CONCORDIA UNIVERSITY

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

MECH 421 – Mechanical shaping of metals and plastics (3.5 Credits)
MECH 6511 – Mechanical forming of metals (4.0 Credits)
Winter 2017
Instructor: Dr. T. H. Kwok Lecture Time: M - - - - 11:45 to 14:30
Office: EV 004.239 Lecture Room: MB 3.210 SGW
Phone: (514) 848-2424 #3807 Office Hours: M - - - - 14:30 to 16:30
e-mail: tszho.kwok@concordia.ca Course website on Moodle
Lab Instructor: Alireza Zandi Karimi
Tutor: Gagandeep Banger
Email: alireza.zandikarimi@gmail.com
Email: gagandeepbanger18@gmail.com
Office/Phone: EV 13.119 / # 7224

Recommended Textbooks:
1. Degarmo’s Materials and Processes in Manufacturing, J.T. Black and R.A. Kohser, Wiley,
11th edition, 2011. (Earlier editions will be fine).
2. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Mikell P.
Groover, Wiley, 6th edition, 2015 (Earlier editions will also be fine).
Related Material:
 Material Science and Engineering: An Introduction, W.D. Callister, D.G. Rethwisch, 9th
Edition, Wiley, 2013. (Earlier editions will be fine).

Lectures Schedule
Week (Date) Topics Note
1 (Jan 9th) Introduction of Manufacturing
2 (Jan 16th) The Nature of Materials
Weekly writing starts (6511)
3 (Jan 23rd) Properties of Materials
Form teams (421 & 6511)
4 (Jan 30th) Fundamentals of Metal Forming Submit present topic 1 (421)
5 (Feb 6th) Bulk-Forming Processes Submit project topic (6511)
6 (Feb 13th) Finite Element Method Assignment #1 due
7 (Feb 20th) ----->>Break<<-----
8 (Feb 27th) First Presentation
9 (Mar 6th) Sheet-Forming Processes
10 (Mar 13th) Powder Metallurgy Submit present topic 2 (421)
11 (Mar 20th) Plastics and Shaping Process for Plastics Assignment #2 due
12 (Mar 27th) Advanced Manufacturing Technologies Simulation project due (6511)
13 (Apr 3rd) Second Presentation
14 (Apr 10th) Quality Control & Review Team project report due (6511)

A brief description of the course

This course provides fundamental information on plastic deformation of metals/alloys and plastics.
Based on this, the mechanical shaping processes which are commonly used to manufacture metallic
and plastic products (e.g., plastic bottles, cell-phone cases, laptop bodies, car hoods, etc) are
discussed. Some of the advanced manufacturing techniques including nanofabrication technologies
and 3D-prinitng are also reviewed.
Note: There is a laboratory for MECH 421 (cold working, roll milling and annealing of brass) where
you can experiment and observe what you have learned in theory. There are an individual
implementation project and a team project for MECH 6511.

Learning Outcomes:
This is a course aimed at Mechanical Engineering Students who will need to know how components
(whether big or small, simple or complex) are made and the effect that this shaping has on the
properties of the material. A car door, a wing spar, a cell phone casing are all made from materials
and must all be shaped in some way. How this shaping is carried out affects many factors; the cost,
the complexity available, the mechanical properties such as strength and ductility and other less
obvious properties such as corrosion resistance and toughness. Any engineer who is designing
components need to know not just how to make things but the effect that this has on the final product.
By the end of this course, you are expected to know:
1. the material properties and selection of metals/alloys and plastics;
2. how to measure, interpret and calculate the mechanical properties of metals and plastics;
3. the main processes by which metals and plastics can be formed;
4. the hot and cold (working) manufacturing processes to create metallic and plastic products;
5. the effect of these processes have on material properties;
7. about the advanced manufacturing techniques and their applications.
This course should be seen as part of the whole process of Design and Production in that the shaping
of a component will influence the designs possible, the mechanics of the system, the ease of
manufacture, and finally the performance of the product.

Note: This course does not cover welding and casting of metals as these topics are covered in Mech 423.

Grade Composition
MECH 421 MECH 6511
Final Exam: 50% Team Project: 30%
Presentations (2): 30% Implementation Project: 30%
Assignments (2): 10% Assignments (2): 10%
Lab: 10% Reflective Writing: 30%

NB1: "In the event of extraordinary circumstances beyond the University's control, the content and/or
evaluation scheme in this course is subject to change".

NB2: The faculty has required each student at the beginning of the term to commit into performing
his homework as individual or group work, to use references that are cited and make sure that he/she
is not committing plagiarism. So far, such a document was required at the submission of each and
every assignment. Starting this year, a statement of expectations of originality on the submitted work
is required to every student at the beginning of the term. Please read carefully the document and sign
it. You need to submit it along with your first assignment. This document is required to receive a
grade at the completion of the course.

