KU: Center for Teaching Excellence

an understanding of material selection criteria
a familiarity with the material behavior of engineering materials, particularly alloys of iron (steel), aluminum and titanium as well as ceramics, plastics and composites
a familiarity with manufacturing processes common to the aerospace industry

Course topics will be presented in a manner to provide students the knowledge required to produce designs of aerospace systems with appropriate material and process specifications.

Texts:

Manufacturing Engineering and Technology, Serope Kalpakjian, 4th edition, Addison-Wesley, 2001.
Excerpts from MIL-HDBK-5E

Course Topics:
I. Material Behavior and Selection
            Metal Alloys                        Ceramics
            Polymers                        Composites
II. Manufacturing Processes
            Forming                        Material Removal
            Joining                                    Surface Treatment
            Measurement                        Testing and Inspection
            Automation                        Computer Aided Manufacture
            Economics                        Environmental Compliance
III. Design Application

Special Events:
One or two field trips will be taken. Past trips have been to Wichita to tour Boeing, Raytheon or Cessna, and the TWA Rework Facility at KCI airport. If there is enough interest in an overnight trip, a tour of Boeing facilities in St. Louis can be arranged. Each student is expected to attend at least one of these trips.

Evaluation:
Grades will be based on homework (20%), an individual research project (10%), a group manufacturing project (15%), two exams (20% each), and a final group design project (15%). Each student is expected to actively participate in class discussions and design reviews.

Any student in this course who has a disability that may prevent him or her from demonstrating his or her full abilities should contact me personally as soon as possible to discuss necessary accommodations.

lsn	date	topic	reading	homework (tentative)	due
1, 2	8-21 8-26	Introduction Integrated Product Dvlpmnt. Design for Manufacturing	General Intro
3,4	8-28 9-2	Communication, Teaming Business aspects of engrg.	Ch. 1	1.22, 1.25, 1.27, 1.28, 1.30, 1.32, 1.35a	9-2
5	9-4	Structure of Metals	Ch. 2	2.17, 2.27, 2.29, 2.30, 2.36, 2.38	9-5
6, 7	9-9 9-11	Introduction to Manuf. Lab		Rivet Design Project	9-23
8	9-16	Structure of Metals Mechanical Properties Research Project Intro.			9-23 (abstracts) 10-21 (papers/ websites)
9, 10	9-18 9-23	Mechanical Properties Physical Properties Fatigue, Surface Treatment	Ch. 3	SP-1	9-30
11	9-25	Metal Phase Diagrams	4.1-4.6	4.1, 4.2, 4.5	10-2
12, 13	9-30 10-2	Metal Heat Treatment	4.7-4.13	4.9, 4.11, 4.14, 4.16, 4.19, 4.30, 4.32, 4.33	10-7
14, 15	10-7 10-9	Steels (Iron Alloys) Intro. Manuf Project	Ch. 5	5.7, 5.17, 5.23, SP-2	10-14
16	10-14	Aluminum Alloys	6.1-6.4	6.1, 6.2, 6.5, 6.12, 6.15, 6.17	10-21
17	10-16	Review
18	10-21	* EXAM 1 * Research projects complete	Chs. 1-6
	10-23	Fall Break
19	10-28	Exam Review Titanium; Nickel & High Temperature Alloy	6.5-6.14
20	10-30	Environmental Effects, Corrosion
21, 22	11-4 11-6	Casting Rolling & Forging	Chs. 10-12 Chs. 13-14	10.20, 10.22, 11.25, 13.34	11-11
23, 24	11-11 11-13	Extrusion, Drawing Sheet Metal Formation	Chs. 15-16	16.47, 16.56	11-18
25	11-18	Cutting & Machining Welding, Bonding & Fastening Final Design Project Intro. (DP2)	Chs. 20-26 Chs. 27-30	22.43, 22.47, 23.49, 23.52, SP-3	11-25
26, 27	11-20 11-25	Polymers, Ceramics & Composites Plastics & Composites Surfaces & Treamtnets Metrology & Quality Assur.	Chs. 7-9 Chs. 18-19 Chs. 31-37	7.18, 7.28, 9.2, SP4 36.40, 36.41	12-2
28	12-2	DP2 Presentation of Manufacturing Article
29	12-4	DP2 Conceptual Design Briefs Manufacturing Projects Complete
30	12-9	DP2 Prelim. Design Briefs
31	12-11	DP2 Final Design Briefs
	12-15 thru 12-19	Final Exams