MFE 201 MANUFACTURING SYSTEMS PROCESSES

Fall 2014
Lec:
Lab:

MFE201-01 (73834) Tuesdays 6:00 8:50PM Bldg. 17-1211 and

MFE201L-01 (73837) Thursdays 6:00 8:50PM Bldg. 17 Room 1540 (This is the main lab)
MFE201L-02 (73838) Thursdays 1:00 3:50PM Bldg. 17 Room 1540 (This is the main lab)
NOTE: Week 2 and 3 labs will be in Bldg. 13 Casting/Heat Treat/Plastics Lab (Engineering Annex)
Outside door, closest to the library, facing Engineering building. See picture
herehttp://www.csupomona.edu/maps/dynamic/index.php?structureID=Bg-13

Instructor

Prof. W. Dixon Davis, PE, CMfgE (IME Dept)

NOTE: If you use/purchase an older edition, you are responsible to identify the changes to the
most current edition and obtain the necessary information from your classmates.

Text

Office Hours
week 1-10

Introduction to Manufacturing Processes by Mikell P. Groover

(ISBN 978-0-470-63228-4) October 2011, 2012 ~ Paperback, 720 pages
Note: Due to the large amount of material to be covered in the class, I
highly advise that you read the materials to be covered in class PRIOR to
class. Weekly reading assignments are averaging 65 pages.

MFE 201L Laboratory Manual (current edition) See Blackboard.

Note: All lab materials must be pre-read PRIOR to lab session. See
Class/Lab preparation requirement section below.

Stapler (to staple your homework, lab assignments, etc.) Points will be deducted
from assignments not stapled (appropriately.)

Monday 6-7pm (I may be in 17-2654) and Thursday, 4-5pm (I may be in the lab).
To help ensure that there is sufficient time for you to discuss matters that are important to you
and minimize scheduling conflict, please make an appointment by sending a calendar invite to
wddavis@csupomona.edu. On the subject line, please indicate which course you would like to
discuss and a short description of the topic to be discussed (e.g., MFE 201 - Review Midterm #1)
Those who make prior arrangements will be given priority.
Please be there on-time (or early). No show will have consequences.
No office hours will be offered 30 minutes prior to exams.

Office Location

Building 9 Room 145

Office Phone

909-869-4798 (leave a message)

E-Mail

wddavis@csupomona.edu

COURSE OBJECTIVE:
Study of basic manufacturing processes with emphasis on terminology, technology, process principles and
capabilities, material selection and comparative advantages and disadvantages. Processes discussed include
material removal, joining, assembly and casting. Other topics include NC, lean and additive manufacturing,
measurement and gauging, and statistical methods.
Note: The laboratory content of the class is subordinate to the lecture content.
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SPECIFIC GOALS FOR THE COURSE:

1. Understand manufacturing processes as a system with the combination of tooling, equipment,
material and human input.
2. Learn specific design criteria about casting, forming, joining, material removal and other
manufacturing processes.
3. Ability to identify the proper manufacturing process for the production of a component taking into
account material and geometry to be produced.
4. Ability to identify basic design criteria for the various manufacturing processes covered.
5. Ability to understand rudimentary aspects of supply chain issues (i.e., implications of incoming
material availability, etc.) along with lean manufacturing techniques.
6. Understand the basics of quality control.
7. Understand the basics of industrial automation.
8. Will understand basic aspects of the economic and competitive aspects of manufacturing.

1
2
3
4
5
6
7
8

IK
IK
IK
IK
I
I

Interdisciplinary Teamwork

Problem Solving

Professionalism & Ethics

Communication Skills

Global & Societal Impact

Lifelong Learning

Contemporary Issues

IK
IK
IK
IK
IK
I
I

IK
IK
IK
IK

I
I
I

I
I
I

Employability

Business Skills

Engineering Skills & Tools

System Design

Design Experiments

Outcomes:
I = Introduction
K = Knowledge S
= Skill
A = Application or
Ability

Apply knowledge

Criterion 3 Student Outcomes (SO) Addressed by the Course Outcomes Check List

IK
IK
IK
IK
IK
I
I
I

PREREQUISITE: None.
GRADING:

Lecture and lab are integrated. Thus, the same grade will be given to both.

Pop Quizzes, Homework, Team Assignment, and/or Class Participation ~15%

Midterm Exams and Final ~60%
If you would like to review your midterm, it will ONLY be available from the time the grade is
posted up to 7 days later.
Laboratory 25% (final exam, quizzes, attendance, reports, and participation).
Note that passing the safety quiz with 80% score is a prerequisite to secure credit in the
laboratory.

