Enhancing teaching and laboratory capacity of the undergraduate Manufacturing Processes course by acquiring force dynamometer

Project Title: Enhancing teaching and laboratory capacity of the undergraduate Manufacturing Processes course by acquiring force dynamometer

Project Lead’s Name: Muhammad Jahan

Email: jahanmp@miamiOH.edu

Phone: (513) 529-0347

Please Choose the Primary Affiliation: CEC

Are There Other Project Team Members?: Yes

Other Project Team Member: Fazeel Khan

Other Team Member Email Address: khanfj@MiamiOH.edu

Other Project Team Member: Karl Reiff

Other Team Member Email Address: reiffkr@MiamiOH.edu

Brief description of project: This proposal presents a case for the acquisition of a force dynamometer system for Computer Numeric Controlled (CNC) Turning and Milling Machines. The main objective is to enhance the laboratory capacity of the undergraduate "Manufacturing Processes" class. The proposed force dynamometer system will be used in the machining lab of the course. The "Manufacturing Processes" course is a combination of laboratory and theory, where the students participate in hands-on lab activities throughout the semester to understand various manufacturing processes. The students finally complete a project, where they make parts of a reciprocating pump using machining processes. In the machining lab, currently students run experiments to investigate the tool tip temperature with the variation of machining parameters, i.e. feed rate, depth of cut, cutting speed; use of coolant, cutting tool material, and workpiece material. However, it would be beneficial for the students if they could also study the effect of various parameters on cutting forces. Using the proposed force dynamometer system, the students could investigate the effect of machining parameters on cutting forces as well as analyze the relationship between cutting forces and the tool tip temperature. Currently, the students learn the effect of machining parameters on cutting forces in theory class. The proposed force dynamometer will provide the students an opportunity to test their theoretical knowledge by conducting experiments and comparing experimental findings with theoretical knowledge. The 'Manufacturing Processes' is a required course for both the mechanical and manufacturing engineering majors and all the students (about 600) in the MME departments needs to take the course.

Besides the undergraduate "Manufacturing Processes" course, the CNC turning and milling machines are being used extensively by the students for senior design projects and multiple research projects at both undergraduate and graduate levels. The CNC machines also provide strong support to our SAE Baja and Formula SAE projects by allowing them to manufacture various parts and components of the racing cars built at Miami University. The force dynamometer for the CNC machines will impact these projects immensely, as it will gather the real time data on the cutting forces for machining various materials and provide important guidelines in the selection of cutting tools and machining conditions rather than using a trial-and-error basis.

With the acquisition of force dynamometer, we will re-design the machining lab by allocating an extra class for the analysis of cutting forces and tool tip temperature in machining. In the revised machining lab, the students will be asked to conduct a comprehensive experimental study to investigate the effect of operating parameters, coolant, cutting tool and workpiece material hardness on the cutting forces and tool tip temperature generated during the machining process. Running experiments with force dynamometer and analyzing the data will enrich the in-depth understanding of the machining process. We believe acquisition of force dynamometer would enable students to receive training on the state-of-the-art facilities, which will make them ready for industry work environment. The force dynamometers are very common in most of the aerospace and automotive industries.

We believe that the acquisition of force dynamometer will impact the education and training of undergraduate students at the MME department. This new equipment will not only increase the teaching capacity in the MME Department, but also will train the students to make them ready for working in state-of-the-art machining facilities at any automotive or aerospace industries. It will also contribute to the advancement in machining research at the undergraduate and graduate levels, and impact the SAR Baja and Formula SAE projects.

Does this project focus on graduate student education or graduate student life?: Yes

If yes, please explain: The primary use of the force dynamometer system will be in undergraduate education, yet it can also be used for graduate education and research. This is because the system will allow advanced level experimentation on the machinability of materials. With the growth of the graduate program at the MME department, we are in need of the development of graduate courses in Manufacturing. The force dynamometer system will definitely enrich the capability of engaging graduate students in hands-on lab activities for graduate level 'Advanced Manufacturing Processes' course. However, the force dynamometer system will immediately impact the research experience of graduate students working on the machining projects. The new equipment will enhance the quality of research by allowing the students to conduct in-depth study on the machinability of automotive and aerospace materials.

