This course covers manufacturing processes with material properties and design requirements taken into account. Processes studied include casting, bulk deformation, sheet-metal forming, powder-metal and ceramic processing, polymer processing, additive manufacturing, machining and finishing, advanced machining, and joining. The course also introduces engineering metrology, geometric dimensioning and tolerancing, and statistical process control, and closes with a framework for process selection, manufacturing cost, and sustainable manufacturing.

Learning outcomes- on completion, students should be able to:
1. Explain the physical principles, capabilities, and limitations of the major manufacturing process families.
2. Relate material properties and part geometry to process feasibility, defects, and achievable tolerances and surface finish.
3. Select an appropriate joining process and design a joint for a given material combination and service condition.
4. Interpret measurement data and tolerances (GD&T) and apply basic statistical process control.
5. Compare candidate processes for a given product on the basis of quality, rate, cost, and sustainability, and justify a selection.

Physics, Solid Mechanics, 기계재료학

(DeGarmo’s) Materials & Processes in Manufacturing, Tenth edition, J.T.Black and R.A. Kohser

Week 1: Overview of the course (9/7)
General Introduction (9/9)
Week 2: Ch. 10 Fundamentals of metal casting
Ch. 11 Metal-casting processes and equipment & Ch. 12 Metal casting: design, materials, and economics (9/16)
Week 3: Ch. 13 Metal-rolling processes and equipment
Ch. 14 Metal-forging processes and equipment (9/23)
Week 4: Ch. 15 Metal extrusion and drawing
Ch. 16 Sheet-metal forming I (16.1–16.8) (9/30)
Week 5: Ch. 16 Sheet-metal forming II (16.9–16.16, design & economics)
Ch. 17 Powder-metal processes and equipment (10/7)
Week 6: Ch. 18 Ceramics and glasses: processing (overview)
Ch. 19 Plastics and composite materials: forming and shaping
Week 7: Ch. 20 Additive Manufacturing I (20.1–20.10: methodology and process families)
Ch. 20 Additive Manufacturing II (20.11–20.13: rapid tooling, DfAM, economics) (10/21)
Week 8: Midterm exam (Wed)
Week 9: Ch. 21 Fundamentals of machining (11/2)
Ch. 22 Cutting-tool materials and cutting fluids (11/4)
Week 10: Ch. 23 Machining processes: turning and hole making (11/9)
Ch. 24 Machining processes: milling, broaching, sawing, gear manufacturing (11/11)
Week 11: Ch. 25 Machining centers, machine-tool structures, and machining economics
Ch. 26 Abrasive machining and finishing (+ 33.2–33.3 surface roughness)
Week 12: Ch. 27 Advanced machining processes (+ 29.2 MEMS overview)
Ch. 30 Fusion welding processes (11/25)
Week 13: Ch. 31 Solid-state welding processes
Ch. 32 Brazing, soldering, adhesive bonding, and mechanical fastening; joint design and process selection (30.10) (12/2)
Week 14: Ch. 35 Engineering metrology and instrumentation; GD&T (35.8)
Ch. 36 Quality assurance, testing, and inspection; SPC (36.7–36.8)
Week 15: Ch. 40 Process selection, manufacturing costs, and sustainable manufacturing I (40.4–40.10)
Ch. 40 Process selection, manufacturing costs, and sustainable manufacturing II(40.4–40.10)
Week 16: Final Exam (Wed) / Wrap-up

Welcome to the class on MECH330, Materials Processing.
For this course, we will have in-person classes in room 011 (Engineering Building 5) on Mondays and Wednesdays at 11 am.