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All lab written assignments are due at the beginning of lab, on my desk ONE WEEK after the lab
unless otherwise instructed. (e.g., If lab on week 1 covers Heat Treat, then the written assignment
is due week 2 at the beginning of lab).
Writing assignments are DUE on my desk at the beginning of class ... this means they must be
printed, not softcopy, emailed, or in the cloud.
Trucks (or other lab projects) are due the last day of lab (week 10).

No make late assignment will be accepted.

There is absolutely no make up for missed reading quizzes.

Cell Phone Rings, Computer Usage in Class/Lab, Texting during Class/Lab, iPad/iPhone, etc. = Pop
Quiz------You have been Warned!

Note: The instructor reserves the right to make changes as necessary. Please LISTEN to INSTURCTIONS made
during class and/or lab.
Make ups for exams will only be allowed in cases of emergency and as approved by the instructor.
To ensure fairness, re-grading will be done at the students written request. Requests must be received within
one week of the assignments return and the entire assignment will be re-graded (this means your score may
go up, stay the same, or go down.)

** NO LATE LAB ASSIGNMENTS and/or HOMEWORK WILL BE ACCEPTED **

ADVICE: If you have any issues or concerns, bring it to my attention as soon as possible rather than waiting until the end
of the quarter. It will be too late by then.

Academic integrity will be enforced strictly according to university policy as described

in the university catalog. ANY act of dishonesty will result in expulsion from the class
and a failing grade. Acts of dishonesty include but are not limited to: Copying
assignments or providing them for this purpose, copying during quizzes, copying during
exams. Particularly tempting is to copy a lab/homework assignments. I routinely find
people cheating and the consequences are SEVERE! If you will miss the assignment,
dont turn it in at all .. it is better than failing the entire class.
NOTE: INTERNET REFERENCES WILL NOT BE ACCEPTED FOR THE ASSIGNMENTS. Internet references can be
used to guide an information search, however, the actual information needs to be from a reviewed source
such as a textbook, handbook, research papers, etc. Unfortunately, much of the information on the internet is
NOT reviewed, and some is factually wrong.

POLICY FOR CLASSROOM AND LAB MANNERS AND OFFICE APPOINTMENT:

Turn off cell phone BEFORE entering the class/lab. Leave cell phone off during class/lab.
Put away all headphones, laptops/iPad/tablets, MP3 players, gameboys, etc. in your book bag and
leave it there through the end of class/lab.
Laboratory Schedule: Be ready to begin work at the start of Lab. A quick demonstration of the task will
follow, and then the rest of the lab will be used on that task. Operations in the lab will finish at 2 hrs
and 20 minutes, after which clean-up will take place. NOBODY MAY LEAVE UNTIL THE INSTRUCTOR
INDICATES THAT THE LAB IS CLEAN.
Tardiness or leaving early without prior permission will definitely impact your overall grade.
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No-show to a scheduled office hour will result in a reduction of your score.

POLICY FOR QUIZ/MIDTERM/FINAL:

NO cell phone during Quiz/Midterm/Final. Turn them off and put them in your book bag, NOT in your
pocket. Violation will result in automatic F for the course (including lab)
NO QWERTY calculator.
NO Bathroom breaks during Quiz/Midterm/Final. Go BEFORE test begins. If you must go, your exam
becomes VOID.
NO hooded sweater, hat, ball cap, etc.

SIGN-IN SHEET
Anytime during a class session, I may pass out sign-in sheet(s). I may pass it out at the beginning of the class,
in the middle of the class, towards the end of the class, or anytime of my choosing. It is YOUR RESPONSIBILITY
to make sure your presence is reflected at the time the sign-in sheet was routed. For example,
If you came late and everyone has signed-in (hence, I have the sign-in sheet), your presence may not
be reflected or you may be marked late. As stated above, " Tardiness or leaving early without prior
permission will definitely impact your overall grade."
If you left early and I passed out the sign-in sheet after you leave, please do not e-mail me to let me
know that you were there. Your early departure may be the exact reason for the sign-in sheet to be
passed out.
If you did not sign-in because you were not paying attention, YOU ARE STILL RESPONSIBLE.

CLASS/LAB PREPARATION REQUIREMENTS:

Weekly Reading/Video Preview Assignments(Weekly Assignments) are included towards the end of
this syllabus. View the videos and read the books as instructed to help you prepare for lecture.
o NOTE: Student should study for this class by examining the objectives, learning the material to
meet them (in a broad sense) using the modules, videos, class and text book. Once the
student has met the objectives, his/her study is done. One word of caution, interpret the
objectives in a broad sense, not a narrow one. For instance, if an objective were to read The
student will know and understand how to use the turn signals in a car, the intent is that the
student will know how to actuate the turn signals, what information they provide to other
drivers and pedestrians, what are the laws regulating the use of turn signals, etc. Not simply
how to push the lever up or down.
o Student is responsible for providing a reliable internet connection to access materials.
Students should contact CPPs help desk, by phone or email. The instructor will ensure that the
material can be accessed in the computer labs on campus, so if the student cant establish a
reliable connection, they should plan on spending time on campus accessing the material. The
instructor will do all in his power to keep the learning platform stable, so if you do encounter
problems, please inform instructor to ensure action can be taken.

