ME1800 A19

Introduction

ME1800, “Manufacturing Science, Prototyping, and Computer Controlled Machining,” is taught at WPI four times per year. The course content and curriculum have been developed jointly by professors Brown and Bergstrom in the Mechanical Engineering Department at WPI and is constantly subject to revision and update through a continuous improvement program.

Objectives

The primary objective of the course is to empower engineers and engineering students enrolled in the course to become better engineers. Whether it is consciously considered or not the primary reason for all engineering work is to facilitate the manufacture of goods. It is our believe therefore that engineers that have an understanding of manufacturing processes and manufacturing science (the study of manufacturing processes) will be better engineers. We are with this course trying to manufacture engineers who understand how things are made so that they will be able to design things that can be made. For reference the published course description is listed below:

Course Description

This course introduces students to manufacturing science and engineering and prototype part production. It emphasizes CNC (computer-controlled) machining. Students will learn how to go from a solid (CAD, computer-aided design) model to a machined part, using CAM software (computer-aided manufacturing) and CNC machining. They will also be exposed to associated issues in manufacturing process analysis, engineering design, material science, and in dimensional and surface metrology. Using machining as an example, the science of manufacturing processes is developed in a combination of class work and laboratory experience. The laboratory experience includes an experimental component that associates process variables in machining with performance and machined part quality. Students whose project work will necessitate fabrication of parts and those who want a background in manufacturing process science and engineering should take this course.

     To fulfill the primary objective listed above and to cover the specific items listed in the course description the course consists of a series of reading assignments, lectures and video presentations, in class exercises, laboratory exercises, and online and hands on quizzes and examinations. Although much of the work including laboratory exercises and some quizzes will be done in groups and as collaborative exercises, some of the assignments and Quizzes and examinations will be based on individual effort and will be indicated as such.

Instructors

Lecture and Conference

Torbjorn Bergstrom

torbjorn@wpi.edu (see email FAQ at profBerstrom.com)

office: WB107i

phone: 508 208 3024

Office Hours:

By appointment only http://profBergstrom.com/schedule 

TAs

Zhaolong Zhang zzhang4@wpi.edu

Yutao Wang ywang32@wpi.edu

Labs

Lab exercises are operated and administered by a group of Peer Learning Assistants, PLAs, who as a group have significant experience in these activities. There are currently two Lab Coordinators and there is a team of three PLAs assigned to each lab section.  Each team of three PLAs consists of a Lead PLA who has many terms of experience teaching these exercises. There are also the Head PLAs in charge of the structure of the lab, Matt Bisson and Chloe Melville, if you have any questions you can contact them at topdogs@wpi.edu.

Section

Lead

Second

Third

A01

Dan Matthews

dfmatthews@wpi.edu 

Ryan Luisi

rluisi@wpi.edu 

Rich Steinberg

rdsteinberg@wpi.edu 

A02

Chloe Melville

cemelville@wpi.edu 

Brendan McClelland

bjmcclelland@wpi.edu 

Vince Lucca

vlucca@wpi.edu 

A03

Emily Hammer

ehammer@wpi.edu 

Joe Niski

jniski@wpi.edu 

Devan Blechinger-Slocum

dblechingerslocu@wpi.edu  

A04

Alex Johnson

adjohnson@wpi.edu 

Howard Zheng

hzheng3@wpi.edu 

Sam Johnson

sqjohnson@wpi.edu 

Help Sessions

We have multiple weekly Help Sessions in which our PLAs are available to assist you with your CAM Assignments or to catch up on Machining exercises. These are the scheduled times every week:

Day

Time

Wednesday

12-2 PM

Thursday

7:30-9:30 PM

Friday

11 AM - 4 PM

Schedule

Lectures

Week 0

Thursday

Manufacturing

Week 1

Tuesday

Quality

Wednesday

Thursday

Metrology

Week 2

Tuesday

Prototyping

Wednesday

Art to Part

Week 3

Tuesday

Energy and Forces

Wednesday

Chip Formation

Thursday

Stress and Strain

Week 4

Tuesday

Production

Wednesday

TBA

Thursday

TBA

Week 5

Tuesday

Economics

Wednesday

TBA

Thursday

Lean Manufacturing

Week 6

Tuesday

Design for MFG

Wednesday

TBA

Thursday

TBA

Week 7

Tuesday

Design of Safety Systems

Wednesday

No Class

Thursday

No Class

Labs - CAM

SUNDAY

MONDAY

TUESDAY

WEDNESDAY

THURSDAY

FRIDAY

SATURDAY

Week 0

First day of term.

8/24/2019

Week 1

First Day of Labs

8/31/2019

Week 2

CAM Assignment 1 due at 11:59PM

9/7/2019

Week 3

Grades Due at 11:59 PM

CAM Assignment 2 due at 11:59PM

9/14/2019

Week 4

Grades Due at 11:59 PM

CAM Assignment 3 due at 11:59PM

9/21/2019

Week 5

Grades Due at 11:59 PM

CAM Assignment 4 due at 11:59PM

9/28/2019

Week 6

Grades Due at 11:59 PM

Aca Adv Day. No Classes.

