Syllabus

Ternopil Ivan Puluj National Technical University

Каф. інжинірингу машинобудівних технологій

Fundamentals of Technology for Assembly and Machine Parts Production

syllabus

1. Educational programs for which discipline is mandatory:

# Educational stage Broad field Major Educational program Course(s) Semester(s)
1 bachelor's 13. Механічна інженерія 131. Прикладна механіка (бакалавр) 3 6-7

2. The course is offered as elective for all levels of higher education and all educational programs.

3. Information about the author of the course

Full name Diachun Andrii
Academic degree Cand. Sc.
Academic title Assoc. Prof.
Link to the teacher`s page on the official website of the University http://library.tntu.edu.ua/personaliji/a/d/djachun-andrij-jevhenovych/
Е-mail (in the domain tntu.edu.ua) Andriy_Dyachun@tntu.edu.ua

4. Information about the course

Study hours structure Lectures: 34
Practical classes: 34
Laboratory classes: 34

Amount of hours for individual work: 138
ECTS credits: 8,0
Teaching language english
Form of final examination credit
exam
Link to an electronic course on the e-learning platform of the university https://dl.tntu.edu.ua/bounce.php?course=5414

5. Program of discipline

Description of academic discipline, its goals, subject of study and learning outcomes

The purpose of study of the discipline «Fundamentals of Technology for Assembly and Machine Parts Production» is acquisition of knowledge and practical skills from development highly coefficient and economic technological processes (TP) of machining, assembling and testing of industrial parts. The task of a given discipline is the receipt by the students of theoretical knowledge from basic positions of technology of parts production and machines assembly, in particular theories of location and size chains, methods of development of operating technological processes of parts machining and machines assembly. The study of objective laws, that arises up in the process of creation of machines and factors, that determine its quality, reliability, prime price. Acquisition of abilities and practical skills in development of technological processes of machining and assembly of machines, forming at the students of knowledge, abilities and acquisition of experience in the region of analysis of objective laws at manufacturing of machines parts and planning of technological processes.

The place of academic discipline in the structural and logical scheme of study according to the educational program

Prerequisites. List of disciplines, or knowledge and skills, possession of which students needed (training requirements) for successful discipline assimilation

Techniques of Mechanical Engineering, Technology of Structural Materials and Material Science

Contents of the academic discipline

Lectures (titles/topics)

What Is Manufacturing?
Manufacturing Defined. Manufacturing Industries and Products. Production Quantity and Product Variety. Manufacturing Capability. Technological Processing Capability. Physical Product Limitations. Production Capacity.
Manufacturing Processes.
Processing Operations. Shaping Processes: Solidification Processes, Particulate Processing, Deformation Processes, Material Removal Processes. Property-Enhancing Processes. Surface Processing. Assembly Operations. Production Machines and Tooling.
Engineering Manufacturing Processes. Fundamental Principles.
Production and Manufacturing Processes and Their Elements. Fundamentals of Production and Manufacturing Processes. Concentration and Differentiation of the Manufacturing Process. Organizational Aspects of Process Planning. Types of Production.
Production systems.
Production Facilities. Low-quantity Production. Medium Quantity Production. High Production. Flow Line Production. Manufacturing Support Systems. Production Cycle Time Analysis. Manufacturing Cost Models. Overhead Costs. Equipment Cost Rate.
Surfaces.
Characteristics of Surfaces. Surface Texture. Surface Integrity. Measurement of Surfaces. Evaluation of Surface Integrity. Effect of Manufacturing Processes.
Surface Finish in Machining.
Geometric Factors. Work Material Factors. Vibration and Machine Tool Factors
. Locating and Clamping Principles.
Introduction. Restrictions on the Degrees of Freedom of a Workpiece. Basic Principles of Locating. The Mechanics of Locating. Forms of Location. Locating from External Surfaces. Locating from Internal Surfaces. Locating Guidelines. Clamping Guidelines. Positioning the Clamps
Economic and Cutting Conditions in Machining.
Machinability. Selection of Cutting Conditions. Optimizing Cutting Speed. Selecting Feed and Depth of Cut. Optimizing Cutting Speed. Maximizing Production Rate. Minimizing Cost per Unit. Product Design Considerations in Machining.
Group Technology.
Plant Layout. Advantages of Group Technology. Classification and Coding of Parts. Coding Systems.
Process Planning.
Traditional Process Planning. Problem Solving and Continuous improvement. Computer-aided Process Planning. Process Planning for Parts. The Route Sheet. Process Planning for Assemblies.
Principles Followed in Planning the Operation Sequence. Time Standards.
Principles Followed in Planning the Operation Sequence. Time Standards and Their Structure. Determining the Principal Components of The Standard Time. Principal Considerations in Selecting the Machining Method. Methods for Increasing Productivity in Machining Operations.
Fundamentals of Assembly Operations.
The Product and Its Components. Assembly Flow Charts. Joining Methods in Machine Assembly. Assembly Organizational Structures. Planning the Assembly Process. Rate Setting for Assembly Operations.
Mechanical Assembly.
Threaded Fasteners. Screws, Bolts, and Nuts. Other Threaded Fasteners and Related Hardware. Stresses and Strengths in Bolted Joints. Tools and Methods for Threaded Fasteners. Rivets and Eyelets. Assembly Methods Based on Interference Fits. Press Fitting. Shrink and Expansion Fits. Snap Fits and Retaining Rings. Other Mechanical Fastening Methods. Stitching, Stapling, and Sewing. Molding Inserts and Integral Fasteners. Inserts in Moldings and Castings. Integral Fasteners. Design for Assembly (DFA). General Principles of DFA. Design for Automated Assembly.
Statistical Process Control.
Process Capability and Tolerances. Statistical Process Control. Control Charts for Variables. Control Charts for Attributes. Interpreting the Charts. Six Sigma.
Quality Control and Inspection.
Quality Programs in Manufacturing. Total Quality Management. Six Sigma. Taguchi Methods. ISO 9000. Inspection Principles. Manual and Automated Inspection. Contact Versus Noncontact Inspection.
Automation Technologies for Manufacturing systems.
Automation Fundamentals. Three Components of an Automated System. Types of Automation. Fixed Automation. Programmable Automation. Flexible Automation. Hardware for Automation. Sensors. Actuators. Interface Devices. Process Controllers.
Production Planning and Control.
Aggregate Planning and the Master. Production Schedule. Material Requirements Planning. Capacity Requirements Planning. Shop Floor Control. Enterprise Resource Planning.