Homework will not always be assigned.

o When it is assigned, problems are NOT selected in a whimsical fashion, but ARE selected with
the students edification in mind! They will be relative to the students understanding of the
material and/or concepts. Correct answers are appreciated and awarded appropriately.
o As assignments may NOT be returned to you, please make a copy for yourselves BEFORE you
turn yours in.
o Homework assignments are DUE on my desk at the beginning of class ... this means they must
be printed, not softcopy, emailed, or in the cloud.
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Lab:
o

SAFETY QUIZZES: Prepare for the safety quizzes (week 2 and week 3) by reading and
understanding Laboratory Safety Guidelines in this syllabus AND the lab manual.
o Lab Preparation:
Materials in the lab manual must be read PRIOR to lab session. Your preparation will
be graded intensely. To help you be successful, spend extra time obtaining an
understanding of the activities to be done during the lab session PRIOR to the
beginning of the lab.
All associated videos must be viewed prior to lab. This includes the videos listed in
the Weekly Reading/Video Preview Assignments (Weekly Assignments). Questions
will be given from these materials during lab in the form of quizzes or class
participation points.
There will be lab quizzes.
Lab homework is to be turned in AT THE BEGINNING of lab, on my desk, up front. If
yours is not there, then it is assumed that it is not turned in or turned in late (= late
penalties apply). Working on last weeks assignments in this weeks lab will be
awarded with a ZERO SCORE. 2nd such issue or copying labs will result in your
expulsion from the lab for the rest of the quarter with a grade of F.
Writing assignments are DUE on my desk at the beginning of class ... this means they
must be printed, not softcopy, emailed, or in the cloud.
Only HEAT TREAT and PLASTICS lab assignments are to be done as a group. The
remaining lab homework assignments are to be done individually.
o As lab assignments are NOT returned to you, please make a copy for yourselves BEFORE you
turn yours in.
Tardiness or leaving early without prior permission will definitely impact your overall
grade.SEVERELY!
Language: Foul, vulgar, offensive language, when used, carries no engineering intellect and will not be
tolerated. You would not use this language when taking with your boss, customer, or anyone to gain
respect. Therefore, do not use these words in the lab or lecture. If you have time to use such
language, you are not diligently practicing the art of engineering. Be assured, I will find additional use
for this lost time. If you insist of using such language, I will ask you to leave the class or lab, and you
will receive a failing grade for that session. A repeat incident will result a failing grade for the class
and lab.

This class requires a lot of self-discipline.

The material is accessed at your own time and

convenience, but by the same token, many people ignore it. Are you self-disciplined enough to follow this
independent study regime? Do you learn well by yourself reading books and looking at other material or do
you require more direct lecture instruction from the teacher? Should you miss a class, it is YOUR
responsibility to catch up with your classmates on any material you missed.
When looking through the modules on the web, be active not passive. Simply watching the modules WILL
NOT be sufficient to ensure learning. You must actively take notes, go back on items that you did not
understand, and ask questions. When students submit questions via email note MFE 201 QUESTION in subject
line and the instructor will prioritize these emails for reply. The instructor will also post answers in the FAQ
section of the class.

READ THE BOOK.

The instructor will provide the learning objectives so that students can tailor their
reading in order to meet this objectives. The modules will concentrate on giving on overview of the material
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and explain the more difficult concepts in more detail. The student should strive to meet the learning
objectives and use them as their study guide for the content. The exams will come from these study guides.
It is expected that the class will take about NINE HOURS PER WEEK outside of class and lab to study the
online modules and perform the proper book based reading and note taking. Exam preparation is extra.

If you cant dedicate the necessary time, drop the course now, and take it later.
The difficulty of this class is not the difficulty, but rather the quantity of material.
COMMUNICATION CHANNELS:
Cal Poly e-mail and Blackboard will be used as one of the communication channels between the professor
and students. Please ensure that your Cal Poly e-mail account is capable of receiving e-mails (e.g. not full)
and check Blackboard regularly for announcements and grades received. WORD TO THE WISECHECK
YOUR E-MAIL!
Occasionally, I will send out a survey (using survey monkey) to have you signed-up for extracurricular
activities, such as plant tours and extra lab session. These activities are offered for your benefits. These
types of requests require quick turn-around. Please make sure your email does not block this type of
survey and please respond promptly by filling out the survey (i.e., do not send me an e-mail to sign-up. It
will not be recorded).

