Conference Session

Micromachining in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Wayne Hung, Texas A&M University; Sujeev Chittipolu, Texas A&M University; Saurabh Kajaria, Texas A&M University

Tagged Divisions

Manufacturing

staticcomponent the force in the direction of feed will increase continuously until tool breakage.Experimental evidence indicates a tool failure due to increasing cutting force up to three or fourtimes although cutting conditions are remained the same7.To evaluate tool life, a tool is traditionally used at constant speed until failure. This technique istime consuming if a speed is too slow to start with, and does not simulate the real machiningpractice. Concept of cumulative tool wear was developed with which a tool can be used atdifferent cutting speeds until reaching the tool life criterion. The model for side milling was beenderived mathematically and verified experimentally 9, 10 as: 1

Conference Session

Micromachining in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Clifford Mirman, Northern Illinois University; Andrew Otieno, Northern Illinois University

Tagged Divisions

Manufacturing

-manufacturing technologies. Micro-manufacturing focuses on technologies used toproduce parts in the sub-millimeter range, and essentially bridges the gap between nano-scalemanufacturing and macro-manufacturing. According to the World Technology EvaluationCenter’s (WTEC) commission report [1], micro-manufacturing has and will continue to havevery significant impacts on national security, defense, energy, healthcare and domesticmanufacturing base. Micro-parts are being utilized in the electronic and drive systems for small Page 14.855.2unmanned reconnaissance planes, for high precision parts used in missile guided systems, formedical devices to deliver

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Xiaolin Chen, Washington State University, Vancouver; Dave Kim, Washington State University, Vancouver

Tagged Divisions

Manufacturing

basic principles in product designand manufacturing, but will also instill problem-solving skills, teamwork skills, and hands-onexperiences. Both software technologies (CAD/CAE/CAM) and modern hardware tools (RP,CNC, etc) have been implemented into the track courses. Upon completion of the seven trackcourses, students can receive the certificate from the school. This paper presents details ofplanning and implementation of such a curriculum development activity in design andmanufacturing within the mechanical engineering curriculum. Overall student experience andlessons learned in developing such a curriculum are also discussed.1. IntroductionCurrent mechanical engineering curricula are originated from a century-scale “grand scientificparadigm

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

Janet Dong, University of Cincinnati; Janak Dave, University of Cincinnati

Tagged Divisions

Manufacturing

-ended problems and to prepare them for the transitionfrom an academic environment to industry.Most projects consist of designing, building, and testing a prototype of a product or process. Atthe completion of this capstone project, students will have acquired the following necessaryskills, which will apply to their professional careers: 1. Synthesizing knowledge from earlier courses. 2. Starting from concept to a working prototype. Page 14.424.2 3. Project management. 1 4. Time management. 5. Dealing with vendors. 6. Oral communication

Conference Session

Our Future in Manufacturing: STEM Outreach

Collection

2009 Annual Conference & Exposition

Authors

Tom Brady, Purdue University, North Central

Tagged Divisions

Manufacturing

products ofinterest to middle school age students, i.e., candy, a much more positive image of manufacturingcareers was presented.References 1. Otieno, A., Wasonga, T. (2005) A Conceptual Model For A University – K-12 Partnership Utilizing The Page 14.1004.6 Internet And After-School Activities And Engineering: Resiliency Approach, Proceedings of the 2005 IL/IN Sectional Conference, ASEE, DeKalb, IL. 2. “Manufacturing Matters In Michigan”, (2003) Online Survey Results, Public Policy Associates, Inc.3. Ziemian, C., Aument, J., Whaley, Jr., D. (2007) Manufacturing Technology in Middle School Classrooms: A

Conference Session

Design Education in Manufacturing Programs

Collection

2009 Annual Conference & Exposition

Authors

Ramesh Narang, Indiana University-Purdue University, Fort Wayne; Jihad Albayyari

Tagged Divisions

Manufacturing

course has been kept at a levelof applying it to a single product.Quality AttributesQuality or attribute as used in this paper refers to a product feature that is useful to the userbecause of the function(s) it performs and it can be provided at a reasonable additional cost. If afeature does not provide a function at a reasonable cost, it would not be considered as a desirableattribute. This relationship can symbolically be shown as given in equation (1): FAttribute = (1) cWhere F is the function provided by a product feature, and c is the cost of providing that featurein a product or service. Therefore, the customer satisfaction, as