Describe the problem you are attempting to solve and your approach for solving that problem.: This proposal, if successful, will cover a gap created in the laboratory capabilities of the 'Manufacturing Processes Lab', an instructional laboratory of the MME Department. We will re-design our 'Machining Lab' and allow students to conduct experiments on the upgraded capacity. The force dynamometer will enable students to study the effect of machining parameters, coolant, and material hardness on the cutting forces generated during machining. The students will also be able to use the equipment in their final project for the 'Manufacturing Processes' course as well as for making parts for their senior design projects.

The criteria state that technology fee projects should benefit students in innovative and/or significant ways. How would you describe the innovation and/or significance of your project?: 'Manufacturing Processes' is one of the core learning classes in Mechanical and Manufacturing Engineering. All students in the MME department (Mechanical Engineering, Manufacturing Engineering and Engineering Management) must take MME 231 (Manufacturing Processes) as part of their degree. Manufacturing Engineering and Engineering Management students are also required to take MME 437 (Automated Manufacturing), while Mechanical Engineering students has options to take MME 437 course as one of their technical electives. A major portion of the MME students use CNC machines to fabricate their required parts during their final capstone design project. Additionally, students' clubs SAE Baja and Formula SAE heavily rely on the CNC machines to fabricate their suspension components and transmission for these prestigious intercollegiate races. This proposal aims to enhance the Manufacturing Processes Laboratory capabilities, especially for Machining Lab and Final Project, and to enhance the quality of students' academic opportunities in preparation for their professional activity. To summarize, the new force dynamometer system will: 1. benefit all MME students (about 600) by training them on how to use force dynamometer system for machining, 2. benefit many MME students through capstone projects, 3. enhance the quality of Manufacturing Processes course at undergraduate level, and 4. enhance the quality of research at both undergraduate and graduate levels.

How will you assess the project?: The primary objective of the project is to make a significant contribution to enhance the students' hands-on learning experience and fundamental understanding of machining process in their "Manufacturing Processes" course. The realization of this goal will be assessed through three evaluations methods. At the end of the course, we will evaluate the students' learning of the machining lab and if the new equipment helps improve their understanding of the machining concept. The second measure of efficacy will be the data collected through senior exit interviews, which specifically inquire about the quality of the laboratory experience and laboratory facilities available for senior design projects. The third evaluation method will be through the Alumni surveys, which will constitute the most reliable body of information on the level of preparation instilled by laboratory activities. These surveys are conducted regularly by the department, and will be modified to elicit information specific to this project.

Have you applied for and/or received Tech Fee awards in past years?: No

What happens to the project in year two and beyond? Will there be any ongoing costs such as software or hardware maintenance, supplies, staffing, etc.? How will these be funded?: The requested force dynamometer system will be used for the machining laboratory experiments by installing them into the Hass TM-1P CNC Mill and Hass CNC TL-1 lathe. The force dynamometer system come with the data acquisition system which will enable students to monitor and collect real time data during machining, and later analyze the data by plotting graphs and including the results in their lab reports. Mr. Karl Reiff, who is in charge of the laboratory coordinator, will be in charge of installing the equipment to the machine as well as conducting periodic maintenance of the equipment. The cost of installation and periodic maintenance of the force dynamometer system will be covered by the MME laboratory upkeep budget.

Budget: Hardware, Contractual Services/Installation/Shipping/Maintenance

Hardware Title(s) & Vendor(s): Kistler Force Dynamometer System

Hardware Costs: $49,840.84

Contractual Services/Installation/Shipping/Maintenance: Facilities, electrical connections and Shipping

Contractual Services, etc. Costs: $3,000.00

What is the total budget amount requested?: $52,840.84