ANY INFORMATION IN THIS SYLLABUS IS SUBJECT TO CHANGE AND

MAY BE UPDATED THROUGHOUT THE QUARTER.

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MFE 201 MANUFACTURING SYSTEMS PROCESSES

Fall 2014
Lec:
Lab:

MFE201-01 (73834) Tuesdays 6:00 8:50PM Bldg. 17-1211 and

MFE201L-01 (73837) Thursdays 6:00 8:50PM Bldg. 17 Room 1540 (This is the main lab)
MFE201L-02 (73838) Thursdays 1:00 3:50PM Bldg. 17 Room 1540 (This is the main lab)
NOTE: Week 2 and 3 labs will be in Bldg. 13 Casting/Heat Treat/Plastics Lab (Engineering Annex)
Outside door, closest to the library, facing Engineering building. See picture
herehttp://www.csupomona.edu/maps/dynamic/index.php?structureID=Bg-13

Lec#
1
2
3
4

7
8

10

Finals
Week

Lecture Topics

Textbook Chapters

Laboratory Topic

9/30
Chapters 20 & 21
9/25 Lab Introduction
Heat Treatment
10/7
Chapters 5 & 6
10/2 Safety Quiz #1;
Casting
Heat Treatment
10/14
Chapters 12, 13
10/9 Safety Quiz #2;
Forming of Metals
Casting I, Green Sand Casting
10/21
Chapters 10, 8, 14
10/16 Plastics; Sheet Metal Forming
Powder Metal, Plastics,
(Video Preview Required)
Ceramics, Composites
10/28
Midterm I
(In class, closed book/notes, all materials covered to-date, in-class & lab, narrow scantron required)
Machining: Cutting, Turning, and
Chapters 5
10/23 Machining I
Boring
(Video Preview Required)
11/4
Chapters 16 & 17
10/30 Machining II
Machining: Drilling, Milling, and
(Video Preview Required)
Other
11/11
Chapters 18 &19
11/6 Machining III
Machining: Abrasive
(Video Preview Required)
11/18
Midterm II
(In class, closed book/notes, all materials covered to-date. In-class & lab, narrow scantron required)
Joining
Chapter25
11/13 Machining IV
11/25
Chapters
11/20
Additive Manufacturing and
22, 23, 24, 26, 27
Welding/ Soldering/Brazing (Video
Rapid Prototyping, Automation
Preview Required if available)
12/2
12/4 Welding
Lean Manufacturing, Quality
Chapter 29
Time Allowing: Lost Foam Casting or
Topics: Measurement,
Kaizen and cellular manufacturing.
Inspection, NDT, QC,
Manufacturing Systems, Surface
TRUCK IS DUE TODAY - NO
Treatment and Automation
EXCEPTION.
(Time Permitting)
COMPREHENSIVE FINAL EXAM All materials covered during the quarter
WEDNESDAY, 12/9/2014 6PM to 8:30PM (Narrow scantron required)

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LABORATORY SUPPLIES
You will need to purchase a 3/8 X 3/8 high speed tool steel blank. Available at Enco, McMaster Carr or the
Bronco Book Store.
You will also need to purchase a pair of safety glasses/goggles. They must be ANSI Z87.1 standard approved.
These are available at the same locations. Purchase a pair that fits comfortably and snugly. You will be able to
use these beyond this lab.at home, work, other labs and projects.

LABORATORY SAFETY GUIDELINES

These laboratory safety guidelines have been established for the safety and protection of the students, faculty,
staff, and equipment.

ATTIRE:
Students participating in activities in all labs will wear the following attire:
Safety glasses with proper side shields or goggles
Long/FULL-length pants (NO shorts).If you are wearing shorts during lab sessions, you will be asked
to leave the lab and receive a failing grade.
Closed toed shoes (with leather topside for welding and casting laboratories).
Short sleeve shirts, T-shirts, or lab coats are appropriate UNLESS long sleeve as directed by the
Instructor for specific labs. (Tank tops are not acceptable at any time),
o It is almost a certainty, that you will get dirty during labs, so bring appropriate work clothing or
a lab coat.
NO loose or dangling items such as long hair, long earrings, necklaces, loose clothing (i.e. sweatshirts).
Jewelry, inclusive of watches, rings, bracelets, etc. should be removed
NO hooded sweatshirt in lab it blocks peripheral vision; it is a safety hazard
Specific operations require additional safety equipment such as welding masks, special clothing for
pouring metal, etc. Students will be responsible for using proper attire.
SAFETY VIOLATIONS WILL NOT BE TOLERATED AND WILL RESULT IN EXPULSION FROM THE CLASS WITH A
FAILING GRADE if any of the following occurs:
STUDENTS ENDANGER THEMSELVES OR OTHERS, OR
STUDENTS DAMAGE EQUIPMENT DUE TO NEGLIGENT OPERATION. IN ADDITION, HE/SHE WILL BE
RESPONSIBLE FOR PAYING/REPLACING ANY EQUIPMENT THAT IS DAMAGED.

