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Major: Production
Deanship of Academic Affairs
CURRICULUM FOR
PRODUCTION
PREPARED BY Dr. Salih A. Al-Qaahtany Dr. Ali S. Al-Watban Dr. A. M. Bassiuny Dr. Abdullah Al Huwaishel Dr. El Amin E. Mohammed
FIRST EDITION
G H
Major: Production
Major Code
Semester Course Description : This introductory course focuses on basic elements of materials science which relate the materials properties and types to the microscopic behaviour of atoms. Credit hr/w L Contact hr/w W T L Contact hr/sem. General Goal : The student should acquire enough knowledge to understand: Basic elements of materials microstructures. Metals deformation and microstructures. Metal alloys and heat treatments Basics of corrosion and polymers W T
Behavioral Objectives : The student should be able to: Explain theoretically materials and microstructures, metal alloys, metal deformation, corrosion and polymers. Perform experimentally microscopic inspection, phase diagram construction, heat treatments and corrosion rate measurements.
Major: Production
Topics:
Theory:
Crystalline structure Imperfections in solids Alloys and phase diagram Heat treatments Corrosion in metals Polymers
Practice:
Specimen preparation Microscopic inspection Cooling curve and phase diagram Heat treatments Corrosion rate measurements
Textbook:
Callister, W. D.:Materials Science and Engineering An Introduction, John Wiley & Sons.
Additional Reading:
1-Van Vlack, L. H.: Elements of Materials Science and Engineering, AddisonWesley. References: 2-Thornton, P. A. and Colangelo, V. J.:Fundamentals of Engineering Materials, Prentice Hall.
Major: Production
Explains lattice defects Relates metal deformation to dislocation motion Explains important factors affecting mechanical properties in metals
6 Alloys and phase diagram Definition of alloys Definition of phase Cooling curve and phase diagram Simple phase diagrams Phase diagram calculations Iron-carbon phase diagram 4 Heat treatments Definitions TTT curves Major heat treatments in iron-carbon alloys Heat treatments and mechanical properties Explains TTT curves Explains the different heat treatments in iron-carbon alloys Shows the effect of these treatments on mechanical properties Explains the basic mechanisms of Corrosion in metals Calculates corrosion rate Explains how to avoid corrosion Explains metal alloys Explains phase diagram Performs phase diagram calculations
Corrosion Definitions Metal corrosion basics Galvanic cells Methods to avoid corrosion
Polymers Atomic bonds in polymers Types of polymers Polymerization Important terms and concepts Revision
Explains the difference of atomic bonds between metals and polymers Explains different types of polymers Explains polymerization process
Major: Production
Major: Production
Microscopic inspection Operating microscope Taking picture of grains Analyzing the picture
Operates the microscope Takes pictures and analyze it Follows the right procedure for handling equipment
Cooling curve (phase diagram) Calibrating the furnace Operating the furnace Constructing cooling curves for different compositions Hands on constructing phase diagram
Constructs cooling curves Constructs few points in phase diagram Understands the importance of calibration
Heat treatments Quenching Tempering Normalizing Annealing Jominy end quench test
Performs a variety of heat treatment experiments Measures hardness and inspects samples under microscope Explains changes in mechanical properties due to heat treatments Measures corrosion rate Shows and explains the effect of cathode to anode area ratio on corrosion rate
Corrosion rate measurements Samples and electrolyte preparation Corrosion rate measurements for different cathode to anode area ratios
Revision
Major: Production
Department Mechanical Technology Course Title Metrology and Basics of Quality Control Prerequisite
Major Code
Semester Course Description : This course focuses on the basic theoretical and practical fundamentals of metrology as well as basic concepts of quality control. It provides the student with proper hands-on experience to use various dimension, angle, surface finish, and thread measuring instruments as well as limit gauges. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The student receives the theoretical and practical back-ground to enable him to use various measuring instru-ments for dimension, angle, and surface finish measure-ments. He is to be familiarised with the international sys-tems of tolerances and fits as well as appropriate devices for tolerance inspection. The student is also introduced to the fundamentals of statistical quality control.
Behavioral Objectives : The student: Uses various dimension, angle, thread instruments and limit gauges Identifys the different types of fits and their applications as well as the different types of measurement uncertainties Explains the basic elements of quality control Constructs control charts
Major: Production
Topics:
Theory:
1. Dimension measurement 2. Angle measurement 3. Tolerances and fits 4. Surface finish measurement (Roughness) 5. Form and position measurement 6. Uncertainty of measurement 7. Introduction to quality control.
Practice:
1. Dimension measurement 2. Angle measurement 3. Tolerances and fits 4. Surface finish measurement (Roughness) 5. Form and position measurement.
Textbook:
J. F. W. Galyer, C. R. Shotbolt, Metrology for Engineers, S.I metric edition 1977 Amitava Mitra, Fundamentals of Quality Control and Improvement, 1993
Bass, Introduction to Engineering Measurements, McGraw Hill, 1971 Additional Reading: J. R. Taylor, Quality Control Systems, McGraw Hill , 1989 Paul Cambell, An Introduction to Measuration and Calibration, Industrial Press, 1995
A. J. Lissaman, S. J. Martin, Principles of Engineering Production, Second edition, 1982 J. P. Holman, Experimental Methods for Engineers, McGraw Hill, 1989 Krar, Oswald, Technology of Machine Tools, Fourth Edition, 1991 Richard R. Kibbe, John E. Needy, Ronald O. Meyer, Warren T. White Machine Tool Practices, 1982
References:
Major: Production
4 2. Angle Measurement Methods of angular measurement Using sine bar Methods of slope measurement 4 3. Tolerances and Fits Tolerance and fits specifications Tolerance tables 2
4. Surface Finish Measurement (Roughness) Introduction to quality of surface finish Methods of measuring surface finish 2
Position measurement
Major: Production
Names some static characteristics of measuring instruments e.g.accuracy, precision, and sensitivity Identifies the difference between measurement error and uncertainty Names the different types of systematic and random uncertainties Estimates typical systematic errors e.g. sine and temperature difference errors Describes the basic concepts of quality, quality control, Explains the benefits of quality control and the international quality standards Explains the statistical process control and the basis for control charts
Revision
Major: Production
2. Angle Measurement
5. Form and Position Measurement Inspection of cylindrical forms Measures the geometric characteristics of a cylindrical form (e.g. cylindricity, coaxiality, concentricity, run out, parallelism, squareness, straitness, flatness, position, angularity) using v-block supported rounndness measurements, measuring between centers, measurement by using computer controlled machines Carries out by using optical measuring instruments and coordinate measuring machine
Position measurement
Revision
Major: Production
Major Code
Semester Course Description : The course covers the fundamentals of forming process of materials both in theory and practice. It describes these processes and their application and economic values. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The goal of this course is to state the principles of forming processes and make available sufficient technical information about these processes.
Behavioral Objectives : The student: Understands the basic principles of forming processes Recognizes the variables and process performance Selects the proper process for certain job Carries out experiments on metal and plastic forming to investigate the factors affecting process performance.
Major: Production
Topics:
Theory:
Metal casting Primary metal forming Sheet metal working Presses Powder Metallurgy Plastic Processing
Practice:
Metal Casting Extrusion of Metals Deep drawing Piercing and blanking Injection of plastics Compression of plastics Thermoforming Plastic Extrusion
Textbook:
E. Paul DeGarmo et al, Materials And Processes in Manufacturing, Machmillan Publishing Company 1988.
Additional Reading:
Lawrence E. Doxle, Manufacturing Processes and Materials for Engineers, Printce-Hall, Third Eddition
References:
Major: Production
Explains methods of metal melting and process of pouring to produce defect free products Compares different types of casting processes i.e. sand casting, shell moulding, investment casting, permanent mould casting Identifies materials used in making moulds and their types and properties Explains Mould making methods Classifies different types of patterns and cores Describes the process variables and operating factors Identifies the expected casting defects Describes the finishing of casting and inspection The student: Describes the fundamentals of metal forming processes Explains forces and acting pressures Classifies forming processes into hot and cold working
Explains the different types of forming processes i.e. Rolling, Forging, Drawing, Extrusion Explains for each process the operations and process variables
Mechanical Technology Department Extrusion The Extrusion process Types of Extrusion processes Applications Processes limitation Drawing (Wire, Tube) The drawing process Applications Process limitations
Major: Production
Identifies the equipment used and their selection for certain process
3. Sheet Metal Working Types of operations Principles of metal shearing Shearing operations Bending operations Process limitations Deep drawing & Stretching Metal Spinning
The student: Describes Sheet metal working processes, shearing, bending & deep drawing, spinning Specifies the design aspects of shearing
Explains the principles of deep-drawing and operating factors i.e. die selection and forces Describes the different types of spinning processes The student: Identifies the types of presses their construction and specification Selects the suitable press for the job
4. Presses Elements of presses Press drives Types of presses Applications Press tools and accessories 5. Powder Metallurgy Principles of the process Powder metallurgy products Powder manufacture Powder testing & evaluation Powder mixing and blending Compacting Dies Sintering Secondary operations (finishing, stamping) 6. Plastic processing Compression moulding Transfer moulding Injection moulding Blow moulding Extrusion Sheet forming Foams Materials selection Classification of plastics
The student: Describes basics of powder metallurgy process and its applications Explains the process sequence and its limitations Explains the proper uses of the process Describes the techniques to produce high density product Explains the finishing operations The student: Explains the types of plastic forming processes Describes the equipment used for each processes and its operations States the suitable operating conditions for each process
2 Revision
Major: Production
1. Metal Casting Sand casting Sand preparation Patterns Cores Mould making Melting and pouring of metal Finishing process Inspection Processes evaluation Safety precautions Permanent Mould Casting The mould Melting & pouring quality of product process limitations & applications
The student: Prepares sand for moulding Selects patterns and cores Builds the mould properly Melts and pours metal Studies the factors affecting the process and quality of product Observes safety precautions Prepares the Mould Melt and pours the Metal properly Studies the process variable for better utilization Inspects the casting
2. Extrusion of Metals The equipment Material selection process parameters (force, speed) process evaluation
The student: Prepares the equipment for extrusion Select the suitable Metal Determines the operating factors Examines the product quality and the affecting factors The student Prepares the equipment for deep-drawing Cuts the blank to proper size Establishes the proper working conditions evaluates the process and the factors affecting quality
3. Deep drawing of Metals The equipment Blank preparation Die and punches Drawing forces and speeds Lubrication Product quality and affecting factors
4. Piercing and Blanking The student: Shearing process Punches and Dies Selection Force requirement The equipment Operating factors. Recognizes the shearing process Knows the types of punches and dies for shearing Determines the force required. Examines the quality of the product and the affecting factors for optimum conditions.