Conference Session

Hands-on Lean Manufacturing Simulation Workshop

Collection

2009 Annual Conference & Exposition

Authors

Merwan Mehta, East Carolina University

Tagged Divisions

Manufacturing

paper.Introduction:Every company wants to cut costs and provide outstanding value and service to their customers.Two philosophies and tools to produce the needed results are lean manufacturing and six-sigma.Lean manufacturing has been defined as “a systematic approach to identifying and eliminatingwaste (non-value-added activities) through continuous improvement by flowing the product atthe pull of the customer in pursuit of perfection,” [1]. Six-sigma methodologies are a businessphilosophy and initiative that enables achievement of world-class quality and continuousimprovement, along with the highest level of customer satisfaction [2].Principles of Lean processes were first identified by Womack and Jones [3] [4], when theyconducted their five-year, five-million

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

, thermomechanical processing of steels and other metallic materials, microstructure characterization and structure – property relationships. He has conducted a number of technical failure investigations, consulted on various materials-related problems, and acted as an expert witness in the Court of Law. Page 14.134.1© American Society for Engineering Education, 2009 A Top-Down Approach for Teaching an Introductory Engineering Materials Course1. BackgroundIt is recognized that teaching an introductory engineering materials course to non-majorstudents is a complex task due a variety of reasons [1

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Nebojsa Jaksic, Colorado State University, Pueblo; Dawn Spencer, Colorado State University, Pueblo

Tagged Divisions

Manufacturing

book of printed lecture notes for the course. This laboratory exercise isdeveloped (1) to introduce students early in the Engineering of Manufacturing Processes courseto the broader concepts and complexities of modern production targeting intuitive learners, (2) tofacilitate active learning of book-making processes targeting sensing learners, and (3) to providescaffolding by building on the book-making processes when analyzing other manufacturingprocesses. Based on student responses to an administered survey, it is confirmed that thislaboratory presents an effective active learning tool. Furthermore, as indicated by students’survey results in two consecutive years, significant improvements in this laboratory are achievedby introducing

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Robert Creese, West Virginia University; Deepak Gupta, Southeast Missouri State University

Tagged Divisions

Manufacturing

would be 90 for thatstudent. Four questionnaires were given to the students, one each time they handed in a report. Page 14.1065.3Each questionnaire used a scale of “1” to “5”, with “1” being “Completely Disagree” or“Definitely NO” and “5” being “Completely Agree” or “Definitely Yes”. The first threequestionnaires were strictly rating the degree of fulfillment of an activity, but the lastquestionnaire had open ended questions regarding the project and software. The firstquestionnaire and the average response values are presented in Table 1. In Assessment Questionnaire 1, questions A and B were to determine if the studentsopened

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Dave Kim, Washington State University, Vancouver; Yongha Kim, Washington State University, Vancouver

Tagged Divisions

Manufacturing

mapping (VSM)techniques to identify the wastes, and improve the process using the Kaizen tools. Theexperimental manufacturing consists of three steps: 1) the open molding process, 2) theflash removal process, and 3) the packaging process. During the open molding process, aliquid pre-polyurethane is mixed with a curing agent and placed into silicone rubbermolds. Through a series of the manufacturing experiments, students developed the VSMof their processes and identify the wastes, which include the waiting time of polymercuring, movement for acquiring a mold release spray, etc. After the Kaizen session,students improved their process by changing the plant layout and improving their set-upand process parameters. According to the student feedback

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Ning Fang, Utah State University

Tagged Divisions

Manufacturing

closed between industry’s manufacturing workforce needs and current educational programs.The four competency gaps include 1) a specific manufacturing process, 2) business knowledge, 3)oral and written communication, and 4) teamwork. In the PB-ACL approach, students formvarious project teams with three or four students on each team. Each student is assigneddifferent responsibilities. Each team works on a semester-long manufacturing project thatincludes three well-integrated tasks. A representative example of student projects is given toshow how the PB-ACL approach works. A Likert-type and open-ended questionnaire wasdeveloped to assess student learning outcomes. Assessment results showed that more than 80%of the surveyed students gained positive

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Arif Sirinterlikci, Robert Morris University

