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ME-542 Manufacturing with Non-metallic Materials
Room: Engineering Building, Room 328, M-W 17:30-18:45
Instructor: Dr. Jim Burns
Office : Engineering Building, Room E105A
Office hours: MW 1000-1130
Email address: jburns@mail.sdsu.edu
Telephone: (619) 594-6076Course Description
PrerequisitesThis course is intended to give the student an overview of contemporary and emerging composite manufacturing methods in use in a wide variety of durable and consumable goods industries. The initial emphasis will be on the mathematics and mechanics of polymer flows and processing. Next, contemporary net-shape composite manufacturing processing techniques, equipment and testing methods will be presented and demonstrated. The course will conclude with hands-on manufacturing projects accomplished in teams.
Mechanical Engineering 340 and Engineering 280 with a grade of C or better.
Text Book
The text Polymeric Materials and Processing by Dr. J. M. Charrier presents domain-specific information on polymers and the business practice of polymer processing. Students will also be provided supplimental course materials on polymer processing mechanics, use of a computer tutorial, and custom software illustrating coursework principles.
Other Documentation
Stereolithography Tutorial Web Page
Urethane Casting from Silcone Molds
Vacuum Forming of Vehicle Transparencies
Reciprocating Screw-Style Injection Molder Operating Manual
Plunger-Style Injection Molder Operating Manual
Resin Transfer Molding Tutorial
Injection Molding Simulation Manual
Fiberglassing with Polyesther Resin
Fabricating a Prepreg Laminate
Using the Capillary Viscometer
Equipment
Stereolithography Machine
Injection Molder
Extruder
Vacuum Forming Unit
Pultrusion Machine
Platen Press
Environmental Control Unit
FANUC RobotStereolithography Machine: Used to create solid epoxy prototypes of complex objects less than 7" on a side.
Injection Molding Machine: Used to injection mold various parts. It is rated at a half ton and a six ounce shot.
Screw Extruder: can be used to extrude a variety of thermoplastics in a continuous process.
Vacuum Former: Uses conventional vaccum forming techniques to produce a variety of different shapes.Pultrusion: A continuous composite manufacturing process that currently produces a rectlinear carbon fiber ruler.
Platen Press: A 200 Ton hydraulic press with heaters that is used to apply the appropriate pressure and temperature to cure composites.
Environmental Chamber: Expose materials and structures to extremes of temperature and humidity for later testing.
Fanuc S-110-R Robot: Used in various manufacturing processes, currently involved in a continuous filament winding process.
Student Projects
Previous Projects
- Solar cell mounting plate fabrication (2 teams)
- Production of fairing lamination mold
- LabVIEW pultrusion simulation
- Injection molding operating manual and demo
- Extrusion operating manual and demo
- Mirror housing tooling fabrication and vacuum forming
- Test specimen fabrication and test using prepreg
- Freezer and oven facilities upgrade
- HPV, Suntracker seat construction
- Production of sandwich panels for RF test
- Construction of underwater processing cell
Current Projects
- Operating manual and demo of press-clave manufacturing
- Production of Urethane foam blocks
- Composite repair station operating manual and demo
- Automated material delivery systemfor injection molding machine
- Foam milling feed and speed study
- Installation of new thermoforming unit
- LabVIEW extrusion simulation
- LabVIEW injection molding simulation
- LabVIEW compression molding simulation
- Resin Transfer molding web tutorial
- Design of modular unit die injection mold using Pro/MOLD
- Tutorial for new 20-ton injection molding machine
Related Resources on the Web
Composites - An overview of composites.
Composites Manufacturing - Composites Manufacturing Association of SME (CMA/SME) serves as a resource to composites professionals in all industries.
Center for Composite Materials - Composites Design, Manufacturing, Test and Implementation Research
Composites Research at MSU - Composites Research at Michigan State University.
Carbon-Carbon Composites - What are carbon/carbon composites?
Polymers - Polymer index resource
Plastics - Plastics Molders and Manufacturers Groups of SME (PMMG/SME)
Polymers DotCom - On-line plastics magazine and comprehensive industry resourse links
Ridout Plastics - Ridout Plastics Home Page