Major: Production
5. Injection of Plastics The student: The equipment Material selection Dies and Moulds Process parameters, temp., and pressure Product quality Process evaluation Prepares the equipment for injection Moulding Selects the proper material Determines the proper operating fac-tors Test for quality Evaluates the process
2 6. Compression Moulding of Plastics The equipment Material selection Process variable Optimization of the process 4 7. Thermoforming of plastics The student: The equipment Plastic sheet preparation process variables product quality 4 8. Plastic Extrusion The extruder Heating of plastic Process variables Applications Process evaluation Prepares the equipment for plastic forming Selects the proper working condition Studies the factors affecting the prod-uct quality The student: Prepares the equipment for compres-sion moulding Select the proper material Performs the process properly Studies the product quality and affecting factors
The student: Recognizes the different types of Extruders Determines the process variables Knows the different Applications of process
2 Revision
Major: Production
Department Mechanical Technology Course Title Machining Technology Prerequisite Engineering Drawing, Material Science
Major Code
Semester Course Description : The course covers both practical and theoretical Ma-chining Technology. It describes the fundamental of met-als of cutting, machining processes, machine tool opera-tions and applications. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The goal of this course is to state the principles of metal cutting processes and provide the required technical in-formation about machining processes to enable the stu-dent to handle and operate the machine tools in a proper way.
Behavioral Objectives : The student: Explains the fundamentals of metal cutting Recognizes the machining variables and their effects on the quality of products. Handles and operates properly the machine tools for optimum production.
Major: Production
Topics:
Theory:
1. Fundamentals of metal cutting 2. Cutting tool 3. Turning 4. Drilling and boring 5. Milling 6. Broaching 7. Abrasive machining 8. Super finishing 9. Economics of machining
Practice:
1. Drilling 2. Turning 3. Milling 4. Grinding 5. Practical projec
Textbook:
E. Paul De Garmo et al., Materials And Processes in Manufacturing, Macmillan Publishing Company, 1988
Lawrence E. Doyle, Manufacturing Process And Materials For Engineers, Prentice-Hall, Third Edition Additional Reading: T.T. EL-Midany & M.A. Mansour, Manufacturing Technology, King Abdulaziz University S.F. Kvav et al., Machine Tool Operations, McGraw-Hill Book Company
References:
Geoffrey Boothroyd, Fundamentals of Metal Machining and Machine Tools, McGraw-Hill Book Company John E. Schey, Introduction to Manufacturing Processes, McGraw-Hill Book company. 1988
Major: Production
2. Cutting tools Tool material Tool geometry Cooling in cutting Tool life
3. Turning Turning operations The lathe Lathe operations Production turning machines Process variables Describes the different types of machine tools and their construction Explains the operations of each machine Identifies the cutting tools and work holding devices Identifies the factors and variables affecting the process performance Determines the cutting conditions needed for certain operation
4. Drilling and boring Drilling & Boring machines Drilling & Boring operations
5. Milling Milling cutters and drives Milling machines Milling operations Process variables
Mechanical Technology Department 4 7. Abrasive machining The process of abrasive machining Abrasives Grinding wheels Grinding operations Other grinding processes Process limitations and design aspects
Major: Production
Explains the basics of abrasive machining Describes the types of abrasives and grinding wheels and specifications Explains grinding operations and other grinding processes Defines the process variables and limitations
8. Super finishing operations Honing Laping Explains the different types of super finishing operations and applications
9. Economics of machining operations Elements of machining costs Affecting factors Explains the machining costs ele-ments Optimizes the cost for economic ma-chining
Revision
Major: Production
12
2. Turning Lathe types and construction Cutting tools and tool holders Cutting speeds and feeds Centering work in a lathe Setup for machining between centers Machining between centers - Facing - Parallel turning - Filling, polishing & knurling - Taper turning - Grooving and form turning Threads and thread cutting Machining in a chuck Mounting work Facing, turning & cutting-off operation Drilling and Reaming Safety precaution
16 3. Milling Types of milling machines Milling machines attachments and accessories Milling cutters and processes Mounting & removing arbors and cutters Work holding devices Cutting speeds and feeds and depth of cut Milling operations The indexing head Gear cutting Recognizes the different types of milling machines and main components Identifies the different types of milling cutters and the purpose of each Operates the milling machine properly Mounts and removes the arbor and tool in milling machines Select the proper cutting speeds feeds and depth of cut for the job Produces flat surfaces and other surfaces Handles indexing heads Produces a spur gear Observes the safety precautions
Mechanical Technology Department - Types of gears - Cutting spur gear - Cutting of other gears
Major: Production
4. Grinding Types of grinding Grinding wheels selections Inspection of grinding wheels Turning & dressing grinding wheels Work holding devices Grinding flat surfaces Cylindrical grinding - External grinding - Internal grinding Safety precautions
Recognizes the different types of grinding machines and their construction Selects and specifies the grinding wheels Operates the different grinding machines properly Prepares the grinding machines for surface grinding Performs cylindrical grinding, internal and external grinding Observes safety precaution
16
5. Practical projects (Team work) General objectives Problem to be solved Possible solutions Comparison and evaluation of solutions Decision for one solution Execution of the project Preparation of the technical drawings Production methodsProduction plan Selection of necessary materials and tools Preparation of required materials and tools Manufacturing of parts Assembly of project 4 Evaluation Checking out of the project Correction if necessary Evaluation of the project Identifies the general objectives Defines the problem and suggests the best possible solution
Prepares the Drawing Suggests the production plans Determines the materials and machines needed Produces the parts
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title Material Testing Prerequisite Material Science
Major Code
Semester Course Description : This course is designed to provide the students with the fundamentals of mechanical properties of materials ob-tained by different destructive testing methods as well as identification of internal and external defects using NDI methods. The course includes mechanical properties of materials; destructive testing methods and non-destructive inspection using liquid penetrant, magnetic particle and ultrasonic inspection methods. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course aims at providing the students with the theoretical background and experimental skill for conducting different testing methods to determine mechanical properties of materials. The students also acquire the knowledge for identifica-tion of material defects such as surface flaws, porosity, cracks, etc.
Behavioral Objectives : The student: Determines mechanical properties of materials using destructive testing methods Identifies internal and external defects of mechanical parts via NDI methods Prepares technical reports regard his experimental finding.
Major: Production
Topics:
Theory:
1. Tensile Test 2. Compression Test 3. Torsion Test 4. Impact Test 5. Hardness Test 6. Non Destructive Inspection (NDI)
Practice:
1. Tensile Test 2. Compression Test 3. Impact Test 4. Hardness Test 5. Non Destructive Inspection (NDI)
Courtney, T. H., Mechanical Behavior of Materials, N. Y., McGraw-Hill, 1990. Textbook: Harmer E., George E. and George F., The Testing of Engineering Materials, McGrraw-Hill Book Company. 1982.
Additional Reading:
Serope Kalpakjian, Manufacturing Engineering and Technology, Addison-Wesley Publishing Co., 1992. Hardness Tests, Metals Park, Ohio: ASM International, 1987.
Harmer E., George E. and George F., The Testing of Engineering Materials, McGrraw-Hill Book Company. 1982. References: Halmshaw R. Non-Destructive Testing, Edward Arnold, 1991. Courtney, T. H., Mechanical Behavior of Materials, N. Y., McGraw-Hill, 1990. Pohlandt K., Material Testing for Metal forming Industry, N.Y Springer 1989.
Major: Production
1. Tensile Test Objective of tensile test Mechanical properties of materials Stress- Strain Curves Comparison of Stress- Strain Curves for different materials (e.g. Cast iron, mild steel and brass) Determination of: Yield strength, proportional stress, fracture stress, Modules of elasticity, Modules of toughness Factors affecting on mechanical properties of materials 2. Compression test Objective of compression test Effect of compression load on different materials Determination of compressive strength and natural compression limit of an engineering material.