Tagged Divisions

Manufacturing

recordkeeping practice based on OSHA resources2 and other Industrial Safety textbook information7. They are given several hand-outs and links to the OSHA web resources. They study the requirements for qualifying incidences as recordable, distinguishing between the non-recordable first-aid and the recordable medical treatment. They are then given multiple cases to process as shown in Figure 1. They make a decision based on given information for each case. After that, the information for each recordable case transferred to the OSHA 301 Form - Injury and Illness Report as shown in Figure 2 and each recordable case becomes an entry for the OSHA 300 Form - Log of Work-Related Injuries and Illnesses

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Jeremy Li, University of Bridgeport

Tagged Divisions

Manufacturing

resources for the students which can help them tounderstand the real engineering issues and show them how the technical concept can beused in real cases. Several examples from real engineering practices have been discussedin the class to help students to understand how the feasible engineering solutions improvethe quality of industrial product. Some class case studies, which can help studentsunderstand more real and challenging industrial issues, are shown as follows:Case study 1:One small company has the business in an industry dominated by some famouscompanies including General Electric. In order to make this company more competitivein this industry, please make the proper strategies on following products with youropinion: 1st priority, 2nd

Conference Session

Technology Integration in the Classroom

Collection

2009 Annual Conference & Exposition

Authors

Susana Lai-Yuen, University of South Florida; Maria Herrera, University of South Florida

Tagged Divisions

Manufacturing

skills in design and manufacturing, problemsolving, teamwork, and communication for successful careers in industry. This will benefit thegrowing medical device industry by bringing qualified engineers with the technical knowledgeand experience in working with medical doctors in the development of innovative medicaldevice products.1. IntroductionResults from several industry surveys and academic studies show that graduating engineers areinadequately prepared for careers in industry 1-3. The Society of Manufacturing Engineers(SME) conducted a survey in the advanced manufacturing sector that identified the competencygaps as project management, specific manufacturing processes, product/process design, problemsolving, communication, and teamwork

Conference Session

Lean Manufacturing Education

Collection

2006 Annual Conference & Exposition

Authors

Merwan Mehta, East Carolina University; Richard Monroe, East Carolina University

Tagged Divisions

Manufacturing

consulting companies have also developed products of their own. One popular program4developed by the National Institute of Standards (NIST) consists of using two different circuitboard assemblies to simulate two different lines of products as shown in Figure 1. Test A B C E A B C D E D 1 1 2 2 3 3 4 4 5 5

Conference Session

Manufacturing Education Innovation and Assessment

Collection

2006 Annual Conference & Exposition

Authors

David Wells, North Dakota State University

Tagged Divisions

Manufacturing

, manufacturing engineers design processes. However, the purpose of these processesis the production of product. Following the logic of manufacturing traced in the previousparagraph, ‘design’ in manufacturing engineering spans the product realization spectrum. Alogical extension to the fundamental definition of manufacturing is to identify sub-disciplines inmanufacturing engineering. Product Engineering Process Engineering Quality Engineering Production Engineering Figure 1: Four Sub-disciplines in Manufacturing Engineering These sub-disciplines can be defined a bit more

Conference Session

Manufacturing Laboratory Experience

Collection

2006 Annual Conference & Exposition

Authors

Robert LeMaster, University of Tennessee-Martin; David Farrow, University of Tennessee-Martin

Tagged Divisions

Manufacturing

upgraded course inAutomated Production Systems. The objective of the Automation Laboratory is to provideexperiential learning opportunities, while at the same time providing exposure to real worldindustrial automation equipment and tools. Included in the paper is a description of the contentand objectives of each laboratory session and a description of the hardware platforms used toaccomplish the laboratory exercises.IntroductionThe University of Tennessee at Martin offers an ABET-accredited Bachelor of Science inEngineering degree with concentrations in civil, electrical, industrial, and mechanical disciplines.A three course sequence involving various aspects of control technology is offered (Table 1).Some of the courses are required of all

Conference Session

Manufacturing Education Innovation and Assessment

Collection

2006 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

1. Page 11.193.2 Students Instructor and Course Content Community ABET Parents Prospective Employers University Administration Figure 1: Stakeholders in the teaching – learning environment. As shown in Figure 1, there are many stakeholders in the modern teaching –learning environment. As a consequence, the expected quality of teaching is determinednot only by the course content and delivery, but also the need to meet the