CAM Assignment 5 due at 11:59PM

10/5/2019

Week 7

Last day of term

10/12/2019


Labs - Machining

Week 0

First day of term

No Lab

No Lab

8/24/2019

Week 1

No Lab

No Lab

No Lab

First Lab

Introduction

Y Block

Help Session 7:30-9:30

Help Session 11am-4pm

8/31/2019

Week 2

Y Block

Initial Engraving

Cylinder

First Lab

Introduction

Y Block

Help Session 12-2pm

Initial Engraving

Cylinder

Help Session 7:30-9:30

Help Session 11am-4pm

9/7/2019

Week 3

Y Block

Initial Engraving

Cylinder

Initial Engraving Cylinder

Mill Work Offsets

Initial Engraving Cylinder

Help Session 12-2pm

Cylinder

Mill Work Offsets

Tooling

Help Session 7:30-9:30

Help Session 11am-4pm

9/14/2019

Week 4

Initial Engraving Cylinder Mill Work Offsets

Cylinder

Piston

Base

Coad Loading

Cylinder

Mill Work Offsets

Tooling Help Session 11am-1pm

Cylinder

Piston

Base

Coad Loading Help Session 7:30-9:30

Help Session 11am-4pm

9/21/2019

Week 5

Cylinder

Piston

Base

Coad Loading

Piston

Base

Cylinder

Piston

Base

Coad Loading

Help Session 12-2pm

Piston

Base

Help Session 7:30-9:30

Help Session 11am-4pm

9/28/2019

Week 6

Piston

Base

Base

Pawn

Lab Practical

Piston

Base

Help Session 12-2pm

Pawn

Lab Practical

Help Session 11am-4pm

10/5/2019

Week 7

Base

Pawn

Lab Practical

Engine Assembly

Pawn

Lab Practical

Engine Assembly

Pawn

Lab Practical

Engine Assembly

Pawn

Lab Practical

Engine Assembly

10/12/2019

Grading and Expectations

All students are expected to arrive in class prepared to participate. Student grades will be calculated as follows:

Description

Due Date

% of Final Grade

Week 1 Homework

Monday 26 August

5

Week 2 Homework

Monday 2 September

5

CAM 1

Friday 6 September

3

Group Assignment 1

Friday 6 September

5

Week 3 Homework

Monday 9 September

5

CAM 2

Friday 13 September

3

Week 4 Homework

Monday 16 September

5

CAM 3

Friday 20 September

3

Group Assignment 2

Friday 20 September

5

Week 5 Homework

Monday 23 September

5

CAM 4

Friday 27 September

3

Week 6 Homework

Monday 30 September

5

CAM 5

Friday 4 October

3

Group Assignment 3

Friday 4 October

5

Week 7 Homework

Monday 7 October

5

Lab Practical Exam

Thursday 10 October

15

Comprehensive Final Exam

Thursday 10 October

20

Late Submission of an Assignment

Medical

If you miss an assignment for medical reasons please report your situation to Health Services as soon as possible.  They will notify me if you will be missing several classes but you should also notify me by email once you are able.  Please let me know what you will (have) missed and when you believe you will be able to make it up.  I will do everything I can to accommodate your situation.

Emergency

Please use your judgment here.  My cell phone battery died and my alarm never went off is not a personal emergency (See “Oops” below.)  On the other hand I do understand that things happen that affect your ability to attend class and complete assignments.  If you have or are experiencing a true personal or family emergency, please let me know as soon as possible.  As with medical issues I will make every effort to accommodate your needs.  Please remember that the WPI Counseling Office and the Dean of Students office may also be able to help you.

Oops

I understand that mistakes happen and that everyone has a bad day sometimes.  In the event you inadvertently miss a due date please let me know as soon as possible, and submit the late assignment immediately.  One time during the term I’m willing to accept any excuse for a late submission provided the correct answers have not been discussed in class.  In the event we have already reviewed an assignment in class before you realize you missed the submission date I will make an effort to work with you to find and alternate assignment or activity that will demonstrate your understanding of the materials.

Partial Credit

Any unexplained late submissions will receive reduced grade.   Late submissions will be evaluated at face value and then the grade will be reduced by 10% for each day it is late.

To receive consideration go to  https://goo.gl/forms/UMgYeOdw7tHniZmp1 

Academic Honesty

Students should be familiar with the WPI Academic Honesty Policy. Acts of academic dishonesty as defined in the Academic Honesty Policy or violations of specific policies listed below will handled per the procedure outlined in section 3 of the WPI Academic Honesty Policy.

This course is evaluated based on a combination of group work and individual work. All assignments and quizzes will be identified as either individual or group quizzes or assignments. Students in the class are expected to maintain a high degree of Academic Integrity whether doing individual or group work.

Quizzes and Assignments

Most of the Quizzes and assignments in the class are intended to be completed while working together with other students. This means that whether or not a quiz or exercise is labeled as a group assignment I intend for you to consult your peers while working on it.

Individual Assignments will be clearly indicated and announced. For individual assignments follow the following instructions.

Individual

Quizzes and assignments identified as individual are intended to evaluate each student's understanding of the particular material covered. Unless otherwise specified in the assignment:

 

Services/Accommodations Available for Students with Disabilities

All Students Must Self-Identify

By law, it is the student's responsibility to identify themselves to the Office of Disability Services (ODS) and to provide documentation of the disability by a licensed professional. (Please note that learning disabled students' documentation must be less than three years old.) All incoming students have the opportunity to self-identify their disability (physical and/or learning) by filling out the bottom portion of the Voluntary Disclosure Form (60KB PDF file) enclosed in their New Student Orientation Package. Students should send this form, along with the supporting documentation, to the Director of Disability Services. Students with disabilities, who are self-identified after their admission to WPI, must also provide appropriate documentation to the Director of Disability Services, if they wish to receive accommodations.

For more information please see the WPI office of Disability Services