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

generatecomplex 3-D objects directly from computer-based models devised by CAD. In Mech476, aseries of RP projects are integrated. Students designed complex geometries and build their partsusing the RP systems. The students also conducted manufacturing experiments to analyze theprocesses and products quality in MECH 310. Through new manufacturing laboratories in thecourse, the students could run various modern manufacturing tools such as CNC machines,machining force monitoring systems, and product quality measurement systems. See Figure 2 forsome sample student work using the modern technologies. (a) CAD design (b) CAE analysis (c) Rapid prototypeFigure 2. Student work examples in the Design/Manufacturing sequence.Lean

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

back, rendering it unable to move ≠ Full body spinner, uses the entire body and frame of the robot as a weapon by spinning it around itself ≠ Dead blow, uses a hammer-like mechanism to swing at an opponent with large mass or a puncturing weapon. ≠ Inertial spinner, uses the inertia of large rotating masses to inflict damage, picture to be found (Figure 2) (a) (b) (c) Flipper Bot Full Body Spinner Dead Blow Figure 1: Weapon Styles Page 14.424.6

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

study of macromilling Ti 6Al 4V, theauthors find a significantly improvement of tool life (~ 8 times) and a reduction of cutting forceswhen micromist is used 12. Page 14.878.6 (a) (b)Figure 1. Measuring tool offset in (a) x and y directions and (b) z direction.Figure 2. Run out of Haas OM2 air spindle at 10,000 rpm. Page 14.878.7Figure 3. Bending stress on a cutting tool due to spindle run out. The maximum stress reachesflexural strength of the tool material when tool deflection is 0.34 mm

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Benxin Wu, Illinois Institute of Technology

Tagged Divisions

Manufacturing

students. The students within each group did the experiments and datacollection together. However, each group member was required to submit a separate lab reportindividually. The lab report was graded based on its content, format, and language.Because lasers were involved in the experiments, the students were given laser safety trainingbefore the experiments. Also, during the experiments, the operation of the laser itself was mostlycarried out by the teaching assistant, who is also a graduate student of the author.The schematic of the system used in two experiments is shown in Fig.1 (a) and a real photo ofthe system is given in Fig. 1 (b). The laser module can be operated either in continuous mode orpulsed mode, and the laser beam is expanded by

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Yuqiu You, Morehead State University

Tagged Divisions

Manufacturing

controllerwith hand-held programmer, limit switches and wiring tools. Students need to design and drawthe ladder logic program with input/output wiring, wire input/output devices to the controller,and enter theprogram into the PLC by HHP and verify the program.Students wire two spring-return switches to the input module of the controller. Use the PowerSupply A to supply a 15V VDC to each switch. The wiring diagram is as below: Figure 4: Input wiring diagramStudents then wire one DC motor to the output module of the controller. Use the 5V VDC powersupply and the Power Supply B to supply a 5V VDC to the two circuits of motor control. Thewiring diagram is as below: Figure 5: Output wiring

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

Pre-polymer Silicone cover (urethanes), molds, cups, Two polymer wood stirs, souvenirs curative, scissors, plastic bags, stapler. papers, and Plastic bag staples. Top view side view(a) raw materials (b) tools used during production (c) final product descriptions (d) A final product exampleFigure 1. Raw materials, tools used, final product descriptions, and a final productexample for the project.2.1 Production run with the

Conference Session

Micromachining in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Wesley Stone, Western Carolina University; John Graham, Western Carolina University

Tagged Divisions

Manufacturing

CO2. • There are two lasers on-board: a 266-nanometer (nm) and a 532-nm wavelength head for processing softer materials (polymers, plastics, and glass) and harder materials (metals and ceramics), respectively. • It has five-axis CNC control for three-dimensional machining: x- and y-axis control of the table in the horizontal plane, z-axis control of the laser’s vertical position, b-axis rotation about the y-axis, and c-axis rotation about the z-axis. • Galvo scanning heads provide the capability of laser machining inside a workspace of 50 by 50 mm without using the CNC stages; this allows for much higher-speed machining, since the workpiece remains stationary. • The beam can be focused to a