2 States where to use compression test. Describes the behavior of a specified specimen under compression load and determines the maximum compressive strength. Determines the behavior of metal under torsion. Determines Shear stress, shear strain and modulus of rigidity.
3 3. Torsion Test Shear (Direct shear, Torsion, Pure shear stress, Shearing Strain) Torsion Specimen Torsion test apparatus and test procedure Effect of variables. 4 4. Impact test Objective of Impact test Description of the pendulum testing machine Testing procedure using Izods and Charpy methods Determination of impact energy 5 5. Hardness Tests Purpose of hardness tests Methods of hardness tests: Brinell Test Rockwell Test Vickers Test Comparison between the different methods 6 6. Non Destructive Inspection NDI Source of metal defects Objective of NDI Methods of NDI (Liquid penetrant inspection, magnetic particle inspection, ultrasonic inspection and X-Ray inspection) Revision
Explains scope of impact test and its application Identifies Standard test specimen and apparatus. Determines the energy (work done) for fracture impact test specimen. Explains scope and applicability of hardness tests. Describes main differences between the three methods of hardness test. Determines BHN of a specified specimen, the minimum thickness and the approximate hardness number using Rockwell method. Describes the main defects that may occur in the metal Describes the different testing method, equipment and procedure.
Major: Production
Recognizes the difficulties involved in conduction compression test Identifies and uses the compression testing machine Plots stress-strain curve of a specimen under compressive load and extract material properties.
Identifies and uses the pendulum impact testing machine and Conducts the impact test. Determines the relative impact resistance of steel.
Identifies hardness test machines Conducts impact tests (Brinell, Rockwell and Vickes) Determines the hardness number of an assigned test specimen.
Identifies the components of ultrasonic testing machine Carrying out ultrasonic test. Identifies the faults and its location Determine specimen thickness
Major: Production
Major Code
Semester Course Description : This course contains explanation and definition of the fundamentals of statics, study different types of friction, finding centre of gravity, methods of calculating moment of inertia, bending moment and torsion moment. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
30
General Goal : The student should be able to understand the principles of engineering mechanics, such as fundamentals of statics and friction, obtain necessary knowledge about mechan-ics of materials, such as area moment of inertia, princi-ples of bending and torsion.
Behavioral Objectives : The student: Defines the general fundamentals of statics Calculates the resultant force graphically and mathematically Describes stable and unstable balance terms Calculates friction force on horizontal and included levels, and rotation friction Calculates moment of inertia of different areas Draw shear force and bending moment diagrams Draw torsion stress diagram
Major: Production
Topics (Theory):
Meriam, J.L.& Kraige, L.G., Engineering Mechanics : Statics , vol. 1, 4th edition, 1998, New York, John Wiley . Textbook: Meriam, J.L.& Kraige, L.G., Engineering Mechanics : Dynamics, vol. 2, 4th edition, 1998, New York, John Wiley .
Additional Reading:
Joseph F. Shelly, Engineering Mechanics, Statics and Dynamics, 1980, MC Graw Hill Inc. References: F.P. Beer and E.R. Johnston, Mechanics of Materials , 1990, MC Graw Hill Inc.
Major: Production
9 3. Area moment of inertia Moment of inertia in practice Relationship between moment of inertia gravity centre and section modulus Moment of inertia for different sections 9 4. Bending Normal force, shear force and bending moment diagrams Main equation of bending moment Bending stress diagram
Major: Production
Major: Production
Department Mechanical Technology Course Title Computer Aided Drafting Prerequisite Engineering Drafting
Major Code
Semester Course Description : This course comprises an introduction to CAD Software and how to use these for drawing mechanical parts according to DIN 406; Assembly drawing and preparation of technical documents; Importance of jigs and fixtures; Design and developments of some production aids. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
60
General Goal : The student should be able to use CAD software command. He should be able to apply the rules of engineering drawing, prepare a complete assembly drawing and technical documents as well as the construction of some production aids (e.g. drilling jigs and different fixtures).
Behavioral Objectives : The student: Creates and modifies an engineering drawing using CAD software. Draws drilling jigs and fixtures used in turning operation. Puts drawing dimensions and technical documents.
Major: Production
Topics (Practice):
. 2. . 4. 5.
Elements of CAD System Getting Started with AutoCAD Engineering Drawing Using AutoCAD Assembly Drawing using AutoCAD Case Studies
Textbook:
Beall Michael E., Inside AutoCAD 14, New Riders Pub. 1997
Additional Reading:
AutoCAD: Drafting and 3D Design, Mark Merickel, New Rideres Publisher, 1990
1. Beall Michael E., Inside AutoCAD 14, New Riders Pub. 1997 References: 2. Inside AutoCAD Windows, New Riders Publishing, 1995. 3. Frank Conner, AutoCAD Tutor, NRP, 1992.
Major: Production
12
12
Creates various working drawings using AutoCAD commands and engineering drawing principles
10
Draws detail and assembly drawing of a machine part Describes different types of fastening elements Reads technical drawings Draws various fastening elements Create an assembly drawing Describes the benefits of using jigs and fixtures Distinguishes between different positioning and fixing elements. Draws a spur gear
14
Major: Production Draws drilling jig Draws a fixture for turning operation.
Major: Production
Major Code
Semester Course Description : This course introduces the student in to the basic theoretical and practical principles of control systems such as pneumatic, hydraulic and their electrical executions. Also a short introduction to PLC application is given. Developing and building up of simple models of different control systems are practiced. The main differences between pneumatic and hydraulic systems are experienced by small experiments. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The student should be able to analyze engineering systems as control systems with different problems and knows the common possibilities to solve them. He should develop relative simple circuit diagrams for pneumatic, electro pneumatic reps. hydraulic control systems in order to solve technical problem definitions. He should also build up the different solutions in the pneumatic reps. electro pneu-matic lab and carries out some instructive experiments in the hydraulic laboratory.
Behavioral Objectives : The student: Explains the principles of control systems Describes the construction of pneumatic and hydraulic control systems Shows the elements of pneumatic and hydraulic circuits and applies them in lab Names the elements of electro pneumatic reps. electro hydraulic circuits and uses them for problem solutions in lab Explains the principles of basic control systems and applies them in lab exercises Describes the principles of sequence control systems and applies the needed components in lab Explains the functions of power and speed regulation in pneumatic systems and carries out some examples Describes advantages of PLC application Points out the principles of hydraulic systems and carries out suitable experiments.
