MEAM 201 - Wabiszewski - Syllabus PDF

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MEAM 201: Machine Design and Manufacturing Spring 2018 Course Syllabus

Course description Building upon the fundamentals of mechanical design taught in MEAM 101, this hands-on, project-based course provides students with the knowledge and skills necessary to design, analyze, manufacture, and test fully functional mechanical systems. Topics covered include an introduction to machine elements, analysis of the mechanics of machining, manufacturing technology, precision fabrication (milling, turning, and computer-controlled machining), metrology, tolerances, cutting-tool fundamentals and engineering materials. Instructor information Dr. Graham E. Wabiszewski Senior Lecturer, MEAM Office: 224 Towne Email: [email protected] Prerequisites MEAM 101. The MEAM 101 prerequisite may be waived by the instructor if a SolidWorks portfolio that includes assemblies and engineering drawings is demonstrated.

Textbooks Required Hoffman, E. G., McCauley, C. J., & Hussain, M. I. (2000). Shop reference for students and apprentices. New York: IPI. ISBN: 0831130792 Available at the Penn bookstore and Amazon. Suggested Oberg, E., Jones, F. D., Horton, H. L., & Ryffel, H. H. (2016). Machinery's handbook. ISBN: 0831130911 Available in digital format via the Penn Libraries/Knovel. Mott, R. L., Vavrek, E. M., & Wang, J. (2018). Machine elements in mechanical design. ISBN: 0134441184 Available at Amazon.

Class times and locations Lectures are held on Tuesdays from 1:30-3:00pm in 309 Towne. Machining labs (1.5 hrs a week) are held in the Precision Machining Laboratory (PML, 169 Towne) on the following days and times. Lab 101: Thursdays 10:30 am – 12:00 pm Lab 102: Thursdays 1:30 – 3:00 pm Lab 103: Fridays 11:00 am – 12:30 pm Lab 104: Fridays 1:30 – 3:00 pm Digital course resources and software Canvas (https://canvas.upenn.edu/) will be used to distribute lecture slides, submit homework assignments, take laboratory quizzes, and communicate grades. Please email the course instructor if you do not have access to the MEAM 201 Canvas domain. We will use Piazza (https://piazza.com/) as a course message board. Communication via Piazza is preferred over email. SolidWorks and Southwestern Industries PT4SX software will be used extensively throughout the course for the production of solid geometries, assemblies, engineering drawings, and machining toolpaths. SolidWorks is available on all CETS computers. PT4SX software is available on 11 computers in 205 Towne. Computers that are capable of running the full PT4SX deployment have the label “ProtoTRAK dongle” on the computer monitor.

Office hours Office hours will be posted on the home page of our MEAM 201 Canvas page after the first week of classes. Typically, office hours are offered on each day of the working week. Course grading Course grades are derived from four grading categories. Safety/machining quizzes and final exam (25% of final grade) – You will have 6 quizzes covering use and safety of PML machines in the first 6 weeks of the course. A comprehensive written final exam will be administered during the last lecture of the course. Lecture assignments (25% of final grade) – You will have approximately 10 lecture assignments that include a SolidWorks assembly of your engine, production of engineering drawings, and a tolerance stack up. Parts machining (25% of final grade) – You will manufacture 14-15 parts in the PML using the mill, ProtoTRAK CNC mills, and lathe. The parts will be graded for adherence to the features and tolerances provided in engineering drawings. Final assembly (25% of final grade) – Your heat engine assembly will be evaluated with respect to the fit of parts, smoothness of engine operation, runout/balance, clearance, machining accuracy, and general attention to detail.

Final course grades are based on the following absolute grading scale. A+: 97 - 100 A: 93 - 97 A-: 90 - 93 B+: 87 - 90 B: 83 - 87 B-: 80 - 83 etc...

Homework/part submission and lateness policy Lecture assignments will be submitted in a variety of formats to the assignment callouts on Canvas before the lecture on which they are due. Late lecture assignments will incur a 25% reduction if up to 24 hours late, a 50% reduction if up to 48 hours late, and a 75% deduction if more than 2 days late. Quizzes will be taken on Canvas before your laboratory section. Quizzes taken after your laboratory section will incur a 50% deduction. Parts will be submitted to your parts submission box located in the PML before your laboratory section. You are allotted 2 weeks of part lateness, which may be applied to one part (2 weeks late) or 2 parts (one week late each). Parts submitted after your laboratory section automatically incur one week of lateness. Parts that are late in excess of the 2 weeks of allotted lateness will incur a 25% deduction if up to 1 week late, a 50% deduction if up to 2 weeks late, and a 75% deduction if more than 2 weeks late. Academic integrity It is your responsibility to be familiar with the University’s Code of Academic Integrity (https://provost.upenn.edu/policies/pennbook/2013/02/13/code-of-academic-integrity). Instances of academic dishonesty will be referred to the Office of Student Conduct (OSC) for adjudication. Coursework found in violation of the University’s Code of Academic Integrity will be assigned a grade of 0 with no option for remediation.

