Department of Technology
Eastern Kentucky University
MFG 301
NON-METALIC MATERIAL PROCESS
Instructor: Tim Ross Phone: 622-1197
324 Whalin Technology Complex Email: tecross@acs.eku.edu
COURSE DESCRIPTION: Introduction to manufacturing processes used to shape of form wood, plastic and composite materials. Families of processes covered are casting, molding, forming, separating, conditioning, assembling and finishing.
PREREQUISITES: MFG 138 MATERIALS and MFG 201 METALLIC PROCESSES
CREDIT HOURS: Three (3) semester hours
TEXTBOOK: DuVall, Barry J.: Contemporary Manufacturing Processes: Goodheart-Wilcox Company, Inc.; South Holland, Illinois 1996.
SUPPLEMENTARY MATERIALS:
1. "Modern Plastics", "Plastics World", "Plastics Technology", "Plastics Engineering", and Western Plastics" are monthly journals dealing with new developments in plastics technology.
2. "Composites in Manufacturing" is a quarterly flyer published by the Composites Manufacturing Association of the Society of Manufacturing Engineers.
3. "Modern Plastics Encyclopedia", a yearly summation of technical developments and applications of plastic and related processes. This is one of the most complete resources available on plastics.
4. Dubois & Pribble: Plastics Mold Engineering Handbook, 4th Edition, Van Nostrand Reinhold publishing, 1987.
5. Materials Reference Issue-Machine Design, Penton Publishing Co. 1990.
6. Many other books on plastics are available in the Crabbe Library. References dealing with polymer chemistry, design, design in plastics, plastics in architecture and building, ecological implications of plastics.
7. Woodworking for Industry, Feirer, John L.; Glencoe Publishing Company,
Mission Hills, California, 1984.
COURSE OBJECTIVES:
A. To increase the students' awareness of the extensive variety and types of tooling used in the plastics, ceramics, composites and wood-based industries.
B. To develop an understanding of the unique properties and characteristics of Engineered Thermoplastic materials, flow, and temperature/pressure conditions.
C. To acquaint the students with common recycling processes and recent technological developments that are used in producing products from reprocessed materials.
D. To promote an understanding of the design potential and to encourage creative
expression with plastics, ceramics, composites and woods.
E. To develop the student's skills of controlling the interrelated variables of injection molding, extrusion, thermoforming, and encapsulation which effect quality and efficiency in product development.
F. Understand and practice laboratory and shop safety procedures related to industrial plastic and woodworking operations.
G. Be able to perform at least twelve common shop operations related to the processing of wood and related composites.
LAB ACTIVITIES:
A. Material and Process Analysis
This lab experience (to be accomplished in small groups) will involve an analysis of the processing characteristics and resulting physical/mechanical properties of a specific engineered thermoplastic material. Initially, the melt-flow (rheology) characteristics of the material will be investigated and this data will be used to establish specific molding parameters. Test samples will be injection molded and interrelated variables of temperature, pressure, speed, and time will be adjusted and analyzed for optimum results. Tests will then be performed on selected samples to determine the effects of the various molding variables on the physical properties of the polymer. A written report of the data and findings derived from this experience will be submitted for evaluation.
B. Design Problem
This activity is intended to further your appreciation of the unique design and production possibilities of plastics and woods. The problem will be to design, plan and develop a useful product or the reuse of a plastic and wood material. The problem should be approached from a design standpoint and will proceed through the following steps of development:
1. Problem statement--Identification of a product.
2. Idea Development--Sketches and drawings of product and tooling ideas.
3. Tooling--Development of tooling devices (molds) needed to produce the finished product in plastics.
4. Product Development--Creating the finished product using appropriate tooling and processing techniques.
C. Article Reviews (Technical Update Papers)
Three article reviews relating to the plastic, ceramics, and composites industry will be completed by each student one for each of the areas. The format for the all written assignments is as follows:
A. Name in upper right corner of each page
B. Multi-page assignments to be stapled in upper left corner
C. Smooth edge standard (8.5 x 11 inch) paper only
D. Use one side of page only
E. Neatness counts!!!
2. Paper should be typed or computer generated
3. Margins 1" all around
4. Name in the upper right hand corner
5. Font is readable (Times New Roman, Arial, etc.)
6. Font size - 12 pt.
7. Double spaced
8. 2 to 3 pages of text
9. Attach any information used as a resource to the final paper
F. Article Information
1. Article Title
2. Author/s
3. Author's background (if given)
4. Name and date of publication found in
G. Important information concerning the plastics industry you learned.
EVALUATION PROCEDURES:
A. Material Process Analysis and Labs.
Design Problem and Article Reviews 45 %
B. Examinations 25 %
C. Attendance & Participation 15 %
D. Final Examination (MAY 5 @ 1:00-3:15) 15%
ADDITIONAL INFORMATION:
A. Conservation--Materials and the equipment used in nonmetallic are expensive. Please be careful not to waste supplies. If you are not sure about something, look it up or ask the instructor. We have to make a little go a long way.
B. Safety--Please follow all safety procedures relating to equipment as well as ventilation. The equipment and processes will be new to most everybody. They are hot and some are toxic. The equipment demonstrates very little (no) mercy when inflicting injury.
C. Assignments turned in late will be penalized five points per each class period late.
D. Attendance--Students failing to show for class will be penalized ~2.8 points per absence. If you must be absent, call or email me before class to let me know.
E. Machine Operation--Don't operate any equipment you have not been checked approved to operate. Students are required to pass a safety test.
F. Clean-up--Each individual is responsible for returning their own tools and contributing to general lab clean-up at the end of each class session. Maintaining a clean and orderly working environment is essential for safe and efficient operation of the lab.
G. Sinks--are intended for WATER ONLY. Do not allow resins, plastic waste of plaster to enter the drain. Containers are available for proper disposal of these materials.
H. NOTEBOOK--of all work relating to this section of the course is to be kept. All nonmetallic process write-ups, design procedures and other works are to be neatly organized and included in the notebook.