SAFETY PROCEDURES:
Appropriate behavior in the labs is expected. Be mindful of your neighbors, and watch out for everybodys
safety, including your own.
Eating is not allowed in the laboratories. Bottled drinks and cups with lids if allowed will only be allowed in
specific areas at the discretion of the instructor. Specific issues with food and drink include spilling making the
floor slippery or sticky, and also the possibility of contamination of foodstuffs with extraneous (and potentially
dangerous materials) such as chemicals, metal shavings, etc.
Students must behave responsibly, with no running, horse playing, etc. in the lab. Operating machines may
not be left unsupervised. Do not lean on machines. Breaks during lab will be handled as indicated by the
instructor.
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Students will follow the procedures indicated by the instructor/manual. If the student does not know how to
perform a specific or procedure, or does not know how to properly use a tool, it is his/her responsibility to ask
for proper guidance from the instructor.
If an instructor creates an atmosphere of intimidation that leads to the above conditions not being met, the
student should approach the department chair with this situation, or if the chair is the instructor in question,
then the student should approach the laboratory coordinator with this situation.

INDEPENDENT WORK:
A student may only be granted permission to work in the laboratory after a proper assessment that he/she
knows and understands the procedures required to use the described equipment, the lab procedures, and the
pertinent safety procedures. The certification will be carried out by the faculty supporting the students
request for access.

LOCATION OF EMERGENCY EQUIPMENT:

The student is responsible to become acquainted with the location and operation of fire extinguishers, first aid
kits, lavatories for washing small wounds, and telephones.
Fire extinguishers: Follow directions on the label.
First aid kit: Follow directions on kit.
Telephone: In case of emergency call 911, it will connect to campus police.
In many of the laboratories it will be required to change tooling on machines. Prior to changing the tooling,
make sure that the power TO THE MACHINE has been shut off. This is particularly true of the machining
laboratories. Also, make sure that any equipment is unplugged or main power disconnected prior to accessing
areas to be cleaned such as the sand Muller in metal casting.

GENERAL SAFETY GUIDELINES:

Eye safety: ALWAYS wear your safety glasses/goggles. They must be ANSI Z87.1 standard approved (It will say
on the package or on the glasses if the standard is met). They must be kept on at ALL times during the
laboratory sessions, in all sessions.
Slips, trips and falls: Slips can occur from spills on the floor that make the floor slippery. This can be from
liquids, such as oil, or solids, such as plastic pellets, or loose sand. Trips can happen due to clutter,
debris, cords and hoses on the floor.
Hot items: In all labs, assume that all metal and plastic components are hot unless specifically knowing that
they are not. Always use proper handling devices such as tongues. Gloves are meant to protect from
accidental contact with hot materials, NOT meant to be used to hold hot items. Gloves will be ruined
by this type of use, and will not effectively protect the wearer.
Back and lifting: Heavy objects such as casting molds and plastic injection dies require care when handling.
When lifting or moving heavy objects, get help from other students and use proper postures, such as
lifting with your legs, not your back.
Lacerations and cuts: In many laboratories, sharp items will be handled at some point. Always be careful of
instances where sharp edges are present, and do not handle by holding at the sharp edge. Deburr
sharp edges as soon as possible.
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Pinching and blunt injuries: Pinching and blunt injuries may occur from dropping a heavy object on fingers,
hands, feet, etc. Pinching may also occur by the operation of certain equipment. Prior to engaging
equipment make sure that your hands, feet, head, etc. are not in the way.
Entanglement of loose clothing, jewelry and long hair particularly in high speed rotating equipment such as
lathes and mills poses a significant and serious risk. Also, loose clothing can get caught on equipment knobs,
etc. Make sure that your attire is appropriate.
Proper footing is also very important for safety. Do not overreach. That is, when reaching, always make sure
that you can maintain your balance. Do not lean on tables or cabinets to reach for items. In machining, on the
mills, if necessary use the footstools that are provided to reach to the top of the mill (if necessary). Also ask
for help from someone who can reach (if necessary).
Whenever a hazardous situation is seen, warn others, fix it (if something simple like sweeping plastic pellets)
and/or report it to the instructor immediately. If another student is behaving in an unsafe manner point this
out to him/her and if necessary get the instructor involved.