Major: Production
Topics:
Theory:
1. Principles of control systems 2. Elements of pneumatic and hydraulic circuits 3. Elements of electro pneumatic and electro hydraulic circuits 4. Principles of basic control systems 5. Sequence control systems 6. Introduction in PLC - application 7. Power and speed regulation in pneumatic systems 8. Principles of hydraulic systems
Practice:
1. Construction of pneumatic and hydraulic control systems 2. Elements of pneumatic and hydraulic circuits 3. Elements of electro pneumatic and electro hydraulic circuits 4. Principles of basic control systems 5. Sequence control systems 6. Introduction in PLC - application 7. Power and speed regulation in pneumatic systems 8. Principles of hydraulic systems
Textbook:
Course Manual for Fundamentals of Control Technology by Karlheinz Mayer GAT Riyadh
Additional Reading:
Fundamentals of Pneumatic Control Engineering A text book from FESTO DIDACTIC ISBN 3-8127-0851-5 Inroduction to Pneumatics by H.Meixnber / R. Kobler Published by FESTO
References:
Training System for Control Technology by FESTO DIDACTIC Electropneumatics Basic Level Book of exersices with solutions ISBN 3 - 8127 - 0891 - 4
Major: Production
1. Principles of control systems Different examples e.g. punching or feeding device Block diagrams Break down of the control chain Criteria for pneumatic, hydraulic and electrical application Automation systems, heavy machines
2. Elements of pneumatic and hydraulic circuits Signal, processing and control elements Working and their assigned elements Media ways and switching positions Execution elements: manual like push button, lever, etc., mechanical like roller plunger etc. Via pressure and electrical power
Describes the different levels of circuit diagrams Names cylinder and throttle Explains principles of symbols in pneumatic and hydraulic circuits Uses operating symbols of valves
3. Elements of electro pneumatic and electro hydraulic circuits Switches and relays Elctro magnetic valves and working elements, assigned elements to them Normal open, normal closed, changer over etc. Solenoids and the electro magnetic effect Describes the elements of the electrical and the pneumatic/hydraulic part of a circuit diagram Uses symbols for the electrical part of circuit diagrams Explains the function of an electromagnetic valve
4 4. Principles of basic control systems Direct and indirect controlled systems (pilot control) Single acting cylinder direct controlled by a 3/2 valve Double acting cylinder direct controlled by a 5/2 valve Difference between single acting and double acting cylinders 3/2 normaly closed disk seat valve 3/2 normaly closed disk seat electro magnetic valve pneumatic piloted valve electro magnetic piloted valve Explains the purpose, function and conditions of different given technical examples Names the needed elements to solve the problem Explains the different structure of cylinders Descibes the design and the function of a pneumatic 3/2 valve Descibes the design and the function of a electro magnetic 3/2 valve Sketches the according circuit diagram Defines and describes direct and indirect controlled systems Compares indirect controlled systems in pure
Mechanical Technology Department pneumatic and electro pneumatic design 2 Logic control systems AND, OR and NOT Two-hand releasing Switching at different places Series and parallel connection and logic components Normal open valve Two-pressure valve, shuttle valve
Major: Production
2 Holding control systems (memory control) Storage of given impulses Pneumatic and electro magnetic double pilot valve Relay and self-latching circuit
Distinguishes between different types of basic logic controls Names typical applications of AND, OR and NOT Discribes solutions in pure pneumatic and electro pneumatic designs Explains the function of logic components in pure pneumatic systems Designs simplified logic circuit diagrams as pure and electro pneumatic systems Explains the meaning of holding element control Names the used elements Explains the realisation of a holding control
5. Sequential control systems 2 Priciples Signal transmission Process and time depentend signal transmission Function diagram and function chart 2 Process controlled systems Position, pressure, counting, temperature, Mechanic acted valves and limit switches Pressure-sequence valve and pressure switch
Explains the characteristics of sequence controls Distinguishes between different signal transmissions Describes sequence processes by drafting graphic representation Names different signal parameters of processes Prepares the function and circuit diagramms as solution for a position depending sequence in pneumatic and electro pneumatic design Names the possibilities to transmit signals depending on pressure Prepares the function and circuit diagramms as solution for a pressure depending sequence in pneumatic and electro pneumatic design Describes the pneumatic and electric elements for time delay Prepares the function and circuit diagramms as solution for a time depending sequence in pneumatic and electro pneumatic design Explains the general property of a PLC controlled system Compares between traditional electro pneumatic and PLC controlled systems Names components of PLC controlled systems
6. Introduction in PLC application Programmable Logic Controls use a program language Hardware wired versus open, any time changeable software programming Sensorics, actorics, PLC hardware and software Sequencies and cycle process Function chart, ladder diagram and
Mechanical Technology Department statement list Input and output commands, logic algorithem, timer, counter, set and reset
Major: Production Explains the general function of a PLC system Describes the general PLC programming possibilities Names the most important program structures
7. Power and speed regulation in pneumatic systems Pressure reducing and pressure relief valve 4 Data sheets of cylinders One way flow control valve (throttle) Advantage of exhaust air flow control
8. Principles of hydraulic systems Power supply, one way valve, pressure relief valve Changing energy to pressure, delivering of constant oil flow Constant oil delivery of the pump Pressure depending oil division Flow control and pressure relief valve. 2
Explains the prinziple of the power regulation Names the pressure regulating devices Calculates power of different cylinders and pressures Explains the prinziple of speed regulation Justyfies supply air and exhaust air flow control
Revision
Analyses the hydraulic circuit symbols Explains the functional performance of hydraulic pumps Calculates pressure, flow quantity and piston speed in a hydraulic circuit Explains the difference of speed control in pneumatic and hydraulic systems Describes the speed regulation as a division of the oil flow Names the available elements for initiate the division of the oil flow.
Major: Production
Major: Production
identifies real elements used in a built up control system sketches a circuit diagram according to the built up control carries out a simple example to set up a control system according to a given circuit diagram analyses the function of an existing very simple control system sketches the circuit diagram according to the existing control carries out a simple example of an electro pneumatic control
4. Principles of basic control systems Direct and indirect controlled systems (pilot control) single acting cylinder indirect controlled by a 3/2 push button acted and a 3/2 pneumatical acted valve single acting cylinder indirect controlled by a normal open electrical switch and a 3/2 electro magnetic acted valve Logic control systems two-hand releasing alternative switching on or off NOT e.g. door locking system Holding control systems (memory control)
carries out direct and indirect controlled circuits in pure and electro pneumatic design
builds up and executes simplified logic pneumatic and electro pneumatic circuits
builds up and executes holding element control circuits builds up and executes electro pneumatic holding control circuits
Major: Production
2 5. Sequential control systems Priciples different systems: process and time depentend 2
defines the signal sequence in a built up control system sketches function diagrams according to an existing control system sketches circuit diagrams according to an existing sequence control carries out the developed position, pressure and counting depending control systems
carries out the developed time depending control system rializes the differences between a built up wire programmed and a PLC programmed example sketches the function chart of the existing control follows the program run according to the existing statement list stepwise describes the procedure for changing the program run
6. Introduction in PLC application two double acting cylinder time related controlled
2 builds up and executes a pneumatic system with a pressure and speed regulated double acting cylinder compares supply and exhaust air flow regulation by experiments
7. Power and speed regulation in pneumatic systems installation of pressure reducing and one way flow control valve installing of one way flow control valve in different flow directions
8. Principles of hydraulic systems one single acting cylinder loaded by a weight adjusting different pressures flow meter curve of flow characteristitcs 2
builds up a simple hydraulic system analyses the function of the pressure relief valve compares measured speed with precalculatet values builds up a test system for meassuring the characteristics of pressure relief valve
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title CNC Technology Prerequisite Machining Technology
Major Code
Semester Course Description : This course contains overview of the evolution of NC technology, its applications; coordinate system, displacement measurements and control systems; as well as development of simple CNC milling and turning programs. It also includes planning of machining operations and the use of computer to prepare and test programs, and then implement them for machining on CNC milling and lath. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The student will have a good knowledge of the principles of CNC programs structure, and the necessary procedures for simulation and manufacture.
Behavioral Objectives :
The student
Writes basic milling and turning CNC programs, Uses the computer for editing and verifying these programs Operates both CNC milling and lathe machines according to safety precautions, for actual machining.
Major: Production
Topics:
Theory:
1 Introduction 2 The Coordinate Systems 3 Positioning and Datums 4 Types of Control Systems for tool motion 5 Programming CNC milling & turning
Practice:
1 Introduction 2 Identification and operation of CNC milling and turning machines. 3 Program development and transfer to CNC machine 4 Program Simulation without tool for verification 5 Programs execution for actual machining
Textbook:
Warren S. Seams, Computer Numerical Control Concepts and Programming, Delmar Publishers INC, 1990
Additional Reading:
F.Nanfara, T.Uccello and D.Murphy, The CNC Work book : An introduction to computer Numerical Control, Addison-Wesley Publishing Company, 1995.
1. B. Leathman-Jones, Introduction to Computer Numerical Control, Pitman Publishing 1994 References: 2. G.E. Thyer, Computer Numerical Control of Machine Tools, Industrial Press 1991
Major: Production
2. The coordinate systems Two dimensional Cartesian Coordinate System Three Dimensional Cartesian Coordinate System Polar Coordinate System Axes Identification Right-Hand Rule of Coordinates Coordinate System for CNC lathe and milling machines
Describes the cartesian Coordinate and polar Systems Defines a CNC machine axis of motion Names the necessary assumptions to identify a machine axis Applies the Right-Hand Rule for CNC lathe and milling machines
4 3. Positioning and datums Positioning System: Absolute Positioning, Incremental (chain) positioning Setting the programming origin: Milling zero points: Machine zero-point (M) Workpiece zero-point (W) Reference point (R) Setting zero-point with the Edge Finder Setting zero point in the tool axis Turning zero-point Machine zero-point (M) Workpiece zero-point (W) Tool Mount Reference Point (N) Tool Edge Point (P) Machine origin and Work Coordinate Systems: Describes the difference between absolute & incremental positioning
Defines the zero-points for milling and lathe machines Describes setting the programming zero-point in milling & lathe machines
Major: Production
Describes the difference between datum and delta dimensioning Dimensioning: Datum dimensioning; Delta dimensioning Explains the three types of control systems and their use in CNC machines Classifies CNC machines according to old & modern methods and explains the difference
4 - Types of control systems for tool motion Positional control (P) Linear-path control (L) Continuous-path (Contouring) control Classification of CNC machines: old method: according to no. of axes of continuous control (C);modern method: based on the three types (P,L & C) 5 - Programming CNC milling and turning machines Program structure according to Word Address Format Preparatory Words (G-Function): 1. Milling: G0 G1 G2 G3 G17 G18 G52 G51 G90 G91 G40 G41 G42 G43 G44 G98 G99 2. Turning: G00 G01 G02 G03 G94 G95 G96 G97 G92 G53 G54 G55 G56 G57 G58 G59 Miscellaneous Words (M-Function) 1. Milling: M3 M4 M5 M6 M8 M9 M30 M6 M66 2. Turning: M03 M04 M05 M08 M30 Technological Words : F, S, T Simple Milling Programs: (linear and circular interpolation): Based on cutter center path Based on workpiece dimensions Simple Turning Programs: Face turning Longitudinal turning Circular interpolation 2
18
Explains the principles of CNC programs structure Differentiates between preparatory, miscellaneous and technological words
Writes basic milling and turning programs based on Word Address Format to perform linear and circular interpolation (whether based on cutter center path or cutter diameter compensation)
Revision
Major: Production
Explains main parts and driving system at different axes Uses machining data to select speeds & feeds Changes the tools and knows their movement Starts operating the machine according to safety precautions
Prepares and enters basic CNC programs into computer Interprets the graphics associated with the program Transfers program and data from the computer to the machine Simulates the program on the computer screen Tests and runs the program on the machine without tools Corrects any found errors Prepares the machine for operation Fixes the workpiece according to clamping principles Adjusts the zero-point of the workpiece and enters such data to the machine Produces first-off component after initial proving Carries out measurement test and correct errors for final part program proving Follows the mentioned sequence for production.
