Standards & Assessment Center

September 2010

Channel Coding (EDPT901): Non Conventional Manufacturing

Processes

Professor: Nahed El Mahallawy

Instructor Office Monday from 2 to 5 pm

Hours:
Course Schedule Saturday 1st slot in H 2

Course Type Mandatory.

Prerequisites Introduction to Materials and

Manufacturing Processes EDPT 302,
Material Removal Processes and Machines
EDPT 402

I. Course Description

The course first reviews briefly the different conventional

manufacturing processes. It then clarifies the main non
conventional and finishing processes which were not covered in
previous courses including mechanical energy processes,
electrochemical machining processes, thermal energy processes,
chemical machining processes such as ultrasonic machining water
jet machining, electric discharge machining, chemical machining.
Laser and its applications in manufacturing including laser cutting,
welding, marking principles and techniques are covered in addition
to Rapid prototyping techniques.

The course clarifies the principles of operation, the applications and

limitations of the different processes. It also points out the design
considerations of the parts for each type of process. It also
pinpoints the economics of manufacturing and related
environmental considerations.

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 II. Course Instructional Goals

Instructional Goals:

1. Help the student build an understanding of fundamentals and

applications of non conventional manufacturing processes

2. Illustrate to student the new trends in manufacturing.

3. Help the student build a view of the new and most effective
processes for the different types of materials

4. Illustrates to student the concepts economics of

manufacturing.

III. Course Content

I- Introduction about non – conventional processes

II- Mechanical energy processes:

Ultrasonic machining
Water jet and abrasive water jet machining

III. Electrochemical machining processes and chemical processes

ECM

IV. Thermal energy processes:

• Electric discharge machining
• Electron beam machining
• Arc cutting processes
• Oxy fuel cutting processes
• Laser beam machining

III. Abrasive Machining and Finishing Operations:

• Grinding Processes
• Honing
• lapping
• Polishing
• Ultrasonic machining
• Deburring
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IV- Lasers in manufacturing:
• Fundamentals
• Applications in cutting, welding, marking, heat treatment and
others

V. Rapid prototyping and related Processes:

• Rapid prototyping
• Rapid Tooling
• Rapid Manufacturing

IV. Course Material

Text Book:

- “P. DeGarmo, J. Black, R, Kohser: "Materials and

Processes in Manufacturing", 9th edition, Hoboken, NJ:
Wiley, c2003
- M.Groover, “Fundamentals of Modern Manufacturing
Materials, Processes and Systems”, 3rd ed, John Wiley,
2007

References:

- “S. Kalpkjian, S.R. Schmid: " Manufacturing Engineering

and Technology" 4th edition, Prentice Hall, c2001
- Hwaiyu Geng: "Manufacturing Engineering Handbook"
McGraw Hill, c2004
- William J. Stevenson: “ Operation Management” 8th ed.,
McGraw Hill Publ., 2005

V. Methods of Instruction

Lecturing, Discussions, Assignments, Oral Presentations, Quizzes,

and Exams with continuous feedback and evaluation by the
instructor.

This includes:

One Lecture per week with power point slides

Weekly tutorials will have in-class practice and assignments.

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Field trips may be organized.

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 VI. Course Assessment (Assessment System)

Classification for IT definition Description Weight

Quiz – Theoretical 2 out of 3 10%
Assignments – Theoretical Assignments 15%
Project- theoretical Report and Presentation 10%
Midterm exam Covers until 25%
Mid-Term Exam - Theoretical
Lecture 5
Final Exam – Theoretical Final exam Covers all lectures 40%
Total 100

Please note the following rules:

• Assignments and assignment reports shall be handed-in the

week after taking the assignment and before the dead line.

• You can work in groups and hand-in one assignment, but you will
be questioned about the contents of the assignment. The grade
will be put based on your knowledge of each assignment by
questions either oral or written during the tutorial

• There will be NO makeup examinations for students not

attending the Quizzes and Mid Term.

• No marks will be given to students attending the examinations in

a different time other than their assigned examination time
except with permission form the instructor.

• To pass the course, follow the university rules and policies.

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 VII. Course Implementation Plan

Week Lecture Assignment Quiz

1 Course Outline

(Sep 18- 23) I. Introduction

2 II. Mechanical Energy Assignment 1
Processes:
(Sep 25- 30)

• Ultrasonic machining
• Water jet and abrasive water
jet machining
3 III. Electrochemical Assignment 2 Quiz1
Machining Processes ECM (Lec.
(Oct 2-7) 1,2)
and Chemical Processes
4 No Teaching Activity Assignment 3

(Oct 9-14)
5 IV Thermal energy processes: Assignment 4
• Electric discharge
(Oct 16-21)
machining
• Electron beam machining
• Arc cutting processes
• Oxy fuel cutting processes
Laser beam machining

6 IV Thermal energy processes:

• Electric discharge
(Oct 23-28)
machining
• Electron beam machining
• Arc cutting processes
• Oxy fuel cutting processes
Laser beam machining

7 III. Abrasive Machining and Assignment 5 Quiz2

finishing operations Finishing (Lec.
(Oct 30- Nov 4) processes 3-5)
8 IV Lasers in Manufacturing Laser
applications
(Nov 6-11) Industry park
9 IV Lasers in Manufacturing Eid El Adha
Holiday (Mon
(Nov 13-18) & Thu)

10 Mid Term

(Nov 20-25)

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 11 IV Lasers in Manufacturing

(Nov 27- Dec 2)

12 V. Rapid prototyping Quiz3
(Lec.
(Dec 4-9) 6-8)
13 V. Rapid prototyping Project
Presentations
(Dec 11-16)
14 V. Rapid prototyping

(Dec 18-23)
15 Western Christmas

(Dec 25-30)
(Jan 1-6) Revision week
(Jan 8-20) Final exams

Note: Due date of assignments is one week after the

assignment is given unless stated otherwise

Attendance policy

It is necessary to attend the lecture and tutorials

Please note:

• No marks will be deducted for not attending the lectures,

However note the material covered in the lectures will not be
repeated in tutorials.
• The attendance policy for the tutorial: follow the university rules
and policies.

How to drop:

Follow the university rules and policies.