Conference Session

Design Education in Manufacturing Programs

Collection

2009 Annual Conference & Exposition

Authors

Guanghsu Chang, Minnesota State University, Mankato; William Peterson, Minnesota State University, Mankato

Tagged Divisions

Manufacturing

Assessment Criterion 2 by Bridge Design Project (Supporting Evidence) Outcomes a-k Pratt bridge truss, Warren truss, HoweRecognize different types of trusses b,f roof truss, Fink roof truss Axial tension, bending, and axialIdentify forces in structures

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

Wayne Hung, Texas A&M University; Sriharsha Sundarram, Texas A&M University; Fatih Ozkeskin, University of Michigan; Mike Powers, Agilent Technologies; Juan Manriquez, Cideteq; Venkata Vasiraju, Texas A&M University

Tagged Divisions

Manufacturing

. Figure 3: Current density as a function of electrode gap. (a) (b) Figure 4: Effect of frequency on machined feature sizes. Page 14.524.7 3,500,000 3,000,000 Closed Loop 24 Vpp 2,500,000 MRR (µm3/ sec) Open Loop 24 Vpp 2,000,000 Theory

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Terence Fagan, Central Piedmont Community College

Tagged Divisions

Manufacturing

-123JSpring-2006/CourseHome/index.htm 5. http://www.sfi.mtu.edu/About_SFI.htm 6. http://www.epa.gov/nrmrl/lcaccess/ 7. Pre Product Industrial Consultants "Eco-indicator 99 Manual for Designers: A damage Oriented Method for Life Cycle Impact Assessment" 2000, Ministry of Housing, Spatial Planning and Environment. 8. Diamond J. “Collapse: How Societies Choose to Fail or Succeed” 2005, Penguin Group USA. 9. Lovins A., Lovins, H., Hawken P. “Natural Capitalism Creating the Next Industrial Revolution” 2000, Little Brown & Company. 10. Coulter, S., Bras, B., Foley C., “A Lexicon of Green Engineering Terms” Praha, August 22-24 1995, International Conference on Engineering Design

Conference Session

Technology Integration in the Classroom

Collection

2009 Annual Conference & Exposition

Authors

Hung-da Wan, University of Texas, San Antonio; Venkata Tarun Cherukuri, University of Texas, San Antonio; Saumya Tamma, University of Texas, San Antonio; Kranthi Kumar Tiyyagura, University of Texas, San Antonio

Tagged Divisions

Manufacturing

addition to the interactive online curriculum. There are more similar commercial packages thatthe authors did not have an opportunity to evaluate, but the three packages give a good overviewof the “teaching assistant” type of online learning systems. Figure 1. Examples of teaching systems: (a) course management (b) online learning4The other category of online learning applications is the interactive programs. Various modulesand packages have been developed to enhance the online learning experiences via moreinteractive activities. Simulation and gaming are the main methods to achieve this goal. Puresimulation demonstrates a process or the operation of a system and may also provide data forfurther analysis. Using proper computer programs

Conference Session

Our Future in Manufacturing: STEM Outreach

Collection

2009 Annual Conference & Exposition

Authors

Terence Fagan, Central Piedmont Community College

Tagged Divisions

Manufacturing

our Future NJ: Promoting Engineering in K-12 Schools Through Professional Development, Policy Initiatives, and Partnerships" 2008 American Society of Engineering Educators. 4. Ragusa G., Khoo M., Meng E., Cocozza J., "Engineering Outreach: Connecting Biomimetic Research to Urban K-12 Classrooms" 2008 American Society of Engineering Education. 5. Boyle P., Houchens B., "Adaptive Water Laboratory for K-12 Outreach on Sustainable Water Use" 2008 American Society for Engineering Education. 6. Birnkrant M., Cathell M., Blount P., Robinson J., Fontecchio A., Fromm E., " Introducing Engineering through Candy" 2008 American Society for Engineering Educators. 7. http://howtoons.com 8. Lima M., Oakes W.C

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Ning Fang, Utah State University