4. Program Simulation Without Tool for Verification Program simulation on the computer screen Program test run on the machine without tools Program verification and correction
40
5. Programs Execution for Actual Machining Machine preparation Workpiece clamping Workpiece zero-point setting Program execution without tools Actual program execution First-off component inspection Production of other different workpiece.
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title Machine Elements & Machine Tool Components
Major Code
General Goal : The student will have a good knowledge of the functions and basics design calculations of various machine ele-ments, in addition to clear understanding of machine tools classifications and their components.
Behavioral Objectives : The student: Describes various machine elements Carries out basic calculations for such elements Identifies basic machine tool components Explains their functions, with special focusing on the stepped gearboxes and the devel-opment of their layouts and structural diagrams.
Major: Production
Topics (Theory):
1. Rivets, Welding & Bonding 2. Threaded fasteners & power screws 3. Shafts 4. Gears 5. Bearing 6. Clutches and brakes 7. Belts Drives 8. Types & Classification of machine Tools 9. Basic Elements of Machine Tools 10. Gear Boxes for Machine Tools
Textbook:
R.C. Juvinall, K.M. Marashek, Fundamentals of machine Component design, John Wiely and Sons, 1991
Additional Reading:
Kenneth S. Edwards, JR. Robert B. Mckee, Fundamentals of Mechanical Component Design, McGraw-Hill, 1991
References:
M.F. Spotts, T.E. Shoup, Design of machine elements, Prentice-Hall intern., 1998
Major: Production
2. Threaded Fasteners and power screws Kinds of threads, terminology and standards Basic threaded fastener types Power screw : total force on the threads
Identifies different kinds of threads in commercial use Describes use and design of power screws
Selects gear type according to application Calculates the dimensions of a spur gear
5. Bearings Sliding and rolling-element bearings Features and type of loading, types and applications Selection of ball bearings from a manufacturer catalogue
Compares sliding and rolling-elements bearings in terms of features, properties and uses Selects ball bearings according to design requirements
6. Clutches and Brakes Clutches: - Disk clutch, - Cone clutch: torque Brakes: - Disk brakes, - Band brakes: torque
Explains function of both clutches and brakes Calculates torque capacity for a clutch or a brake
Mechanical Technology Department 3 7. Belt Drives Types (flat belts, V-belts and toothed belts) and uses Basic torque equation for a flat belt Standard cross sections of V-belts
Major: Production Explains various types of belts as power transmission elements Calculates the limiting torque for a flat belt Explains the standard size of a V-belt
8. Types and Classification of Machine Tools Machine tool definition and function Basic requirements of a machine tool design Materials removal techniques: single-point tools, multi-point tools, abrasives Kinematic principles of operation : generation, copying and forming Classification based on : produced surface, purpose, automation level
Explains the different types of machine tools, their operating principles and applications Classifies machine tools according to various classification methods
9. Basic Elements of Machine Tools Structure: bed, column and guide ways Guide ways classification: - Sliding contact: flat, V-shaped & inverted vshaped, dovetial and cylindrical - Rolling Contact: ball and rolling bearings Frictionless guide ways Tool and work holders Spindles and spindle bearings
Describes the main elements of a machine tool Specifies the functions of each element and its basic design features
Carries simple calculations for bed deflection and its natural frequency
10. Gear Boxes for Machine Tools Gear box elements and function Principles of stepped speed regulation Spindle speed gradation: arithmetic, geometric and harmonic progression Geometric Progression: Progression ratio, number of steps Layout of spindle speeds: Ray diagrams Structural diagram of gear box drive: Germar diagram Simple gear box design examples : e.g. Norton gear box in a lathe.
Revision
Major: Production
Department Mechanical Technology Course Title Production Planning and Control Prerequisite
Major Code
Semester Course Description : Production planning and control encompasses a number of activities. Determining end items demand, translating end-item demand into feasible manufacturing plans, es-tablishing detailed plans for material features and capac-ity to support the overall manufacturing plans, and finally helping execute these plans. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
30
General Goal : The main objectives of the course is to explain clearly the fundamentals of production planning and control tech-niques so that the student will be able to use these infor-mation in managing and controlling production to ensure that the products are produced at the right time, right quantities, and desired quality, at minimum cost.
Behavioral Objectives : The student: Uses principles of inventory control, MRP or JIT to plan production Controls by finding machine loading & job sequence
Major: Production
Topics (Theory):
1. Introduction 2. Demand management 3. Aggregate production planning (A.P.P) 4. Capacity planning 5. Inventory control 6. Material Requirement Planning (MRP) 7. Just-In-Time (JIT) production 8. Shop floor scheduling and control
Steven Nahmias, Production And Operations Analysis, McGraw-Hill, 1997 Textbook: Thomas E., Manufacturing Planning And Control Systems, VOLLMANN et al., Third Edition, 1992, IRWIN
Additional Reading:
David D. Bedworth et al., Integrated Production Control Sys-tems, John Wiley & Sons, 1982
References:
Major: Production
4 3. Aggregate production planning (A.P.P) The objective of aggregate production planning A.P.P. for high variety discrete product manufacturing environment Aggregate production planning options Master production schedule 4 4. Capacity planning Definitions Capacity planning role in manufacturing planning and control Capacity planning techniques Management and capacity planning Data for capacity planning 5. Inventory control Functions of inventory Inventory costs ABC inventory system Economic Order Quantity (EOQ) for purchased parts Inventory order policies Explains the functions of inventory in production Identifies the cost elements and their relation to volume of stock Explains the ABC inventory system and its uses Defines the (EOQ) using simple models Defines capacity planning Explains the measure of capacity Classifies capacity planning control horizons Describes the capacity planning techniques and applications
4 6. Material Requirements Planning (MRP) Over-view Definitions How does MRP work 2 7. Just-In-Time (JIT) production The concept The benefits of JIT Comparison with Inventory and MRP methods
Explains the basic concept of MRP Defines the terms used in MRP Determines how many of each item in the bill of material must be manufactured or purchased and when using MRP information and Basic Records Explains the basic concept of JIT and the necessary requirements for its application Compares the three approaches for production planning
8. Shop floor scheduling & control The main objective Operations scheduling: Machine Loading Job Sequence: Priority Rules Gantt Charts Line of Balance
Explains the main objective of shop floor control Uses the various priority rules (e.g. Earliest due date & Shortest processing time) to find job sequence
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title CAD - CAM Technology (Elective 1 Course I)
Major Code
General Goal : The main objective of this course is to provide the students with the theoretical background for conducting different testing methods to determine mechanical properties of materials. The students also acquire the knowledge for identification of material defects such as surface flaws, porosity, cracks, etc.
Behavioral Objectives : The student: Generation of part contour using CAD Specify the technical data, working plan and machining procedure Generation of a part program in CAM mode. Execution of the generated part program using a CNC machine
Major: Production
Topics:
Theory:
1. CAD/CAM Concept 2. Elements of CAD module 3. Part Design and Drafting 4. File Handling 5. CAM Elements 6. Program Generation 7. Machining
Practice:
1. CAD/CAM Concept 2. File Handling and post-editing by AutoCAD 3. The CAD module of CAD/CAM software 4. Case study: Turning 5. Case study: Milling 6. Machining
Textbook:
Groover, Mikell P., CAD/CAM Computer Aided Design and Manufacturing, Englewood Cliffs, Printice Hall, 1990 EMCO WinCAM Software Guide, 1996 (Selected Parts)
Additional Reading:
Seams W., Computer Numerical Control: Concepts and Programming, Albany, N. Y.: Delmar 1990.
Valliers, David , Computer Aided Design and Manufacturing, Englewood Cliffs, Printice Hall, 1990 References: Groover, Mikell P., CAD/CAM Computer Aided Design and Manufacturing, Englewood Cliffs, Printice Hall, 1990 EMCO WinCAM Software Guide, 1996
Major: Production
Major: Production
6 6. Program Generation Import ASCII data, Path identification, Program generation Cycles and Subprograms Periphery CAM (Spindle status, Clamping device, Coolant, ... etc.) Using CAM module in CAD/CAM software to generate part program for milling and turning 4 7. Machining Setting the machine Operation break down sheet Clamping devices Tool plan 2 Revision Prepares the necessary machining documents (e.g. Tools, machining data, clamping devices, etc.) regarding a specific workpiece Uses of file handling facilities for importing DWG file into CAM module Make the necessary changes in the imported drawing Defines the main milling and turning cycles Explains and uses of subprograms. Make the necessary changes in the generated CNC part program
Major: Production
2. File Handling and post-editing by AutoCAD 4 .DWG and .DXF files by using OPEN, IMPORT and INSERT BLOCK Export ASCII data (DXF format) Connected intersections of lines, not contour lines on the contour layer etc. Erasing or freezing frames, texts, dimensions, etc.
