ME1800 C18

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 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 

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, if you have any questions you can contact them at topdogs@wpi.edu.


Grading and Expectations

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

Week

Day

Date

Time

Location

Topic

% of Final Grade

100

Wk1

Friday

1/19/18

23:59

Canvas

CAM 1

4

5

Wk1

Friday

1/19/18

23:59

Canvas

Group Assignment 1

1

Wk2

Monday

1/22/18

23:59

Canvas

Week 1 Quiz

4

13

Wk2

Monday

1/22/18

23:59

Canvas

Week 2 Survey

1

Wk2

Wednesday

1/24/18

14:00

Canvas

CAM 2.1

4

Wk2

Friday

1/26/18

23:59

Canvas

CAM 2.2

4

Wk3

Monday

1/29/18

23:59

Canvas

Week 2 Quiz

5

10

Wk3

Monday

1/29/18

23:59

Canvas

Week 3 Survey

1

Wk3

Friday

2/2/18

23:59

Canvas

CAM 3

4

Wk4

Monday

2/5/18

23:59

Canvas

Week 4 Survey

1

14

Wk4

Wednesday

2/7/18

14:00

Canvas

Group Assignment 2

5

Wk4

Friday

2/9/18

23:59

Canvas

Week 3 Quiz

4

Wk4

Friday

2/9/18

23:59

Canvas

CAM 4

4

Wk5

Monday

2/12/18

23:59

Canvas

Week 4 Quiz

4

9

Wk5

Monday

2/12/18

23:59

Canvas

Week 5 Survey

1

Wk5

Friday

2/16/18

23:59

Canvas

CAM 5.1

4

Wk6

Monday

2/19/18

23:59

Canvas

Week 5 Quiz

4

13

Wk6

Friday

2/23/18

23:59

Canvas

Group Assignment 3

5

Wk6

Friday

2/23/18

23:59

Canvas

CAM 5.2

4

Wk7

Monday

2/26/18

23:59

Canvas

Week 6 Quiz

4

36

Wk7

Friday

3/2/18

23:59

Canvas

Machining the Piston

4

Wk7

Friday

3/2/18

23:59

Canvas

Assemble Engine

1

Wk7

Friday

3/2/18

23:59

Canvas

Before Lab Practical

2

Wk7

Friday

3/2/18

23:59

Canvas

Lab Practical

15

Wk7

Friday

3/2/18

23:59

Canvas

Comprehensive Final Exam

10

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.

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:

Multiple Attempts

For logistical reasons, most posted quizzes will allow 2 attempts.

 Do not begin a 2nd attempt at a quiz if you have discussed your first attempt with another member of the class after completing it.

The 2nd attempt is not to be used in order to try to improve your grade but rather to allow you to start over if you have inadvertently submitted the quiz without finishing.