Practical classes (topics)

Boring Machines and Operations.
Technological Process and Its Structure.
The Types of Production Processes.
Surface Finish in Turning.
Locating Principles.
The Location on the Planes of Symmetry, Axes, Lines or Points of Their Crossing.
Economic and Cutting Conditions in Machining.
Group Technology.
Preparation of Technological Documents.
Process Plan for Bike Chain Puller Body.
Assembly Flow Charts.
Mechanical Assembly Methods.
Determining the Principal Components of The Standard Time.
Statistical Process Control.
Quality Control and Inspection in Machining
Hardware for Automation.
Material Requirements Planning.

Laboratory classes (topics)

Determination of Dependence of Size Wear of Cutter From the Distance of Cutting.
Determination of Dependence of Relative Wear of Cutter from Cutting Speed.
Determination of Dependence of Temperature Deformations of Cutter from the Distance of Cutting and Cutting Conditions.
Determination of Dependence of Temperature Spindle Deformations of Vertical-milling Machine from Time of Work and Cooling.

Comparative Researches of Machining Processes of Surfaces by the Finish Grinding and Polishing.
Research of Influencing of the Cutting Conditions and Geometry of Cutting Tools on the Surface Roughness at Machining on the Lathe and Milling Machine-tools.
Determination of Influencing of Workpiece Deformation under Action of Cutting Forces on Machining Quality of Shaft.
Methods of Receipt of Tolerance Dimensions and Determination of Exactness of the Repeated Adjusting of the Machine-tool.
Determination of Influencing of Locating Errors on Machining Quality.
Research of influencing of the system rigidity of shaping machine-tool on quality of the machined surface.
The reducing gear assembly and computation of size chains
Research of influencing of the cutting conditions on machining quality at boring.
Research of Influencing of the Cutting Conditions on Machining Quality at Grinding.
The Influence of Clamping Force of Workpiece on the Machining Error.
Research of Location Error of Workpiece on Lathes.
Research of Influencing of the Cutting Conditions on Machining Quality at Drilling.
Research of Influencing of the Cutting Conditions on Machining Quality at Milling.

Learning materials and resources

1. Mikell P. Groover. Fundamentals of Modern Manufacturing. Materials, Processes, and Systems. Fifth Edition. John Wiley & Sons, Inc., 2013.
2. Kalpakjian, S., and Schmid S. R. Manufacturing Processes for Engineering Materials, 6th ed. Pearson Prentice Hall, Upper Saddle River, New Jersey, 2010.
3. Hornyak, G. L., Moore, J. J., Tibbals, H. F., and Dutta, J. Fundamentals of Nanotechnology, CRC Taylor & Francis, Boca Raton, Florida, 2009.
4. Groover, M. P. Work Systems and the Methods, Measurement, and Management of Work, Pearson Prentice-Hall, Upper Saddle River, New Jersey, 2007.
5. Groover, M. P. Automation, Production Systems, and Computer Integrated Manufacturing, 3rd ed. Pearson Prentice-Hall, Upper Saddle River, New Jersey, 2008.
6. Boothroyd, G., and Knight, W. A. Fundamentals of Metal Machining and Machine Tools, 3rd ed. CRC Taylor & Francis, Boca Raton, Florida, 2006.
7. Bakerjian, R. (ed.). Tool and Manufacturing Engineers Handbook. 4th ed. Vol VI, Design for Manufacturability. Society of Manufacturing Engineers, Dearborn, Mich., 1992.
8. Parsai, H., Leep, H., and Jeon, G. The Principles of Group Technology and Cellular Manufacturing, John Wiley & Sons, Hoboken, New Jersey, 2006.

6. Policies and assessment process of the academic discipline

Assessment methods and rating system of learning results assessment

Form of final term control – examination. 3 points of term mark equals to 1 point of final term mark.


Table of assessment scores:

Assessment scale
VNZ
(100 points)
National
(4 points)
ECTS
90-100 Excellent А
82-89 Good B
75-81 C
67-74 Fair D
60-66 E
35-59 Poor FX
1-34 F
Approved by the department
(protocol №
on «
»
y.).