3. The CAD Module of CAD/CAM Software 4 The drawing editor (file, edit operation, set up functions, tool library) Define unmachined part, target control and target machine setup Display setting Drawing files and project files Zero resp. Reference point Machining position Contents 6 4. Case Study: Turning Example of CNC turning part (longitudinal, face and cone turning, chamfering, fillets and threading) Turning cycles Subroutine facilities 6 5.Case Study: Milling Example of CNC milling part (linear, contouring, drilling, circular and pocket milling) Milling cycles Programming aids
Tests the main feature of CAD module Sets the general presetting as well as display presetting according to a given example Opens projects and imports drawing files Sets zero point of workpiece (turning and milling) Shifts the contour to the machining position
Prepares the CAD drawing for turning operation to work on CAM module Identifies the contour to be machined Uses single tool motion, cycles and subroutines. Edit, analyzes and optimizes the generated program Tests the generated program via simulation Prepares the CAD drawing for turning operation to work on CAM module Identifies the contour to be machined Uses single tool motion, cycles and subroutines Edits, analyzes and optimizes the generated program
6. Machining Setting the machine Manufacturing the workpiece on CNC turning machine using the transferred program Manufacturing the workpiece on CNC milling machine using the transferred program Sets up the machine according to the working documents Chooses and sets up the needed tools according to the working documents Selects and prepare the raw materials needed Transfer the developed program to the machine Make the necessary changes according to the machine specifications Simulates the program on the machine (dry run) Machines the workpiece Measure the results Sends the optimized program back to the CAD/CAM system
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title Plastics Technology (Elective 1 Course II) Prerequisite Forming Technology, Material Science
Major Code
Semester Course Description : This course covers the basic polymers, function and use of additives as well as properties and applications of thermoplastics and thermosets. The different methods of plastic forming are discussed and analyzed. These meth-ods include: compression molding, injection molding; blow molding, extrusion thermoforming. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
30 30
General Goal : This course aims at providing providing the students with the knowledge of some processing methods, including their capabilities and limitations.
Behavioral Objectives : The student: Identifies the forms of raw materials for processing plastics into products Describes the features of an extruder Applicates different forming processes to produce: complex shapes, fine detailed shapes Identifies the products which can be produced by a specific production method.
Major: Production
Topics:
Theory:
1. Polymers 2. Mold Design 3. Extrusion 4. Injection Molding 5. Compression molding 6. Blow molding 7. Thermoforming 8. Economics of forming Plastics.
Practice:
1. General Properties of Polymers 2. Mold Design 3. Extrusion 4. Injection Molding 5. Compression molding 6. Blow molding 7. Thermoforming.
Textbook:
Lecture Notes. Brown R., Design and Manufacture of Plastic Parts, New York: Wiely 1980.
Asrarita G. and Nicolais L., Polymer Processing and Properties, New York: Plenum, 1985. Additional Reading: Macosko C., Fundamentals of Reaction Injection Molding, New York: Oxford University Publishers, 1989. Morena, J. Advanced Composite Mold Making, N.Y.: Van Norstrand Reinhold, 1988.
Beck, R. D., Plastic Product Design, New York: Van Norstrand, 1980. Brown R., Design and Manufacture of Plastic Parts, New York: Wiely 1980. References: Cheremisinoff N., Product Design and Testing of Polymeric materials, New York: Marcel Dekker, 1990. Donal V, David P. and Dominick V., Designing with Plastics and Composites, New York: Van Norstrand Reinhold, 1991.
Major: Production
Describes where to use dies and molds Describes conditions of coating molds Makes the essential calculations for making a mold
4. Injection Molding Use of injection molding The process, equipment and material Injection molds Molding variables Injection molding of spur gear
Explains why IM is applied to produce complex and fine details Explains how an injection machine is rated Explains the procedure followed to produce a specified product using IM.
5. Compression molding Molding equipment Component design considerations Processing of material prior to molding
Identifies some products produced by compression molding Explains the procedure of compression molding Identifies different types of molding tools
Mechanical Technology Department Molding procedure Preheating Molding faults (Blistering, Internal voids, Oversize molding, cracking of the molding upon ejection, etc.). Types of molding tools Cooling fixtures and shrink block
Major: Production
6. Blow molding The process Extrusion blow molding (Melt viscosity, Thickness control, Clamping, Shrinkage) Injection Blow Molding. Design Guidelines Advantages of blow molding Difference between IBM and EBM
Explains the different variables that affecting the blow molding process
Describes the differences between IBM and EBM Identifies different types of molds for thermoforming Describes the sequence of manufacturing of a specified product produced by thermoforming
8. Economics of forming Plastics Material limitation Design limitation (Size, surface finish, shape configuration). Equipment capital cost. Production rate.
Revision
Major: Production
Major: Production
1. General Properties of Polymers Physical properties Mechanical properties: (linear, branched and cross linked polymers) Identification of plastics: (PV,PE, PP, PS, PA, PMMA, PF) Burning test: (Behavior of plastic materials when heated) Additives (identify different additives) Use of plastic materials
4 2. Mold Design Types of molds Basic dimensions Main defects Applications Describes the different types of molds Identifies molds for specific use. Identifies the main defects that may occur in molds Makes the essential calculations for making a mold
4 3. Extrusion Types of extruders The materials used and main products Procedure of extrusion Effect of process parameters on the product Plant visiting Identifies different extruders Explains the effect of temperature on the produced shape Describes the procedure followed and carries out experiments
4 4. Injection Molding Specification of injection molding machine The injection molding tool Materials used for injection molding Procedure of injection molding The influencing parameters: (Injection path of screw, injection pressure, tool temperature) Recognizes the main parts of an injection molding machine Explains the machine safety precaution. Identifies materials and injection molding tools. Explains the main parameters affecting the injection molding process. Performs the test and reports results
Major: Production regarding: injection temperature, injection pressure, cooling time, etc.
5. Compression molding Specification of facilities used for compression molding (press force, molding tools, precision scale, saw, etc.) Materials used for compression molding Test procedure Molding faults (Blistering, Internal voids, Oversize molding, cracking of the molding upon ejection, etc.).
Identifies some products produced by compression molding Identifies different types of molding tools. Performs the test and reports main results (e.g. pressing die temperature, capacity, compression force, and compression time). Recognizes the problems connected with compression molding
6. Blow molding The students visit one of the plastic forming factories where they identify the machine, tools, the procedure followed and main products
Explains the different variables that affecting the blow molding process Describes the blow molding machine Describes the production process
7. Thermoforming Specification of the vacuum forming machine Male and female pattern Testing materials Test procedure Studying of the main parameters.
Identifies different types of molds for thermoforming Describes the sequence of manufacturing of a specific product produced by thermoforming Reports the results of experiments (underpressure, heating power, heating time, cooling time, etc.) and interprets the observations.
Revision
Major: Production
Major: Production
Department Mechanical Technology Course Title Quality Control (Elective 2 Course I) Prerequisite Mathematics - II
Major Code
Semester Course Description : The course covers the fundamentals of quality control and its importance in industry. Control charts, acceptance sampling and process control techniques are covered as well as quality costs and reliability. The practical part covers applications and computer uses in quality control. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
30 30
General Goal : The main objective of the course is to offer the student a chance to learn and understand the basics of quality con-trol and be able to apply quality control techniques in actual production and also to enable the student to use computers and available software.
Behavioral Objectives : The student: Explains the fundamentals of quality control and its importance Identifies the quality control techniques and its practical implications as a tool to control quality of products. Uses and construct the control charts and acceptance sampling to control quality Uses computer to practice quality control activities
Major: Production
Topics:
Theory:
1. Introduction to quality 2. Fundamentals of statistics 3. Control charts for variables 4. Control Charts for attributes 5. Forms of acceptance sampling plans 6. Process control 7. Quality costs 8. Total quality control concept 9. Reliability
Practice:
1. Control Charts 2. Process Control 3. Reliability Measurements 4. Computer Aided Quality
Textbook:
A.V. Feignbaum, Total Quality Control, McGraw-Hill Book company, 1983, Third Edition
Additional Reading:
Dale H. Besterfield, Quality Control, Prentice-Hall International Editions, 1990, Third Edition
J.M. Juran & Frank M.Gryna, Quality Planning And Analysis, McGraw-Hill Book Company, 1980, Second Edition References: Instrumentation Catalogue - Measurement and Automation, National Instruments, pp. 119-120, 1998
Major: Production
Recognizes the fundamentals of statistics and uses statistics as a technique for quality control Classifies the manufacturing variations and their possible causes Explains and defines the terms, frequency distribution, mean, standard deviation etc. Calculates the standard deviation and range Explains the uses of frequency distribution in quality control and its importance Determines the sample size used in connection with frequency distribution calculations Explains the basic concept of control charts and their applications Defines the control charts for variables and attributes Constructs the control charts and calculates the control limits Uses control limits for controlling the quality for actual production Identifies the types of limits Analyzes results to take the corrective action
3. Control Charts for Variables Control chart approach Uses of control charts control limits Modified control limits Practical aspects of control charts Applications
4. Control Charts for Attributes Probability concept Random variable and probability distribution Statistical inference Hypothesis testing Construction of control charts Applications
Explains the probability concept Describes the methods of statistical inference Determines the sample size required to achieve a specified accuracy Tests hypothesis Constructs the control chart for attributes Explains the significance of control charts for attributes and applications
Major: Production
Describes the operating characteristic curve (OC) Describes the types of sampling plans and their uses Uses the sampling tables properly. Applies acceptance sampling for controlling quality
6. Process Control Process control Techniques Machine and process capabilities Incoming Material inspection Production testing Vendor rating and vendor performance
Applies process control techniques to control the process, incoming materials, production and the supplier
7. Quality Costs Concept Internal and External Failure costs Appraisal costs Prevention costs
Classifies the quality costs and analyzes these costs for the purpose of reducing them and economize the process of quality control
8. Total Quality control Concept Scope of total quality control Total quality management
Explains in general terms the concept of total quality and its implications
9. Reliability Definition of product reliability Measurement of reliability Nature and classification of failure Establishing the product reliability curves
Explains product and system reliability Identifies failure rate-curves Describes the measurements of reliability and reliability Explains in general terms how to establish the productreliability requirements