SAFETY ISSUES IN SPECIFIC LABORATORIES:

MACHINING:
The main danger in machining comes from working with very powerful equipment. Thus, very high
forces can hurt people very quickly. Specific things to pay attention to include making sure that all work
pieces, tools, and work holding devices are properly tightened. If they are loose, they can fly off at very high
speeds and cause substantial injury. Chuck keys may only be on your hand while using it; otherwise, stowed
away in their proper place.
Since the student will be watching a machine perform work in a stationary place, often students will
lean on the equipment, or divert their attention from it. Do not lean on operating machines. You can slip and
fall on the moving machine causing substantial injury. Also, do not take your eyes from the work piece. If
something happens, and you need to power off the machine, it will happen very quickly. This is particularly
true if using vertical fly cutters in milling.
Because the equipment is moving very fast, it can grab loose clothing, long hair, etc. and pull the
student into the machine. Secure long hair. Remove all jewelry. Do not wear loose or baggy clothing. Ask the
instructor if you are not certain.
In order to prevent accidental start up while setting up a machine, turn off the power to the
equipment.
All machined edges will have sharp burrs. Deburr all sharp edges. Use a rag to handle sharp tools,
such as end mills.

WELDING:
The main danger in welding is from a GAS EXPLOSION, burning eyes and skin with UV light, and burning
hands from handling hot metal and spattering.
A gas explosion can occur if there is a leak in acetylene gas anywhere in the lab. Prior to turning on the
gas sources make sure that ALL torches, and supplies to stations are off. At the end of lab, also make sure that
all torches and supplies to stations are off.

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There are two types of face shields on each booth: One for oxy fuel welding (half shield/light lenses),
and one for electric welding (full shield/dark lenses). Use proper face shield for the welding that you will be
undertaking. If in doubt, compare the darkness of the lenses by looking at the lamps in the lab through the
glass. If still in doubt, ask.
To protect arms and hands from sun burning and spattering during welding, use proper welding
gloves, apron, and arm covers. NOTE: GLOVES ARE NOT DESIGNED TO HANDLE HOT METAL. THEY ARE
DESIGNED TO PROTECT IN CASE OF ACCIDENTAL CONTACT. HOT METAL SHOULD NEVER BE HANDLED WITH
GLOVES; THEY WILL NOT PROTECT YOU AND WILL DAMAGE THE GLOVES. Use tools, such as pliers or tongs to
move hot metal.
Hot metal in the form of work pieces, filler rod, and electrodes should be handled with the pliers and
tongues that are in each workstation. Slowly cool off work piece with running water, prior to placing on center
counter. Dispose of other materials in the metal disposal bin in the lab. Also be sure not to let any hot
material come into contact with paper, rubber, or other flammables as a fire may ensue.
Make sure that the ventilation system for the lab is on; otherwise fumes will accumulate and fill the
lab with smoke. It is unlikely that any harm will come, however, it is very uncomfortable.
One should never weld containers that are sealed, or whose previous contents are unknown, or that
are dirty. There is the possibility of fire or explosion if these containers have or held organic volatiles, such as
gasoline, alcohol, or even grease and oils.
When cutting in the welding laboratory make sure that the molten material does not fall on yourself or
any flammable materials.

FOUNDRY:
In the foundry laboratory several things can cause injury. First, molten aluminum has a tendency to
stick to the skin if a splash should fall on someone. Thus, if handling molten metal, suit up properly. This
includes vest, leggings, jacket, helmet, and face shield (in addition to safety glasses, etc.). If not handling
molten metal stay at least 15 feet away. Also, nobody should stand in the front direction of the furnace
(regardless of distance) while pouring operations are taking place. Metal can be splashed from the ladle on to
the floor if not properly handled. To help eliminate this possibility, never fill the ladle more than 2/3 full, and
place a bed of sand in front of the furnace and in the pouring area. Someone with a shovel full of sand should
be standing by in case any metal does splash in order to cover it. If metal splashes, suspend pouring
operations until it has been safely swept away so the student does not step on the hot metal and burn his foot.
The ventilation fans should be on.
At any time during the laboratory, be careful when using compressed air as it can blow sand and other
debris into the eyes of people around the work area. Be mindful of neighboring people.
NEVER set your foot on the rolling conveyors. Much less, do not stand on them.
Weights should be placed on molds prior to pouring to prevent the cope (top part of mold) from lifting
due to metallostatic pressure. In the case of lost foam casting, place weights on top of sand.
At all times be careful not to grab a hot piece of metal or handle hot sand or flasks. After pouring, the
sand in the mold will heat up quite substantially, so be careful to not touch the sand when breaking out molds.
In some instances, parts of the flask will also heat up, so be careful to handle them with care as well.
When shaking out the castings and using cooling water, do not just throw the casting into the water,
this can lead to a dangerous steam explosion. UNDER NO CIRCUMSTANCES SHOULD MOLTEN METAL BE
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HANDLED IN THE PRESCENCE OF WATER. Slowly lower the casting into the water as it sizzles. Also, the water
will become hot, dont put your hands in it, and the castings may still be too hot to handle when pulled out of
the water. If so, let them cool off in air.
Nobody may cut off castings using the bandsaw until approved by the instructor. If improperly used,
the bandsaw will cause very serious injury, such as the amputation of fingers. Thus, wait for the instructor.