Absences due to religious holidays The University of Pennsylvania recognizes a multitude of religious and secular holidays (http://provost.upenn.edu/policies/faculty-handbook/students/iv-h). Per policy, students observing religious or secular holidays that occur during regularly scheduled course proceedings should email the course instructor indicating observance within the first two weeks of the course. Disability access The University of Pennsylvania provides reasonable accommodations to students with disabilities who have self-identified and been approved by the office of Student Disabilities Services (SDS). All services are confidential. If you have not yet contacted SDS, and would like to request accommodations or have questions, you can make an appointment by calling 215-573-9235. The SDS office is located in the Weingarten Learning Resources Center at Stouffer Commons, 3702 Spruce Street, Suite 300.

General course schedule The following table outlines the topics covered and quiz, homework, and part due dates. The schedule may evolve as the course progresses. Week 1 (Lab) 2 (Lecture) 2 3 3 4

4 5 5

6 6 7 7 8 8 9 9 10 10 11 11 12 12

Short form topic PML tour, PML safety, tools and lockers, and introduction to the vertical bandsaw Course logistics, the heat engine, and engineering drawings and tolerances

Assignments, quizzes, reading, and parts due

Quiz 1 : Vertical bandsaw Quiz 2: Mill 1 Reading 1: Shop safety policies Assignment 1: Design brainstorming The mill, holemaking, and threads Reading 2: Engineering drawings Holemaking, angled holes, marking, and piston flange Quiz 3: Mill 2 blanks Part 1: Mounting block (squared up) Homework 2: CAD of fully-defined parts ProtoTRAK operations Reading 3: Speeds and feeds Quiz 4: ProtoTRAK ProtoTRAK operation, piston flange, mounting block, Assignment 3: Piston flange PT4 and web sequencing on the ProtoTRAK Part 1: Mounting block (w/ holes) Part 2: Piston flange (holes only) Turning Reading 4: Screw thread systems Quiz 5:Turning Introduction to the lathe, piston sequencing, and web Part 1: Mounting block Part 2: Piston flange sequencing Turn in piston tube and piston flange for soldering Precision measurement and producing engineering Reading 5: Precision measurement drawings Rod fork sequencing, creating slots, and corner Part 3: Web rounding Quiz 6: Precision measurement Geometric dimensioning and tolerancing Reading 6: Geometric dimensioning and tolerancing Crankshaft bearing tube sequencing Part 4: Piston Tolerance stack ups Assignment 4: Assembly Displacer bushing tube sequencing and external Part 5: Displacer Rod fork threads Spring break Spring break Design review Assignment 5: Balance weight and fixture engineering drawings Balance weight drawing review and connecting rod Part 6: Crankshaft bearing tube sequencing Machinability and metals Assignment 6: Displacer connecting rod and piston connecting rod engineering drawings Connecting rod drawing review and heat sink Part 7: Displacer bushing tube sequencing Metals manufacturing processes Assignment 7: Final bedplate dwg for NextFab Part 8: Balance weight Heat sink mill operations and shaft and flywheel Part 9: Piston connecting rod sequencing Part 10: Displacer connecting rod Introduction to the mill and squaring up stock

13

Plastics and plastics manufacturing processes

13

Secondary piston assembly operations and base sequencing

14

Assembly methods

14

Finishing operations and common debugging/remediation steps

15

Machine components

Assignment 10: GD&T and tolerance stack up

15

TBD

Part 15: Base

Final exam Engine testing period

Assignment 8: Shaft and flywheel engineering drawings and work permit

Part 11: Heat sink Assignment 9: Base work permit Part 12: Shaft Part 13: Flywheel Part 14: Hub

Final engine assembly

Notice of change This syllabus is subject to change based on the needs of the class. Check the MEAM 201 Canvas site for the most up-to-date schedule....