Tagged Divisions

Manufacturing

., Barnes, S., Coe, S., Reinhard, C., and Subramania, K., “Globalization and the Undergraduate Manufacturing Engineering Curriculum,” 2002, ASEE Journal of Engineering Education 91, pp. 255-261.[2] National Association of Manufacturing, “Keeping America Competitive: How A Talent Shortage Threats U.S. Manufacturing,” a white paper on http://www.nam.org/~/media/Files/s_nam/docs/226500/226411.pdf.ashx, accessed October 6, 2008.[3] Bee, D., and Meyer, B., “Opportunities and Challenges for Manufacturing Engineering,” 2007, Proceedings of the 2007 ASEE Annual Conference & Exposition, June 24-27, 2007, Honolulu, HI.[4] Waldorf, D., Alptekin, S., and Bjurman, R., “Plotting a Bright Future for Manufacturing

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

George Gray, Texas Tech

Tagged Divisions

Manufacturing

. Theimplementation of these labs will provide students with the hands-on knowledge ofmanufacturing processes and applications which industry values, while affording the universityprograms with a proven retention tool. References1. Gordon, B. M., 2007, “Engineering Education Must Get Real,” New England Journal of Higher Education, Summer p. 28.2. Mike Popejoy (personal communication, October 17, 2007).3. Informational Brochure, “Profiles of Mechanical Engineers,” American Society of Mechanical Engineers.4. Rick Graff (personal communication, November 8, 2007).5. http://itll.colorado.edu/GEEN1400/index.cfm?fuseaction=RetentionStudy6. Kramer-Koehler, P., Tooney, N., Beke, D., 1995, “The Use of Learning

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

Briggs and Myers, Peter B., Gifts Differing: Understanding Personality Type. Mountain View, CA: Davies-Black Publishing, 1980, 1995.15. Poynter, Dan, The Self-Publishing Manual: How to Write, Print and Sell your Own Book, 14th ed., Para Publishing, 2003.16. EZ27 Roll Laminator Operating Instructions, http://www.banam.com/Ezlam.pdf , accessed April 9, 2008.17. QCM-1200E Desktop Paper Cutter: User’s Manual, Quality Commercial machines Corporation, Naperville, IL, 2007.18. GBC 2000XT Therm-A-Bind Operating Instructions, General Binding Corporation National Service, Northbrook, IL. Page 14.46.12

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Tayte Nelson, Oregon Institute of Technology; Jialu Xie, Oregon Institute of Technology; John Anderson, Oregon Institute of Technology

Tagged Divisions

Manufacturing

AC 2009-1927: A SMALL-SCALE AUTOMATED WAREHOUSETayte Nelson, Oregon Institute of TechnologyJialu Xie, Oregon Institute of TechnologyJohn Anderson, Oregon Institute of Technology John Anderson is an Associate Professor of Mechanical and Manufacturing Engineering at Oregon Institute of Technology and a registered mechanical engineer. His primary teaching and research interests are manufacturing processes, industrial controls, and manufacturing automation. He has 12 years of teaching experience in higher education, and over 20 years of experience as a mechanical engineer in industry. Prof. Anderson has been awarded two patents, has authored over 20 published technical papers, and has managed several

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

James Sample, Oregon Institute of Technology; John Anderson, Oregon Institute of Technology

Tagged Divisions

Manufacturing

AC 2009-1400: A COST-EFFECTIVE ROBOT WORK CELLJames Sample, Oregon Institute of TechnologyJohn Anderson, Oregon Institute of Technology Page 14.18.1© American Society for Engineering Education, 2009 Cost Effective Robot Work cellAbstractThis paper describes the design and construction of a cost effective robot work cell using anintegrated software system. Surplus industrial cylindrical coordinate robots were updated withnew electronics and software as well as tooling. A vision system was integrated usinginexpensive USB cameras and a “shareware” vision software system was integrated into therobot operating system.This system uses readily available tooling