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

Schedule

Assignments

Week

Day

Date

Time

Location

Topic

% of Final Grade

100

Wk1

Friday

1/19/18

23:59

Canvas

CAM 1

4

5

Wk1

Friday

1/19/18

23:59

Canvas

Group Assignment 1

1

Wk2

Monday

1/22/18

23:59

Canvas

Week 1 Quiz

4

13

Wk2

Monday

1/22/18

23:59

Canvas

Week 2 Survey

1

Wk2

Wednesday

1/24/18

14:00

Canvas

CAM 2.1

4

Wk2

Friday

1/26/18

23:59

Canvas

CAM 2.2

4

Wk3

Monday

1/29/18

23:59

Canvas

Week 2 Quiz

5

10

Wk3

Monday

1/29/18

23:59

Canvas

Week 3 Survey

1

Wk3

Friday

2/2/18

23:59

Canvas

CAM 3

4

Wk4

Monday

2/5/18

23:59

Canvas

Week 4 Survey

1

14

Wk4

Wednesday

2/7/18

14:00

Canvas

Group Assignment 2

5

Wk4

Friday

2/9/18

23:59

Canvas

Week 3 Quiz

4

Wk4

Friday

2/9/18

23:59

Canvas

CAM 4

4

Wk5

Monday

2/12/18

23:59

Canvas

Week 4 Quiz

4

9

Wk5

Monday

2/12/18

23:59

Canvas

Week 5 Survey

1

Wk5

Friday

2/16/18

23:59

Canvas

CAM 5.1

4

Wk6

Monday

2/19/18

23:59

Canvas

Week 5 Quiz

4

13

Wk6

Friday

2/23/18

23:59

Canvas

Group Assignment 3

5

Wk6

Friday

2/23/18

23:59

Canvas

CAM 5.2

4

Wk7

Monday

2/26/18

23:59

Canvas

Week 6 Quiz

4

36

Wk7

Friday

3/2/18

23:59

Canvas

Machining the Piston

4

Wk7

Friday

3/2/18

23:59

Canvas

Assemble Engine

1

Wk7

Friday

3/2/18

23:59

Canvas

Before Lab Practical

2

Wk7

Friday

3/2/18

23:59

Canvas

Lab Practical

15

Wk7

Friday

3/2/18

23:59

Canvas

Comprehensive Final Exam

10


Lectures

Wk0

Thursday

1/11/18

AK232

Intro

Wk1

Tuesday

1/16/18

AK233

Lean Manufacturing

Wednesday

1/17/18

WB229

Art to Part

Thursday

1/18/18

AK233

Art to Part

Wk2

Tuesday

1/23/18

AK233

Quality Metrology and Roughness

Wednesday

1/24/18

WB229

Quality Metrology and Roughness

Thursday

1/25/18

N/A

<<<No Class>>>

Wk3

Tuesday

1/30/18

AK233

Energy and Power

Wednesday

1/31/18

WB229

Power Force and Chips

Thursday

2/1/18

AK233

Stress and Strain

Wk4

Tuesday

2/6/18

AK233

Fixture Design

Wednesday

2/7/18

N/A

<<<No Class>>>

Thursday

2/8/18

AK233

Functional Design

Wk5

Tuesday

2/13/18

AK233

GD & T

Wednesday

2/14/18

WB229

Design for Manufacture

Thursday

2/15/18

N/A

<<<No Class>>>

Wk6

Tuesday

2/20/18

AK233

Cost Per Cut

Wednesday

2/21/18

N/A

<<<No Class>>>

Thursday

2/22/18

AK233

Design of Safety Systems

Wk7

Tuesday

2/27/18

N/A

<<<No Class>>>

Wednesday

2/28/18

N/A

<<<No Class>>>

Thursday

3/1/18

N/A

<<<No Class>>>


CAM

SUNDAY

MONDAY

TUESDAY

WEDNESDAY

THURSDAY

FRIDAY

SATURDAY

Week 0

First day of term. (Monday Schedule)

1/13/2018

Week 1

Before Your First Lab

due at 11:59pm

CAM 1.1

due at 11:59pm

1/20/2018

Week 2

CAM 2.1

due at 3:00pm

CAM 2.2

due at 11:59pm

1/27/2018

Week 3

CAM 3.3

due at 3:00pm

2/3/2018

Week 4

CAM 4.3

due at 3:00pm

2/10/2018

Week 5

CAM 5.1

due at 11:59pm

2/17/2018

Week 6

CAM 5.2

due at 11:59pm

Reading Day. (No Help Sessions)

2/24/2018

Week 7

Last day of term

3/3/2018


Machining

SUNDAY

MONDAY

TUESDAY

WEDNESDAY

THURSDAY

FRIDAY

SATURDAY

Week 0

First day of term

No Lab

No Lab

1/13/2018

Week 1

MLK Jr Day (No Class)

First Day of Labs

Y Block

Help Session 5-7pm

First Day of Labs

Y Block

Help Session 12-2pm

Y Block

Initial Engraving

Cylinder

Help Session 11am-4pm

1/20/2018

Week 2

Y Block

Initial Engraving

Cylinder

Cylinder

Initial Engraving

Mill Work Offsets

Help Session 5-7pm

Cylinder

Initial Engraving

Mill Work Offsets

Help Session 12-2pm

Cylinder

Mill Work Offsets

Tooling

Help Session 11am-4pm

1/27/2018

Week 3

Cylinder

Mill Work Offsets

Tooling

Code Loading

Cylinder

Mill Tool Offsets

Tooling

Code Loading

Help Session 5-7pm

Cylinder

Mill Tool Offsets

Tooling

Code Loading

Help Session 12-2pm

Cylinder

Mill Tool Offset

Tooling

Code Loading

Help Session 11am-4pm

2/3/2018

Week 4

Cylinder

Mill Tool Offsets

Tooling

Coad Loading

Cylinder

Piston

Base

Code Loading

Help Session 5-7pm

Cylinder

Piston

Base

Help Session 12-2pm

Piston

Base

Help Session 11am-4pm

2/10/2018

Week 5

Piston

Base

Piston

Base

Help Session 5-7pm

Piston

Base

Help Session 12-2pm

Academic Advising Day. (No Class)

Help Session 11am-4pm

2/17/2018

Week 6

Base

Pawn

Base

Pawn

Lab Practical

Help Session 5-7pm

Lab Practical

Pawn

Help Session 12-2pm

Lab Practical

Pawn

Reading Day. (No Help Sessions)

2/24/2018

Week 7

Lab Practical

Assembly

Lab Practical

Assembly

Help Session 5-7pm

Lab Practical

Assembly

Help Session 12-2pm

Lab Practical

Assembly

Last Day of Term

Help Session 11am-4pm

3/3/2018