Conference Session

Advancing Manufacturing Education Through Outreach and Collaboration

Collection

2006 Annual Conference & Exposition

Authors

Val Hawks, Brigham Young University; Michael Miles, Brigham Young University

Tagged Divisions

Manufacturing

always been the source ofAmerica’s innovation and our standard of living.” [1] The crisis is the increasing penetration ofglobal competition on the economic output of the United States, now an issue to whichengineering education is paying serious attention. However, it is not a crisis of just technicalissues. What is needed with respect to global learning and experience is more than just technicalcompetence and expertise. Bill Wulf said “…engineering is now practiced in a global, holisticbusiness context, and engineers must design under constraints that reflect that context. In thefuture, understanding other cultures, speaking other languages, and communicating with peoplefrom marketing and finance will be just as fundamental to the practice of

Conference Session

Manufacturing Education Program Innovation

Collection

2006 Annual Conference & Exposition

Authors

Sean Falkowski, University of Dayton; Gilah Pomeranz, Sinclair Community College; Monica Pfarr, Sinclair Community College

Tagged Divisions

Manufacturing

. In the context of looming workforce shortages, the US manufacturers facetwo significant challenges: (1) the poor images and misperceptions that leave parents,counselors, and students unwilling to pursue technical degree programs that serve themanufacturing sector, and (2) the urgent need for highly skilled workers who canfunction effectively in the current advanced and technologically sophisticatedmanufacturing environment.Manufacturing suffers from a negative—and outdated—view of its role in the nationaleconomy. There is a common misperception that the importance of manufacturing to the Page 11.1069.2US economy is diminishing. This perception is

Conference Session

Manufacturing Processes

Collection

2006 Annual Conference & Exposition

Authors

Tom Carlisle, Sinclair Community College; Charles Winarchick, Sinclair Community College

Tagged Divisions

Manufacturing

”1 state: “It is said that there is nothing so practical as goodtheory. It may also be said that there’s nothing so theoretically interesting as goodpractice.” Marquardt2 in his “Harnessing the Power of Action Learning” states “...allforms of action learning share the elements of real people resolving and taking action onreal problems in real time and learning while doing so.” This is what our educational approach to engineering technology education has been allabout. To address these issues, we create laboratory problems, institute engineering coopprograms, and do capstone projects, all to get students exposed to “real world problems”.These are all excellent approaches and should be applied wherever practical. There areproblems associated

Conference Session

Manufacturing Education Innovation and Assessment

Collection

2006 Annual Conference & Exposition

Authors

Donna Qualters, Northeastern University; Jacqueline Isaacs, Northeastern University; Thomas Cullinane, Northeastern University; Ann McDonald, Northeastern University; Jay Laird, Metaversal Studios

Tagged Divisions

Manufacturing

supply chain. The projectexplores the hypothesis that millennial engineering students approach learning in a communal,active manner using trial and error approaches. Results of this pilot exploratory project suggestthat engineering students are able to learn new information in a collaborative game approach,which impacts their confidence and self-awareness of their knowledge base.1. IntroductionThe goal and challenge of the board game entitled Shortfall is for students to learn to maximizeprofit with an increased awareness of environmental impact. The objectives of the game are tofoster better understanding of these issues and to encourage potential future industry leaders tomake these practices part of every day planning. The auto industry

Conference Session

Lean Manufacturing Education

Collection

2006 Annual Conference & Exposition

Authors

Michael Miles, Brigham Young University; Val Hawks, Brigham Young University

Tagged Divisions

Manufacturing

would have allowed us to implement some of the changes we proposed. We will presenta discussion of the efforts of our students to gather and analyze data, which will be followed by asummary of the recommendations for improvement that they provided to these companies. Page 11.1457.21. Case #1 - Motorcycle Inner Tube ManufacturingBackgroundThis family-owned business has been operating for about 6 years and is led by a father and twosons. They produce inner tubes for motorcycles and sell them to wholesale suppliers in PhnomPenh, who then distribute their products to the rest of the country. At one time they did have alocal competitor, but they

Conference Session

Manufacturing Laboratory Experience

Collection

2006 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University; Hye Jeong Kim, Texas A&M University

Tagged Divisions

Manufacturing

Designs, the user canreview different layouts in terms of operation time and cost of each step, overall cycle time andtotal cost.The toolkit was evaluated by 27 undergraduate students who took a manufacturing automationand robotics course in Fall 2005. Students’ comments and opinions were mostly positive andincluded suggestions for further improvement. Future directions include (1) adding aninteractive tutorial component including a case study of designing an automated system; (2)testing the prototype with a larger student population; (3) soliciting input from industry experts;and (4) comparing and contrasting how similar problems are solved by experts and novices