PLEASE FOLLOW THE INSTRUCTIONS BELOW

Download (https://www.concordia.ca/encs/students/sas/expectation-originality.html) and read the
Expectations of Originality form, in which every individual will commit that his work during the
term will be original and not copied from various sources or from other colleagues. You need to
fill it in the form. You will submit the form along with the first submission to the tutor. This is a
requirement and you have to fulfill it, otherwise your work will not be marked.
 For MECH 421
Laboratory:
There is a laboratory component to this course, namely; the cold working and annealing of brass. The
aim of this lab is to illustrate the effects of cold working processes such as rolling on the mechanical
properties of metals and then how these effects may or may not be reversed. Mr. Peter Sakaris (Extn.
3153) will be supervising this in the Materials Laboratory (H-1059). A lab manual, prepared by Mr.
Peter Sakaris is available at the COPY CENTER, and the labs commence the week of January 16
(Week 2). The lab is in H-1059, and the students are expected in the lab with lab coats and covered
shoes.

Presentations:
There are two presentations. In each presentation, each team will select a paper related to this course
(and approved by the Instructor) and will prepare a 15 minute PowerPoint presentation giving an
overview of the technical detail of the paper, as well as its major advantages/disadvantages,
applications, improvements, etc. Time will be set aside in the lecture sessions for each team to make
the presentation to the rest of the class. Each talk will be followed by a short question period. Each
student will submit a hardcopy of the report prior to presentation. Marks will be awarded for:
 Presentation style (audibility, structure, clarity, quality of visual aids, etc.)
 Technical content (showing understanding of subject, grasp of key points, explanation, etc.)
 Reflection (connecting the content to your own knowledge – reference to the rubric in the
Reflective Writing section below.)

Deadline for submission for laboratory work is available in the Lab Manual. Work must be submitted
to Moodle and hardcopy directly to me on or before the class (reports due by the time of your
presentation). NO DELAYS/EXTENSIONS. Good presentation, including legibility, spelling and
grammar, is expected for all work.
 For MECH 6511
Reflective Writing
The aim of reflective writing is to help you engage with the material in the lecture/textbook, trying to
sort out what you understand and what you do not understand. You should try and relate the concepts
to ideas found in previous chapters and to their life experiences. Write down your own understanding
of concepts, relationship among those concepts, or even relationship of the material to the lectures and
your former knowledge from other disciplines and life experience. The main difference between
summary and reflective writing is that in a summary you write down what you already have in your
mind during your reading, while in doing reflective writing you question what you read and relate it
to other concerns. The reflective writings should be about two to three pages and should cover all the
materials of the week. The following is the rubric for the writing, including the fetaures present in the
reflective writing product:

Team project
Your team (4, 5 or 6 students) must choose an item/article/product; e.g., a car, airplane, cell-phone,
watch, laptop, transmission tower, or an iron. Then you must choose 4, 5 or 6 (same as the number of
your team members) components within that item/article/product; each with a manufacturing history.
After getting the approval of the instructor on the selected item:

Writing a report (materials and manufacturing point of view):

An introduction about the item/article/product (1 page).
For each component, write 1 page (including an image or a table) on “material selection” and the
manufacturing technique(s) and explain why those materials and techniques have been used (at least 1
page for each component = at least 4, 5 or 6 pages).
The report must also include a front page (1 page), and a reference page at the end (1 page).
You may also have summary, conclusion, or appendix ….
The materials and manufacturing techniques are NOT limited to the topics discuses in the class (can
be any material and manufacturing method). Also, do not forget to attach the “Expectations of
Originality form” to your report (signed by all the members)

Due date of submitting the names of your team members (via moodle): Jan. 23rd
Due date of submitting your topic (the item/article/product): Feb. 6th
Due date of submitting your report: April 10th

Important: There is no delay/extension for the submission of your report. The report has to be
submitted in Moodle, and the hardcopy can be submitted in class.

Note: each team will be assessed based on their teamwork – not individually; i.e. all the team members
will receive the same mark for the team project; so work together as a team!

Implementation Project
Finite element analysis (FEA) has been developed during the last decades as a very useful tool for
analysis of metal forming processes. Progress in development of cheap and efficient computer
technology, and the implementation of the finite element method (FEM) into user-friendly, window-
based programs, has brought this technology forward. One can state that this development has more
or less revolutionized the art of metal forming analysis. In this project, you have to implement and
demonstrate how FEA can be applied for the analysis of a particular metal forming operation, e.g.,
cold forming, drawing, and stretching. The output of this project is a simulation program and a report
describing all the implementation details. The assessment is based on the report describing how you
realize and implement the simulation program:
 Mathematical formulation of FEM (including isoparametric mapping)
 Read/generate/refine mesh
 Calculate local stiffness/mass matrix
 Assemble stiffness/mass matrix
 Solve the equation system
 Stress recovery
 Triangular v.s. Quadrilateral elements
 2D v.s. 3D FEA (i.e., tetrahedral/hexahedral elements)

Marks will be given to each of the steps/functions, so don’t worry if you cannot get a valid simulation
result finally. Although C++ is suggested and a basic MFC platform will be provided for visualization
purpose, you are free to use any language/platform for this project as long as you document
everything well.

Due date: Mar 27th