Previously videotaped sessions will be made available. All students, especially
the on-campus students are encouraged to attend the live sessions.

14. EXAM AND Q&A SESSION INFORMATION

A module entitled EXAM AND Q&A INFORMATION resides on the CANVAS.
Within this module you will find information regarding the rules, regulations, and
preparation requirements for the midterm and final exams. You will also find the dates,
times, and locations of the three exams as well as two Q & A sessions pertaining to
GD&T.

15. ACADEMIC HONESTY POLICY

All students are expected to adhere to the policies regarding academic integrity as
outlined in section 49-20 of Policies and Rules for Students. All infractions will be
prosecuted to the fullest extent possible.

Work submitted by a laboratory team is to be that of the laboratory team only. It is

acceptable to discuss general concepts with class mates not in your laboratory group.
That said, your contribution to a team lab report must be entirely your own. This
includes any analysis, computations, and writing. Likewise exam solutions handed in to
the instructor must be your own.

16. STUDENT DISABILITY POLICY

Penn State welcomes students with disabilities into the University's educational
programs. If you have a disability-related need for reasonable academic adjustments in
this course, contact the Office for Disability Services (ODS) at 814-863-1807 (V/TTY).
For further information regarding ODS, please visit the Office for Disability Services
Web site at http://equity.psu.edu/ods/.

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In order to receive consideration for course accommodations, you must contact ODS and
provide documentation (see the documentation guidelines at
http://equity.psu.edu/ods/guidelines/documentation-guidelines). If the documentation
supports the need for academic adjustments, ODS will provide a letter identifying
appropriate academic adjustments. Please share this letter and discuss the adjustments
with your instructor as early in the course as possible. You must contact ODS and request
academic adjustment letters at the beginning of each semester.

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17. COURSE STUDY, ASSIGNMENT, AND EXAM SCHEDULE
All assignments and reports are due prior to 5:00 pm of the posted due dates

Week 1 Day Video Lecture Lecture Note Reading/Review Assignment Assignments Assigned/
8/21/2017 Packet/Slides Due
8/25/2017 to Accompany
Video Lecture
M
T Class Lecture #1 L1 Text: Chapter 1
W Text: Chapter 10, Sections 1- 6
R Class Lecture #2 L2; S1 S17 Text: Chapter 2, Sections
1,2,4,5, 7-10
F GD&T #1 L2A: S1-S29 ASME Y14.5M Chapter 1 & 2

Week 2 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/

8/28/2017 Packet/Slides to Assignment Due
9/1/2017 Accompany
Video Lecture
M Example Home works &
Solutions: GD&T: HW #1 &
HW # 2
T Class Lecture #3 L2: S17 S30 Text: Chapter 3: Sections 1 -
8
W GD&T #2 L2A: S30-S38 GD&T Team Assignment I GD&T Team Assignment
ASME Y14.5M Chapter 3 I Assigned
R Class Lecture #4 L2: S29 - S40 Text: Chapter 2, Section 6
F Example Home works &
Solutions: GD&T: HW #3:
Problems 1 - 3

Week 3 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/

9/4/2017 Packet/Slides Assignment Due
9/8/2017 to Accompany
Video Lecture
M GD&T #2, #3a, L2A: S39-S54 ASME Y14.5M Chapter 6
#3b, #3c Sections 6.1 6.4, 6.6

ASME Y14.5M Chapter 5

Sections 5.1 5.3
T Class Lecture #5 L2; S38 S57

GD&T Q & A
Session I
W GD&T #3d,#3e, #4 L2A: S55-78 ASME Y14.5M Chapter 4
Sections 4.1 4.5

Example Home works &

Solutions: GD&T: HW #3:
Problems 4 -6
R Class Lecture #6 L2: S57-S66 GD&T Team Assignment I
Due
F Example Home works &
Solutions: GD&T: HW #4

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Week 4 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
9/11/2017 Packet/Slides to Assignment
9/15/2017 Accompany
Video Lecture
M GD&T Team GD&T Team Assignment II
Assignment II Assigned
T Class Lecture #7 L2:S66 S84 Text: Chapter 4:
Sections 1 - 3
W Metrology Lab 1 Metrology Lab 1 Metrology Lab 1 Assigned
Document Prelim Report & Lab Data Due
R Class Lecture #8 L2:S84 S89 Text: Chapter 4: Section
L3A 5
L3B: S1-S10 Text: Chapter 8,
Sections 1, 11 - 15
F Example Home works &
Solutions: Surface
Roughness Metrology:
HW #1 and HW #2

Week 5 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
9/18/2017 Packet/Slides to Assignment
9/22/2017 Accompany
Video Lecture
M

T Class Lecture #9 L3B: S10 S30

GD&T Q & A
Session II
W Metrology Lab 2 Metrology Lab 2 Metrology Lab 1 Report Due
Document Metrology Lab 2 Assigned;
Prelim Report & Lab Data Due
R Class Lecture #10 L3B: S30 S41 Text: Chapter 8,
Sections 9.0 9.2
F