SHEET METAL LABORATORY:

In the sheet metal laboratory the main danger is laceration (cuts) and pinching fingers. During the
entire laboratory until the end, there will be a lot of people carrying pieces of sheet metal around the
laboratory, all with sharp edges. Be very mindful of your neighbors, and yourself.
Pinching fingers is something that can be easily prevented with a little care and the danger arises
mainly in the bending presses. The shears have the ability to amputate fingers, simply stay clear from them.
POWER SHEARS AND PRESSES WILL ONLY BE USED BY THE INSTRUCTOR/TECHNICIAN, OR UNDER THEIR
SUPERVISION.

PLASTICS LABORATORY:
In the plastics laboratory the main dangers come from having injection molds or their components
falling on your fingers, feet, hands. Handling with care will prevent any injury. IF AN INJECTION DIE OR
COMPONENT IS FALLING DOWN, LET IT FALL. DO NOT ATTEMPT TO CATCH IT. IT IS BETTER TO HAVE THE
TOOL GET DAMAGED THAN HAVE THE STUDENT GET HURT.
Another danger using the thermoforming machine is to handle hot plastic with your bear hands.
Simply handle the plastic by the edges and it will not be a problem. Also, beware of elements in the machine
that heat up during operation.
Injection plastic comes in the form of pellets. If there should be some on the floor there is danger of
slipping. Please be aware of this and if you see a spill, please report it.

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MFE 201/L Weekly Assignments (In Addition to Reading the Textbook)

Week 1 Metal Casting
View the modules in the following sequence:
1. Manufacturing Process
https://connect.csupomona.edu/manufacturingprocessesclassification
Classification
2. Metal Casting Introduction and
https://connect.csupomona.edu/metalcastingintroandsandcasting
Green Sand Casting
3. Casting Solidification
https://connect.csupomona.edu/castingssolidification
4. Casting Gating
https://connect.csupomona.edu/gating
View the Sand Casting, Investment Casting, Lost/Evaporative Foam Casting, and all Die Casting related segments
5. Casting Processes
on the DVD that came with the book.
https://connect.csupomona.edu/castingprocessesminusgreensand
6. Casting Design
https://connect.csupomona.edu/castingdesign

Week 2 Forming
View the modules in the following sequence:
1. Basic of Metal Forming
https://connect.csupomona.edu/bulkdeformationtheory
https://connect.csupomona.edu/rolling
2. Rolling
Preview the forging segments in the DVD that came with the book.
3. Forging
https://connect.csupomona.edu/forging
https://connect.csupomona.edu/extrusionanddrawing
4. Extrusion
Preview the sheet metal segments in the DVD that came with the book.
5. Shearing
https://connect.csupomona.edu/sheetmetalshearing
6. Bending
https://connect.csupomona.edu/sheetmetalbending/
7. Drawing/stretching
https://connect.csupomona.edu/sheetmetaldrawingstretchingwrapup/

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MFE 201/L Weekly Assignments (In Addition to Reading the Textbook)

Week 3 Powder Metals, Plastics, Ceramics, and Composites
View the modules in the following sequence:
1. View the Powder Metallurgy segments in the DVD that came with the book (2 parts). You will see some repetitive information, but watch both.
https://connect.csupomona.edu/powdermetal1shapeformation
2. Powder Metals
https://connect.csupomona.edu/powdermetal2sinteringwrapup
3. View the Plastic Injection Molding (3 parts), Plastic Blow Molding (3 parts), and Plastic Finishing Processes (2 parts)
4. Plastics
https://connect.csupomona.edu/plasticsprocessing
5. Ceramics
https://connect.csupomona.edu/ceramicsprocessing
6. View the Composite Materials and Manufacturing segments in the DVD that came with the book. You will see some repetitive information but watch all
3 parts.
7. Composite
https://connect.csupomona.edu/compositesprocessingfiberpolymer

Week 4 Machining Introduction, Cutting Tools, Turning and Boring

View the modules in the following sequence:
1. View the segments in the DVD:
a. Machining Processes
b. Cutting Tool Materials
Pay attention to the visuals in this segment, simply to illustrate the process.
https://connect.csupomona.edu/machiningintromfe201part1
2. Machining Introductory Materials:
https://connect.csupomona.edu/machiningintromfe201part2
3. Cutting tools materials in the DVD; all three segments.
4. Cutting tools
https://connect.csupomona.edu/cuttingtools
5. Turning and Lathe Basics materials in the DVD. View in the following sequence:
a. Turning Operations
b. Lather Work holding
c. Lathe Types
d. Lathe Turrets
https://connect.csupomona.edu/turningandboring1
6. Turning Processes Modules
https://connect.csupomona.edu/turningandboring2

