ME 350 Design for Manufacturability Instructor: Dr. Keng Hsu, email: khsu5@illi

1. ME 350 – Lecture 1A ME 350 Design for Manufacturability Instructor: Dr. Keng Hsu, email: khsu5@illinois.edu office hours: Wed: 10-12pm office: 4425 MEL Lab TA: Scott Daigle Labs will meet in 1227 MEL starting next week

2. Textbooks & References Groover, M. P., Fundamentals of Modern Manufacturing, 4th Edition, John Wiley (Available at IUB and Folletts) Make sure you have the DVD with the book. References (available at engineering library): 1) Kalpakjian, S., and Schmid, S.R., Manufacturing Processes for Engineering Materials, Addison Wesley, 4th edition, 2003 2) Callister, W. D, Materials Science and Engineering, Wiley, 2003 3) Devor, Statistical Quality Design & Control, 2006

3. Grading and Homework Policy Grading: Homework 25% Exam 1 25% Labs 20% Exam 2 30% Grade Distribution: A+ to A-: 25-35%, B+ to B-: 35-45% C+ to C-: 20-30%, D to F: < 5% Homework Policy: • Late penalty 20%, and not accepted after 1 week • Posted on class website Thursdays by midnight and due the next Thursday in class • (http://mechse.illinois.edu/content/courses/web_sites.php) • Download and print out the assignment and write directly on it

4. Two Exams • In class, close book and notes. Only pencil(s), an eraser, and a calculator are allowed at your desk. • July 12th : one hour, Lectures 1 through 6 • August 4th : two hours, comprehensive • Typical problems: true/false, short answer, and quantitative analysis (equation sheet provided). • No phone calls or writing after time called • Makeup exams: with medical excuse only.

5. Lecture Schedule

6. Lab Schedule

7. Lab Participation & Reports Lab Attendance and Participation • Each student is expected to attend and actively participate in every two-hour laboratory, read the lab handout, prepare for the in lab quiz, and/or complete the pre-lab assignment for the experiment before coming to their lab section. Each student should also bring a calculator, pens and pencils, notepaper, and the lab handout to each laboratory session. • Students may be allowed to attend a different laboratory session with written notification from the emergency dean due to a medical emergency. Other requests must be considered by the instructor. The penalty for an unexcused absence from a laboratory session or tardiness in excess of ten minutes is 10% off the lab report grade for that experiment. Lab Reports & Grading • The laboratory portion of the course grades is based on prelab assignments, in lab quizzes, and the lab reports. Completed computer generated paper reports are to be submitted to your TA at the beginning of lab on the designated due date. The reports are due immediately at the start of the lab period. The penalty for late submission is 10% for 1 minute to 1 hour late, and 20% for 1 hour to 24 hours. No credit will be given for reports turned in after 24 hours after your lab. Limited extensions to written report deadlines will be considered only in cases of extended illness or personal emergencies of a serious nature. • Although students typically perform laboratory work and preliminary data reduction in groups of two or more, each student is responsible for the preparation of his or her own independent report, and each student is graded individually. Confirmed cases of plagiarism, including copying all or portions of reports of present or former students, submitting reports completed in part or in entirety by others, using data from other lab sections, or using fabricated data, will automatically result in any or all of the following actions: a zero grade being recorded for that report; failure of the course; and referral to officers of the College of Engineering or University

8. What is Manufacturing and Why Steel Aluminum Polypropylene Copper Rubber Silicon

9. Manufacturing segwayofthehudsonvalley.com

10. Course Objectives • Acquire a general overview of modern manufacturing processes and knowledge of state-of-the- art process technologies. • Conduct basic analysis of manufacturing processes as a tool for understanding the physical process capabilities, tolerances and limitations. • Develop ideas and guidelines to evaluate design and manufacturing trade-offs. • Hands-on exposure to manufacturing processes, CAD/CAM, rapid prototype, metal sand casting, injection molding, design-for-assembly (DFA), Design to Cost (DTC), and design-of- experiments (DOE) methodologies through lab sessions.

11. Topics Covered (~30 chapters): • Rapid prototyping • Machining – CNC/Abrasive/Nontraditional • Molding • Casting • Composite manufacturing • Welding/Soldering/Joining • DFA • Si fabrication • Design to Cost (DTC)

12. Manufacturable Materials • Metals • Steel, iron, nonferrous metals and alloys. • Polymers • Three catagories: thermoplastics, • Ceramics • Glasses (i.e. that melt), and crystalline ceramics. • Composites • Mixtures of the other three types

13. Figure 1.4 Classification of Manufacturing Processes

14. Processing Operations • Increases workpart’s value by altering: • shape, • physical property, • appearance • Three categories: • Shaping operations (e.g. casting, forging, machining, etc.) • Property-enhancing operations (e.g. heat treatment) • Surface processing operations (e.g. clean, surface coating, etc.)

15. Assembly Operations • Two or more separate parts are joined to form a new entity • Types of assembly operations: • Joining processes – create a joint • Welding, brazing, soldering, and adhesive bonding • Mechanical assembly – fastening by mechanical methods • Threaded fasteners (screws, bolts and nuts); press fitting, expansion fits

16. What is DFM? • Design for Manufacturability (DFM): By understanding and analyzing the fundamental manufacturing processes, reduce the of production while achieving optimal product • Quality and lifetime of the products should not be left until the test stage, but actively brought into consideration by design, manufacture and assembly • Rule of 10: order of magnitude increase on the cost when changes are made at later stages (from part design → subassembly → assembly → manufacturing → final product to market → customer)

17. Part I Summary • Attend lectures, be on time, read chapters, and participate. • We are going to cover a lot of manufacturing processes – their strengths and weaknesses. • We are going to cover the tools to understand and optimize manufacturing. • This class is to help you be able to better design a product for manufacturing.