Revision
Major: Production
2. Process Control Process capability measurements Establish the shop tolerance of drilling operation e.g.
3. Reliability measurements
Asses reliability from life information using graphical techniques and analysis of results Describes the importance of computers in quality Uses software to establish control charts and other techniques of quality control
10
4. Computer Aided Quality Control charts Computer based sampling plans Computer program for sampling tables On line quality control The use of computer in the optimization and sequential tests
Revision
Major: Production
Department Mechanical Technology Course Title Manufacturing Systems (Elective 2 Course II)
Major Code
Behavioral Objectives : The student: Solves cell formation problems in GT layouts whether manually or by computer Applies lead through programming and robot language programming for entering the commands into computer memory as a controller for industrial robots Writes programs for PLC systems
Major: Production
Topics:
Theory:
1. Introduction - Manufacturing Systems Approaches 2. Traditional Factory Layouts 3. Group Technology 4. Cellular Manufacture 5. Flexible Manufacturing Systems 6. Automated Flow Lines 7. Industrial Robotics 8. Industrial Logic Control
Practice:
1. Factory Layout Development by Computer 2. Computerized Cell Formation Algorithms 3. Robot Programming 4. Workcell Control 5. PLC Programming
Textbook:
M.P. Groover, Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall International Editions, 1987
Additional Reading:
Reza A. Maleki, Flexible Manufacturing Systems: The Technology and Management, Prentice-Hall, 1991
References:
Chrysallouris G., Manufacturing Systems, Theory and Practice, Springer Verlag, 1992
Major: Production
2. Traditional Factory Layouts Layout of conventional manufacturing facility: Static, process-based; product-based: flow lines, continuous production
3. Group Technology (GT) Concept and advantages of GT Cell formation methods: visual inspection, part coding and classification, and analysis of production process Production process based methods: Rank Order Clustering Analysis (ROC 2) and Linear Cell Clustering Algorithm (LCCA): theoretical basis, use of computer for analysis 4. Cellular Manufacture (CM) Types of CM according to material handling procedure: single, group with manual handling, group with semi-integrated handling, flexible manufacturing system (FMS) Best M/C arrangement Applications 5. Flexible Manufacturing Systems (FMS) Definition Components of an FMS Types of FMS: (dedicated and random order) Where to apply FMS Technology FMS workstations: (Machining centers, head changers, milling modules, turning modules, assembly workstations, inspection stations) FMS layout configurations: (in-line, loop, ladder, open-field, and robot-centered cell)
Understands GT as a manufacturing philosophy Describes the benefits of GT compared with process-based layouts Explains the differences between the three types of cell formation techniques Explains the principles of (ROC2) and (LCCA) as examples of production based methods that could be computerized to obtain part families and M/C groups for cells Classifies and describes CM according to material handling procedure Determines the arrangement of M/Cs in the cell based on work processing requirements using from-to-charts Identifies the components of an FMS (based on definition) and specifies their functions Classifies FMS according to variety of part family, and also by layout Compares FMS with high production transfer lines and low production NC M/Cs Identifies FMS workstations (according to type of work) and describes them
Major: Production
6. Automated Flow Lines Objectives Types: in-line and rotary types Workpart transport: continuous, intermittent, and power-and free Transfer Mechanisms: linear and rotary mechanisms Automation for machining: dial indexing M/Cs and transfer lines
Identifies the objectives of using flow line automation Describes the two types of automated flow lines and how to choose between the two Distinguishes each workpart transport method by the type of motion imparted to the workpiece Explains some examples of linear transfer mechanisms (e.g. chain-drive conveyor system) as well as some examples of rotary types (e.g. rack and pinion) Emphasizes machining operations as the typical process carried out in automated flow lines Describes the construction of a robot Explains the basic configurations available in industrial robots e.g. polar configurations Classifies and describes robot control types according to the level of controller sophistication Explains the functions and uses of endeffectors and sensors whether internal or external. Explains motion programming (position and orientation) and provision of interlocks using lead through programming Writes textual statements to describe motion and interlocking as given by famous robot languages (e.g. VALII) Describes the robot use in the most common industrial applications
7. Industrial Robotics The technology Robot anatomy: joints & links, common robot configurations Robot control types: limited sequence, playback with point to point control, play-back with continuous control, and intelligent robots End-effectors: tools and grippers Sensors: internal sensors (potentiometers and optical encoders), external sensors (limit switches, proximity sensors, tactile sensors (touch & force), and M/C vision & optical sensors) Programming: lead through programming (power and manual), robot languages, and simulation & off-line programming Industrial Applications: materials handling, M/C loading, spot welding, and assembly
8. Industrial Logic Control Logic control and sequencing sys-tems Logic control elements: And, OR & Not gates Sequencing elements: times and counters Ladder Logic diagrams Programmable Logic Controllers (PLC) Components for the PLC Programming the PLC: Function chart (FUC), Ladder Diagram (LAD), and Statement List(STL)
Revision
Differentiates between a logic control system and a sequencing system Constructs the truth table and writes Boolean algebra equation for each logic function Draws and understands the electric circuit illustrating the operation of each logic function Describes the function and operation of mechcam timers, mech-drum timers and binary counters (flip-flops) Identifies the symbols used in ladder logic diagrams, and their corresponding hardware components, and hence develops such diagrams Defines a PLC systems and compares it with conventional controls Describes the basic components of the PLC and their function Writes programs for PLC systems using FUC, LAD and STL languages
Major: Production
1. Factory Layout Development by Computer CRAFT (Computer Relative Allocation of Facilities Technique) Software: program use, preparation of inputs (from-to-chart, move-cost chart, and an initial layout)
2. Computerized Cell Formation Algorithms ROC2 and LCCSA: Algorithms: program concept and use, data input (part-M/C matrix, number of rows (parts) and number of columns (M/Cs), results interpretation
- Solves cell formation problem for a given part-M/C route data applying ROC2 and LCCA programs (written in FORTRAN)
3. Robot Programming Lead through methods (powered and manual) Textual programming: VALL II robot language
- Programs motion commands and interlocks manually and by using a teach pendant - Uses VALL II to program motion and interlocks - Constructs a three-dimensional model of a robot cell for evaluation and off-line programming
4. Workcell Control Simulation of an automated flow line consists of a robot, a M/C tool and a conveyor: PLACE (Positioner Layout And Cell Evaluation) software: robot program software (COMMAND), motion sequence, program development using simulation procedure, conversion into the textual language of the used robot
5. PLC Programming 8 Function Chart (FUC) Statement List (STL) Ladder Diagram (LAD) - Programs a PLC system using the three methods (FUC, STL and LAD)
Revision 2
Major: Production
Department Mechanical Technology Course Title Welding Principles (Elective 3 Course I) Prerequisite
Major Code
Semester Course Description : This course introduces the student to the basic theoretical principles of the different welding systems and to the most important procedures of weld inspection. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
45
General Goal : The student learns to distinguish between the different welding methods and their applications. He acquires knowledge on the different welding devices, welding fillers and welding gases. He will be able to explain consequences of shrinkage, distortion and welding tension. The student will be informed on accident and damage prevention.
Behavioral Objectives : The student: Names the classification of welding processes Explains the process of autogenous welding and all the used devices and needed aids as well as the standard safety rules Describes the process of arc welding, the necessary pretreatment, the needed devices and aids and the safety instructions to be kept on. Explains consequences of shrinkage, distortion and welding tension Enumerates the different gas shielded welding methods, the needed equipment and assigns them to corresponding welding assignments Names and explains the different methodes of resistance welding. Explains the most important destructive and non-destructive methods of weld inspection.
Major: Production
Topics (Theory):
1. Introduction in welding principles 2. Gas Welding 3. Arc Welding 4. Gas Shielded Arc Welding 5. Resistance Pressure Welding 6. Inspections of welding joints.