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

AC 2009-27: A TOP-DOWN APPROACH FOR TEACHING AN INTRODUCTORYENGINEERING MATERIALS COURSEPriya Manohar, Robert Morris University Dr. Priyadarshan Manohar is an Assistant Professor of Manufacturing Engineering at Robert Morris University, Pittsburgh, PA. He has a Ph. D. in Materials Engineering (1998) and Graduate Diploma in Computer Science (1999) from University of Wollongong, Australia and holds Bachelor of Engineering (Metallurgical Engineering) degree from Pune University, India (1985). He has worked as a post-doctoral fellow at Carnegie Mellon University, Pittsburgh (2001 – 2003) and BHP Institute for Steel Processing and Products, Australia (1998 – 2001). Dr. Manohar held the position

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University

Tagged Divisions

Manufacturing

AC 2009-1112: UNDERSTANDING AUTOMATED SYSTEM DESIGN PROBLEMSOLVING: CURRENT PROGRESS AND IMPLICATIONS FOR INSTRUCTIONSheng-Jen Hsieh, Texas A&M University Dr. Sheng-Jen (“Tony”) Hsieh is an Associate Professor in the Dwight Look College of Engineering at Texas A&M University. He holds a joint appointment with the Department of Engineering Technology and the Department of Mechanical Engineering. His research interests include engineering education, cognitive task analysis, automation, robotics and control, intelligent manufacturing system design, and micro/nano manufacturing. He is also the Director of the Rockwell Automation laboratory at Texas A&M University, a state-of-the-art

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

David Culler, Oregon Institute of Technology; Noah Anderson, Oregon Institute of Technology; Stanley Ames, Oregon Institute of Technology

Tagged Divisions

Manufacturing

AC 2009-2230: DESIGN AND CONSTRUCTION OF A RAPID PROTOTYPINGMACHINE: A BREAKDOWN OF THE MACHINE SUBSYSTEMS USED TOLEARN MULTIDISCIPLINARY ENGINEERING SKILLSDavid Culler, Oregon Institute of Technology Dr. Culler has more than 20 years experience in CAM systems and is currently an Associate Professor at the Oregon Institute of Technology in Klamath Falls, OR. He has worked with Sandia National Laboratories, the Army Research Organization and most recently spent 4 years teaching at the Costa Rica Institute of Technology. He has published some of his work in the RCIM journal and at the 2004 Frontiers in Engineering Education Conference in Savannah GA.Noah Anderson, Oregon Institute of Technology Noah

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Kenneth Stier, Illinois State University

Tagged Divisions

Manufacturing

AC 2009-1045: TEACHING SUPPLY-CHAIN AND INVENTORY CONCEPTSTHROUGH SIMULATIONKenneth Stier, Illinois State University Page 14.1154.1© American Society for Engineering Education, 2009 Teaching Supply Chain Inventory Concepts through SimulationAbstract This paper describes how effective supply chain strategies using inventory control canhelp companies become more competitive in the global marketplace. It describes a manualsimulation activity that is used in the author’s supply chain class to expose students to thisconcept. Instructional materials used for this simulation activity are shown.Introduction There are four major drivers that play a key role in the

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Jeremy Li, University of Bridgeport

Tagged Divisions

Manufacturing

priority, and 3rd priority: A. Large products B. Small products (normal delivery) Page 14.906.2 C. Small products (fast delivery) D. Emergency product replacementThis case study can help students to gain the knowledge of how to build up the strategyfor small companies to face the challenge. The strategy guidelines with focus on leanmanufacturing will be discussed and learned from this case study.Case study 2:A small but well-organized company attempts to implement the strategy to strengthen thefirm’s competition. Please discuss and explain if the following strategies are properlyplanned for this company: A

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

students could redefinetheir designs and make the necessary changes. Teams of students met with the teaching assistantat the VirtualMD Lab every week to work on their designs and obtain feedback. Students alsoreceived feedback from the medical doctor during the realization of the project.(a) Fusion deposition modeling (FDM) (b) 3D printing machinemachineFigure 2. Rapid prototyping equipment at the VirtualMD Lab.Students worked with SolidWorks® for creating their CAD files during the design stage. Severaldesign iterations were needed until the design was approved for fabrication. Once the design Page 14.767.5was approved, teams were