ADDITIONAL Milling and Lathe Videos http://www.csupomona.edu/~vfokhuysen/dolce/index.html

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MFE 201/L Weekly Assignments (In Addition to Reading the Textbook)

Week 5 Drilling, Milling, Broaching, Sawing, etc.
View the modules in the following sequence:
1. Drilling
https://connect.csupomona.edu/drillingandrelatedprocesses
View the DVD in the following sequence:
a. Milling Cutters and Operations
b. Vertical Machining Center
2. Milling
c. Horizontal Machining center
d. Machining Center Work holding
https://connect.csupomona.edu/milling
View the DVD on Gears and Gear Manufacturing. Pay attention to the parts of Gear manufacturing where they
3. Broaching, sawing, filing, shaping,
illustrate broaching and shaping.
and planning
https://connect.csupomona.edu/broachingsawingfilingplaning

Week 6 Abrasive Processes and Work holding

View the modules in the following sequence:
1. View the four videos under Basics of Grinding in the same order as they are on the DVD.
https://connect.csupomona.edu/abrasivemachining
2. Abrasive Machining
https://connect.csupomona.edu/abrasivemachining2ndhalf
3. View the four segments under Introduction to Work holding in the same order as they are on the DVD.
4. Work holding
https://connect.csupomona.edu/workholding
5. View the three segments under Electric Discharge Machining on the DVD.
6. Also read Electric Discharge Machining in text from page 510 to 515.

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MFE 201/L Weekly Assignments (In Addition to Reading the Textbook)

Week 7 Joining: Fundamentals, Oxyfuel, Arc, Other Fusion, and Solid State Welding
View the modules in the following sequence:
1. Welding
https://connect.csupomona.edu/weldingfundamentalsformfe201
2. Oxyfuel Welding Module
https://connect.csupomona.edu/oxyfuelweldingformfe201
View the DVD section on arc welding.
3. Arc Welding
https://connect.csupomona.edu/arcweldingprocessesformfe201
4. Other Fusion Welding Processes
https://connect.csupomona.edu/otherfusionprocessesformfe201
5. Solid State and Resistance Welding
View the DVD section Resistance Welding
Processes
https://connect.csupomona.edu/resistanceandsolidstateweldingmfe201

Week 8 Joining: Brazing, Soldering, Adhesives and Mechanical Fastening, and Rapid Prototyping
View the modules in the following sequence:
1. Brazing and Soldering
https://connect.csupomona.edu/brazingandsoldering
2. Adhesives
https://connect.csupomona.edu/adhesives
3. Mechanical Fastening
https://connect.csupomona.edu/mechanicalfastening
4. Rapid Prototyping
https://connect.csupomona.edu/rapidprototyping

Week 9 Automation
View the modules in the following sequence:
1. Introduction Automation
https://connect.csupomona.edu/automationintroduction
2. For a more practical explanation
and examples, view the following
https://connect.csupomona.edu/elementsofautomation
module
3. A discussion of Computer
https://connect.csupomona.edu/cim
Integrated Manufacturing
4. Computer Numerical Control
https://connect.csupomona.edu/cncmachiningcenters
Machining Centers

Page 16 of 17

MFE 201/L Weekly Assignments (In Addition to Reading the Textbook)

Quality
View the modules in the following sequence:
1. Quality Introduction (9:26 minutes) https://connect.csupomona.edu/mfe201ch10part1intro/
2. Measurement Basics (4:53 minutes) https://connect.csupomona.edu/mfe201ch10part2measurebasics/
3. Tolerances and Allowances (10:10
https://connect.csupomona.edu/mfe201ch10part3tolerances/
minutes)
4. Measuring Instruments (5:41
https://connect.csupomona.edu/mfe201ch10part4instruments/
minutes)
5. Non-Destructive Testing/Evaluation https://connect.csupomona.edu/mfe201ch10part5ndt/
1 (10:19 minutes)
6. Non-Destructive Testing/Evaluation https://connect.csupomona.edu/mfe201ch10part5bndt/
2 (7:20 minutes)
7. Quality 1 (8:21 minutes)
https://connect.csupomona.edu/mfe201ch36aquality/
8. Quality 2 (5:03 minutes)
https://connect.csupomona.edu/mfe201c36bquality/
9. Quality 3 (9:20 minutes)
https://connect.csupomona.edu/mfe201ch36cquality/

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