Textbook:
Additional Reading:
Appold, Feiler, Reinhard, Schmidt: Technology of the Metal Trade, GTZ 1987 John Deere: Fundamentals of service, Welding, ISBN 0-86691-013-1 References: Akthouse, Turnquist, Bowtitch: Modern Welding, Tinley Park, Illinois 1997 William H. Minnick: Gas Tungsten Arc Welding Handbook, Tinley Park, Illinois 1996
Major: Production
2. Gas Welding The gas welding process Fusion process Heat generation
- Describes gas welding as process of local fusion with or without the use of a filler - Explains the heat generation by burning gases
Welding gases, devices and techniques Acetylene and oxygen Storage of welding gases and safety regulations Welding regulators Hoses and fittings Gas torches and welding tips Neutral, acetylene and oxygen surplus flame Keeping the function of injection torch Join and build-up welding, flame straightening, cutting off and flame descaling
- Describes the properties of the combination of acetylene and Oxygen - Explains the storage of acetylene and its safety regulations - Explains the storage of Oxygen and its safety regulations - Describes the function of welding regulators according to ISO - Enumerates the different types of hoses and their fittings - Describes the different types of gas torches - Describes different types of flames - Calculates the gas consumption using different welding tips - Justifies the importance of maintain of welding devices - Explains the different oxy-acetylene techniques
Major: Production
2 Welding filler rods and welding edges International and Saudi steel standards International and Saudi standards of filler materials Square butt joint Flange butt joint Single-V joint 2 Other oxy-acetylene techniques The flame cutting process Gas supply and cutting torch Safety regulations Spraying material, fumes The braze welding process Uniting and alloying Cast iron, copper, lead bronzes and Aluminum 2 Accident and damage prevention Welding goggles, gloves and protective clothing Non inflammable objects in the welding area, fire extinguisher Air exchange
- Explains the influence of the C-content and other alloys to the welding process - Names the mechanical technological quality standards of welding filler materials - Differentiates filler rod categories according to the material to be welded - Describes the different designs of welding edges - Explains the flame cuffing process - Describes the gas supply and the function of a cuffing torch - Explains fire hazards - Distinguishes between welding and brazing - Names the different procedures according to the material to be welded
- Names the personal equipment for gas welding - Explains the differences between gases, fumes and their impact to human beings - Explains acetylene disintegration and cylinder burning - Describes means of fire prevention and fire fighting - Explains rules for working in small rooms - Names first aid in accidents
3 3. Arc Welding The Arc welding process The electrical arc Transfer of ions Electro magnetic phenomenon Direction of ions transfer Stability of arc Electro magnetic phenomenon 2 Arc welding power supply and safety rules for their application Transformer, generator and rectifier Electrode holders, ground clamps, chipping hammer, weld brush and hand shields Data sheets Operating instructions Fume exhaust facility Organization of working place - Compares the heat sources flames and electrical arcs - Explains the principle of heat generation by electrical arc - Describes the process of drop formation and material transition - Distinguishes between plus and minus polarization - Compares DC and AC welding - Explains the blowing action in direct-current welding - Differentiates between different welding power supplies - Describes the necessary accessories - Explains the electric circuit, idle and working voltage - Names the main adjustment values - Describes how to protect himself against spraying, slags and heat - Explains the protection against gases, fumes, steams and electrical currents - Describes fire prevention
Major: Production
Welding electrodes for different materials Types of stick electrodes Standardization papers Rutile, Basic and Special coated Catalogues from companies standardization papers
- Differentiates the various types of stick electrodes according to international and Saudi standards - Explains the structure and the types of coatings - Describes the role of coatings for different materials and welding tasks - Explains designation examples of standardization of stick electrodes - Explains the preparation of welding joints - Names the different positions of welds and shows their different symbols in drawings - Analyses the different types of drawing weld layouts
Layout of weld and preparation of welding joints Cleaning, beveling Butt joint, single-V joint, fillet joint, corner joint etc Design of weld constructions
Shrinkage, distortion and welding tension Course of events while cooling down the welding puddle Course of events while cooling down the workpiece Preheating and local cooling Procedures of anneal 3 4. Gas Shielded Arc Welding Inert- and active-gas shielded principles Metal-inert-gas, MIG-welding Metal-active-gas, MAG-welding Tungsten-inert-gas, TIG-welding Function of gas shield Power supply and accessories for MIG-, MAG- and TIG- welding Transformer Automatic wire feed unit Gas cylinder Welding gun Data sheets Operating instructions
- Explains how shrinkage occurs - Explains how distortion and welding tension occurs - Describes methods to reduce distortion and welding tension - Describes methods to remove distortion and welding tension
- Explains the different principles of gas shielded arc welding and their application
- Describes the basic elements of MIG-MAG welding sets - Describes the different elements of TIG-welding sets - Describes important maintenance operations - Describes trouble shooting
Materials to be welded, metal fillers and shield gases Structural steel, stainless steel, Al, Cu and its alloys N, Ar, Co2 Accident prevention
- Judges the weldability - Chooses the appropriate welding method according to different material properties - Differentiates fillers and shield gases - Explains accident hazards on gas shielded welding
Major: Production
1 5. Resistance Welding General principles Heat as consequence of electrical resistance in the welding zone Transmission of electrical current by electrodes under pressure Different procedures Continous seam welding Flash butt welding Pressure butt welding Spot welding for metal sheets and plates 3 6. Inspection of welding joints Types of mistakes and defects in welding seams Size and surface mistake Incomplete penetration Lack of fusion Porosity, blow holes Cracks Techniques of inspection Visual inspection and measuring Impact testsing Radiography, magnetic, induction, eddy current resistance and dye penetrants
- Names the different resistance welding procedures - Explains the spot welding procedure and its application
Revision
Major: Production
Department Mechanical Technology Course Title Welding Workshop (Elective 3 Course II) Prerequisite
Major Code
Semester Course Description : This course imparts basic skills in Gas welding, Arc welding, Metal-Active-Gas welding (MAG) and Tung-sten- Inert-Gas welding (TIG). The student applies the techniques accordingly. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
90
General Goal : The student practices Gas welding, Arc welding, Metal Active Gas welding (MAG) and Tungsten Inert Gas welding (TIG) in order to apply his theoretical studies. He expands his knowledge and acquired ability to determine welding processes on different levels.
Behavioral Objectives : The student: Makes sure that the equipment is in working condition Considers safety regulations and uses safety equipment Carries out welding exercises in flat position applying the different welding methods like Gas, Arc, Metal-Active-Gas and Tungsten-Inert-Gas welding Applies different specialized welding processes
Major: Production
Topics (Practice):
1. Gas welding 2. Arc welding 3. Metal-Active Gas welding (MAG) 4. Tungsten-Inert Gas welding (TIG) 5. Additional Welding Processes
Textbook:
Additional Reading:
K. Leake, N.J. Henthorne: Electric Arc Welding, NEWNES - BUTTERWORTHS, London References: J.W. Giachino, W. Weeks, E. Brune: Welding Skills and Practices, American Welding Society, Chicago Dipl. Ing. G. Aichele: Schutz-Gas-Schweien, MESSER GRIESHEIM
Major: Production
- Carries out the procedure of lightening the gas flame - Adjusts oxygen and acetylene to a neutral flame - Carries out different welding exercises in flat position using mild steel and applies the left-ward method - Avoids contact of the welding tip with the puddle or a hard surface - Keeps the proper distance of the white inner cone to the puddle - Notes specific welding rules - Does not use a filler rod on a double flanged butt weld - Keeps the proper width and height of the square butt seam - Makes sure that the surface is very clean before brazing - Selects the proper filler material and flux before brazing - Chooses the appropriate temperature while brazing - Selects the cutting torch size according to thickness of the material - Maintains the proper distance between the torch and the material and an uniform travel speed while gas cutting - Observes the danger of scattering material while gas cutting - Makes sure that the equipment is in working condition - Uses safety equipment
30
2. Arc welding Safety regulations Checking the connections of cables and their proper condition using apron, gloves and head shield Different exercises Bead running exercise Fillet weld Square butt weld Corner weld Single-V butt weld
- Carries out different welding exercises in flat position using mild steel - Chooses the appropriate electrode fitting to the material thickness - Adjusts the welding current - Strikes an arc and runs a continue bead - Carries about the right length of the arc - Notes specific welding rules for single-V butt weld - Prepares the Single-V butt weld according to standard - Welds first a root beat and than a top layer - Offsets the workpieces to avoid distortion
Major: Production
18 3. Metal Active Gas welding (MAG) Safety regulations Checking the connections of cables and their proper condition Using apron, gloves and head shield Different exercises Bead running exercise Corner weld Lap weld Filled weld (flat, concave, convex) 18 4. Tungsten-Inert Gas welding (TIG) Safety regulations Checking the connections of cables and their proper condition Using apron, gloves and head shield Different exercises Bead running exercise Double flanged butt weld Corner weld Square butt weld
- Makes sure that the equipment is working correctly - Uses safety equipment
- Carries out different welding exercises in flat position - Chooses the appropriate wire (electrode) according to his job - Sets the current and the gas flow - Carries out different shapes of fillet welds
- Makes sure that the equipment is in working condition - Uses safety equipment
- Carries out different welding exercises in flat position and different material (e.g. Al, Cu, 18CrMo4) - Chooses the appropriate filler rod according to material properties and thickness - Sets the current and the gas flow according to material properties and thickness - Carries about the right length of the arc - Maintains the proper distance between the welding gun and the material and an uniform travel speed - Keeps a uniform width and height of the seam
5. Additional Welding Processes (according to the available equipment) Pressure welding Resistance welding Friction welding Plasma welding Laser welding 6 Safety regulations according to the chosen welding process
- Makes sure that the equipment is in working condition - Uses safety equipment
Major: Production