Week 6 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
9/25/2017 Packet/Slides Assignment
9/29/2017 to
Accompany
Video
Lecture
M Read through Lecture
Note packet 2B: Slides
S1-S24
T Class Lecture #11 L3B: S41 Text: Chapter 8, Section
S52 10
W Read through Lecture Metrology Lab 2 Report Due
Note packet 2B: Slides
S25-S33
R Class Lecture #12 L3B: S52 Text: Chapter 8, Sections GD&T Team Assignment II
S65 9.3 and 9.4 Due
F

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Week 7 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
10/2/2017 Packet/Slides to Assignment
10/6/2017 Accompany
Video Lecture
M
T Class Lecture #13 L3B: S65 S73 Text: Chapter 8,
Sections 3 - 8
W Metrology Lab 3 Metrology Lab 3 Metrology Lab 3 Assigned
Document Prelim Report & Lab Data Due
R Class Lecture #14 L3B: S73 S87 Text: Chapter 9,
Sections 1 - 8
F

Week 8 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
10/9/2017 Packet/Slides to Assignment
10/13/2017 Accompany
Video Lecture
M Team Peer Evaluation I Period
Starts
T Class Lecture #15 L3B: S87 Text: Chapter 5,
L3C: S1 S14 Sections 1, 5-9

W Machining Lab 1 Machining Lab 1 Machining Lab 1 Assigned

Document Metrology Lab 3 Report Due
R Class Lecture #16 Midterm 1 Exam
(Q & A Session
for Midterm 1)
F Team Peer Evaluation I Period
Ends

Week 9 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
10/16/2017 Packet/Slides to Assignment
Accompany
10/20/2017 Video Lecture
M
T Class Lecture #17 L3C: S14 S35 Text: Chapter 5, Section
10
W Machining Lab 2 Machining Lab 2 Machining Labs 2 & 3
Document Assigned; Prelim Reports &
Lab Data Due
Machining Lab 1 Report Due
R Class Lecture #18 L3C: S36 S51 Text: Chapter 5,
Sections 2 -4
F Machining Lab 3 Machining Lab 3
Document

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Week 10 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
10/23/2017 Packet/Slides to Assignment
Accompany
10/27/2017 Video Lecture
M
T Class Lecture #19 L3C: S52 S65 Text: Chapter 6,
L3D: S1 S13 Sections 1, 2, 3

W Casting Lab 1 Casting Lab 1 Document Casting Lab 1 Assigned

Prelim Report Due
Machining Lab Reports #2 and
#3 Due
R Class Lecture #20 L3D: S14 S36 Text: Chapter 6,
Sections 4,5

Week 11 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
10/30/2017 Packet/Slides to Assignment
11/3//2017 Accompany
Video Lecture
M
T Class Lecture #21 L3D: S36 S51 Text: Chapter 7,
L3E: S1 S4 Sections 1 - 3

W Casting Lab 2 Casting Lab 2 Casting Lab 3 Assigned;

Document Prelim Report & Lab Data Due

Casting Lab 1 Report Due

R Class Lecture #22 L3E: S5 S28

F Casting Lab 3 Casting Lab 3

Document

Week 12 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
11/6/2017 Packet/Slides to Assignment
11/10/2017 Accompany
Video Lecture
M
T Class Lecture #23 L3E: S29 S46 Text: Chapter 7,
Sections 4 - 10

W Rolling Lab Rolling Lab Document Rolling Lab Assigned;

Prelim Report & Lab Data Due

Casting Lab 3 Report Due

R Class Lecture #24 L3E: S46 S56 Text: Chapter 12,

L3F: S1 S8 Sections 1,13- 18

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Week 13 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
11/13/2017 Packet/Slides to Assignment
Accompany
11/17/2017 Video Lecture
M
T Class Lecture #25 L3F: S8 S22 Text: Chapter 12,
Sections 3-5
W Drawing Lab Cupping Lab Document Cupping Lab Assigned;
Prelim Report & Lab Data Due
Rolling Lab Report Due
R Class Lecture #26 L3F: S22 S33 Text: Chapter 12,
Sections 6-12
F

Week 14 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
11/20/2017 Packet/Slides to Assignment
Accompany
11/24/2017 Video Lecture
M Fall Break - - -
T - - - -
W - - - -
R - - - -
F - - - Fall Break

Week 15 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
11/27/2017 Packet/Slides to Assignment
12/1/2017 Accompany
Video Lecture
M
T Class Lecture #27 L3F: S34 S45 Text: Chapter 11,
L3G: S1 S5 Sections 1-3
W Fusion Welding Fusion Welding Lab Fusion Welding Lab
Lab Document Assigned;
Prelim Report Due
Cupping Lab Report Due
R Class Lecture #28 Midterm 2 Exam
(Q & A Session
for Midterm 2)
F

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Week 16 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
12/4/2017 Packet/Slides to Assignment
12/8/2017 Accompany
Video Lecture
M Team Peer Evaluation II
Period Starts
T Class Lecture #29 L3G: S5 S17
W Fusion Welding Lab Report
Due
R Class Lecture #30 L3G: S18 S31 Text: Chapter 11,
Sections 4-7
F Team Peer Evaluation II
Period Ends

Week 17 Day Video Lecture Lecture Note Reading/Review Assignments Assigned/ Due
12/11/2017 Packet/Slides to Assignment
Accompany
12/15/2017 Video Lecture
M
T
W
R
F

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