Standard

AEP 103 - Introduction to Manufacturing Processes

Course Description

Provides an overview of the manufacturing processes found in the aircraft industry. Topics include: metallurgy, machining practices, fabrication characteristics of materials, forming processes, raw material preparation equipment, electronic and chemical milling, surface treating, and total quality management (Deming theories).

Competency Areas	Hours
Metallurgy	Class	5
Machining Practices	D. Lab	0
Fabrication Characteristics of Materials	P. Lab/O.B.I.	0
Forming Processes	Credit	5
Raw Material Preparation Equipment
Electronic and Chemical Milling
Surface Treating
Total Quality Management (Deming Theories)
Prerequisite:
Corequisite:

Course Guide

Competency	After completing this section, the student will:	Hours
		Class	D.Lab	P.Lab/ O.B.I.
METALLURGY		8	0	0
Introduction	Explain how science, engineering, and technology affects the development of manufacturing processes.
Steel and aluminum	Describe the steel and aluminum making process.
	Identify alloys using appropriate charts.
	Test mechanical properties of steel.
Heat treatment	Describe surface hardening and total hardening.
	Describe how tempering works.
	Describe the annealing process.
Powder metallurgy	Describe the powder metallurgy processed for producing parts.
MACHINING PRACTICES		10	0	0
Tool geometry	Describe cutting tool action and tool geometry.
Turning	Identify the various turning machines.
	List the operations of various turning machines.
Drilling	Describe different drill machines and their uses.
Milling	Describe the types of milling machines and their operation.
Grinding	Describe cylindrical, centerless, and surface grinding.
	List tolerance limits obtainable with lapping, holding, and grinding.
	Describe the economics of the choice of abrasive processes.
Reaming	Describe the reaming process. Explain the appropriate use of the reamer.
FABRICATION CHARACTERISTICS OF MATERIALS		6	0	0
Machinability	Define machinability.
	Explain how machinability differs for various metals.
Formability	Describe these types of press forming: die, brake, press, punch, draw, stretch, explosive, form, and block.
FORMING PROCESSES		8	0	0
Forging	Explain the processes of hand, drop, and machine forging.
Castings	Explain the process of various casting methods.
Hot and cold rolling	Describe hot and cold roll forming processes.
Extrusion	List products made by extruding metals.
RAW MATERIAL PREPARATION EQUIPMENT		2	0	0
Saws	Describe the operation of: cut-off saws, circle saws, band saws, chop saws, and abrasive saws.
Shears	Explain how shears operate.
ELECTRONIC AND CHEMICAL MILLING		2	0	0
Electronic milling	Describe the process of electronic milling.
Chemical milling	Describe the chemical milling process.
SURFACE TREATING		6	0	0
Surface treating processes	Describe the purpose and processes of surface preparation.
TOTAL QUALITY MANAGEMENT (DEMING THEORIES)		8	0	0
Introduction to philosophy	Discuss the philosophy of total quality management.
	Explain the process of implementing a total quality management system.
	Discuss the purpose of the total quality management system.
	Identify the factors that lead to successful operation of an organization under TQM.

Suggested Resources

Books

Allegri, T. H. (1989). Advanced manufacturing technology. Blue Ridge Summit, PA: TAB.

Blake, P. (1980). Advanced manufacturing technology: Programming research and operations logistics. New York: Elsevier.

Ellis, T. M., & Semenkov, O. I. (1982). Advances in CAD-CAM. New York: Elsevier.

Hounshell, D. A. (1985). From the American system to mass production, 1800-1932. Baltimore: Johns Hopkins.

Hunt, V. D. (1987). Dictionary of advanced manufacturing technology. New York: Elsevier.

Johnson, G. I., & Wilson, J. R. (1988). Ergonomics in advanced manufacturing technology. Stoneham, MA: Butterworth-Heinemann.

Lindbeck, J. R., et al. (1989). Manufacturing technology. Englewood Cliffs, NJ: Prentice Hall.

Loewenstein, K. L. (1983). The manufacturing technology of continuous glass fibers (2nd ed.). New York: Elsevier.

Radian Corporation Staff. (1987). Polymer manufacturing. Park Ridge, NJ: Noyes.

Seiden, L. S. (1989). Buckminster Fuller's universe. New York: Plenum.

Voss, Q. A. (1986). Managing advanced manufacturing technology. New York: Springer-Verlag