Conference Session

Manufacturing Laboratory Experience

Collection

2006 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University; Landon Gray, Texas A&M University

Tagged Divisions

Manufacturing

studies are being developed. These case studies includeanimations of automated systems to help students to visualize how processes work and thesequence of events. They also illustrate steps in the programming process from identifying thesequence of events and input and outputs to developing code to implement each event. Althoughthe idea of case studies itself is not new, the combination of case study methodologies andinstructional technology to teach PLC programming is relatively novel. This paper will describethe case studies that have been developed so far, how they are being used, results from studentevaluations of these case studies, and future directions.1. IntroductionThe programmable logic controller (PLC) has been described as one of

Conference Session

Manufacturing Laboratory Innovation

Collection

2006 Annual Conference & Exposition

Authors

R. Radharamanan, Mercer University

Tagged Divisions

Manufacturing

. Page 11.909.3CAD/CAM/CMM ModuleThe objective of this module is to train the students to design, fabricate, and measure a simplepart using the knowledge they gained in the manufacturing processes course (ISE 370). Thiscourse is offered in the Fall Semester of the junior year.The design sub-module consists of: 1. Brainstorm ideas of possible parts to design and make.2. Determine the part which would be challenging yet attainable to complete. 3. Draw the partdrawing using correct dimensions on engineering paper. 4. Provide appropriate tolerances, ifnecessary, to certain dimensions in the drawing. 5. Draw the part drawing in Pro-Engineer/AutoCAD. Label all end points and points of interest to tool path. 6. Decide whether to useabsolute or

Conference Session

Projects in Manufacturing Curriculum

Collection

2017 ASEE Annual Conference & Exposition

Authors

Michael G. Mauk, Drexel University; Richard Chiou, Drexel University (Eng. & Eng. Tech.); Shraman Kadapa, Drexel University (Eng. & Eng. Tech.); Tzu-Liang Bill Tseng, University of Texas, El Paso

Tagged Divisions

Manufacturing

vs global measurements, and how to determine bestmethods for research, process development, prototyping, and quality assurance. With theseexperimental modules, students will learn the cost of measurements in terms time, capitalequipment, sample invasiveness, complexity, and the return with regard to accuracy,repeatability, and informational value.Applications for Instruction and Course Work There are many metrics describing the geometry and other features of surfaces and alsomany options for characterizing surfaces based on optics (color, specular and diffuse reflection,scattering), mechanics (1- or 2-D topography, sliding friction), and surface chemistry (e.g.,wetting). Each of the techniques or methodologies described below have

Conference Session

Manufacturing Curriculum and Course Innovations

Collection

2017 ASEE Annual Conference & Exposition

Authors

Ryan W. Krauss, American Society of Mechanical Engineers; Arjumand Ali, Grand Valley State University; Amy L. Lenz, Grand Valley State University

Tagged Topics

Diversity

Tagged Divisions

Manufacturing

-implementexperiments. A key challenge in developing appropriate experiments is keeping the cost downwhile keeping the students from getting lost in implementation details. Hill designed and 2Figure 1: Picture of the Zumo robot chassis and sonar sensor along with a masking tape stoppinglinepresented a series of such experiments that combined an Arduino micro-controller board withMatlab and used them in a flipped dynamic systems and control course 16 .Pedagogical InnovationsOn some level, this paper serves as a benchmark to see how well PDM students who do not takedynamics understand system dynamics and control compared to ME students who do takedynamics as a prerequisite. Additionally, this paper investigates

Conference Session

Manufacturing Curriculum and Course Innovations

Collection

2017 ASEE Annual Conference & Exposition

Authors

Faisal Aqlan, Penn State Behrend; E. George Walters III P.E., Penn State Behrend

Tagged Divisions

Manufacturing

manufacturing philosophy that shortens the time linebetween the customer order and the shipment by eliminating waste”1. There are eight types ofLean wastes: defects, over-production, waiting, non-utilized talent, transportation, inventory,motion, and extra-processing. The first letters of these eight wastes can be summarized in theword DOWNTIME. Table 1 shows the eight Lean wastes and their description. Table 1. Eight Lean wastes Lean Waste Description Defects Products to be reworked or scrapped Over-production Producing more or earlier than required Waiting Any non-work time waiting for tools, supplies, parts, etc. Non