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Louis Reifschneider, Illinois State University

Tagged Divisions

Manufacturing

removal Product Figure 1 Section views of material removal in a machining process Mold Half A Mold Half B Molds Mated Casting/molding Product Figure 2 Section views of a net-shaped manufacturing process Material removal process Net-shaped process Figure 3 Net-shaped manufacturing requires draft for product release from moldThermoforming as an attractive net-shaped process platform for educationOne of the hurdles faced by product design instructors is the limited time available for studentsto create the product they design. This is especially true for product design involving net-shapedmanufacturing because the product is the result of a

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Arif Sirinterlikci, Robert Morris University

Tagged Divisions

Manufacturing

-Integral-Derivative (PID) controls illustrated in Figure 44. This isassociated with a current research project on Real-Time PAC based controls. Figure 2.a NI LabView Model of a simple digital logic example .b NI ELVIS circuit for the model Page 14.1341.3 Figure 3. PLC Ladder logic for a mixer application written in RS Logix 5003Up to this point, the schedule of the course includes hard-wired controls based on ladderdiagrams and PLC systems programmed by ladder logic. The crucial role of ladder diagrams andladder logic in controls has been covered in detail with the utilization of two these areas. On

Conference Session

Manufacturing Curricula for the Year 2015 and Beyond

Collection

2009 Annual Conference & Exposition

Authors

Hugh Jack, Grand Valley State University; Venkitaswamy Raju, State University of New York, Farmingdale; David Wells, North Dakota State University; Robert Mott, University of Dayton

Tagged Divisions

Manufacturing

education since the landmark"Curricula 2000" 1 and "Curriculum 2002" 2 workshops held in 1989 and 1994. They had set thecrucial groundwork for a) widespread improvement in both content and access and b) a futurecomprehensive conference on manufacturing education. Building on the assessment the groupdecided to move forward on expanding the discussion and formalizing the results.The first forum "Manufacturing Education Leadership Forum: Vision for Progress" was heldJune 26-27, 2008 at Robert Morris University, Pittsburgh, PA 3 with the purpose of examiningthe current state of manufacturing education, and deciding what steps should follow. The nextforum " Manufacturing Education Leadership Forum; Moving Forward" 4 was held atFarmingdale State College

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

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Darrell Wallace, Youngstown State University

Tagged Divisions

Manufacturing

learner to Figure 6: OSHA e-tools uses 3D animations toexplore the environment on their own. illustrate concepts such as the operational timing of Type A vs. Type B gates.A variety of technologies exist that allowusers to navigate through 3-D environments. Most academic programs will certainly have accessto solid modeling software such as Inventor, Solidworks, or Pro/E. Most solid modelingpackages also include the ability to generate animations. In some cases, these models may evenbe exported to cross-platform web-friendly formats such as VRML (Virtual Reality MarkupLanguage).Though some of the desired capabilities for developing a virtual environment for

Conference Session

Hands-on Lean Manufacturing Simulation Workshop

Collection

2009 Annual Conference & Exposition

Authors

Merwan Mehta, East Carolina University

Tagged Divisions

Manufacturing

between each operation like at the endof the shift. Operators then come back the next day to a primed process and start where theprocess was stopped. A primed process is often called a “wet” process and an unprimed processis called a “dry” process. Operation Operation Operation Start End A (15 mins) B (25 mins) C (50 mins) Figure 5. Simple Process With Three OperationsTo understand the concept of operator efficiency, let us assume a simple process as shown inFigure 5. The sum of operation times for the three operations is equal to 15 + 25 + 50 = 90minutes

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

summarized as given in equation (2). Thus,relationship similar to equation (2) can be developed for different customer segments: Fmust / be Fperformance Fattractive FreverseProduct Characteristics = + ± ± (2) cmust / be cperformance cattractive creverseApplication of Kano AnalysisKano's model employs a specific questionnaire format since the type of customer requirementcannot be detected by traditional customer surveys. In order to detect the types of the product orservice characteristics, attractive (A), basic (B), and one-dimensional (O) requirements areidentified through a specially designed questionnaire that contains a