MIAE311/YY

Manufacturing Processes
Mechanical, Industrial and Aerospace Engineering
Fall 2023
FG B060 SGW, FRI 2:45-5:30PM
Course Instructor:
Dr.Rocco Portaro
rocco.portaro@concordia.ca
Assistant Adjunct Professor, Concordia University

Office Hours:
Fri 1:30-2:30PM (Alternately e-mail appointment)

Tutorials: Please see your class schedule for details

Tutorial YY-A: Th 5:45-7:25 PM, FG B080 SGW
Tutorial YY-B: We 3:15-4:55PM, FG B055 SGW
Labs: Please see your class schedule for details
Course Calendar Description:
Course Plan:
Lecture: 3 hours/week; Tutorial: 2 hours/week

The instructor has the right to change the course outline if any situation arises.
"In the event of extraordinary circumstances beyond the University's control, the content and/or
evaluation scheme in this course is subject to change".

Objectives:

The objective of the course is to provide the students the feel for manufacturing implemented through basic
understanding of measurements, tolerancing, different manufacturing methods including conventional and non-
conventional, and applications of these methods. Manufacturing Processes is a link between creation and
achievement. It is impossible to design any mechanical system or major mechanical component without a deep
knowledge of the manufacturing processes available to produce them. To familiarize with modern machining
technology and manufacturing processes, a series of topics will be presented and discussed in detail by the
students during the presentation period (the second half of the term during Tutorial periods). Laboratory and the
hands-on work will enable the students to acquire valuable personal experience and the necessary “common
sense”. Sometime will be devoted to the study of the machine shop and preparation of process sheets for
manufacturing the parts. A plant visit may be arranged through the Student Association to give students some
insight into the complexity of a workshop which is organized for efficient production.

Description:
Fundamentals of manufacturing processes and their limitations, metrology, machine shop practice, safety and
health considerations, forming, conventional machining and casting processes, welding and joining, plastic
production, and non-conventional machining techniques. Sustainable technologies. Laboratory includes
instruction and practice on conventional machine tools and a manufacturing project. Lectures: three hours per
week. Tutorial: two hours per week, including industrial visits and field trips to local industries. Laboratory: three
hours per week, alternate weeks.

Prerequisites: MIAE 313 or MECH313

Co-requisites: N/A
Specific Knowledge and Skills Needed for this Course:
Students taking this course are expected to have sufficient knowledge of the following topics. Should you have
difficulties in any of these topics, you are strongly encouraged to review them before the DNE deadline.

Should be familiar with MIAE 211 and MIAE 313 course materials.
Course materials
Required Textbook: DeGarmo's Materials and Processes in Manufacturing, 13th Edition
J. T. Black, Ronald A. Kohser, ISBN: 978-1-119-49282-5 May 2019 896 Pages (Good reference book)

Grading Scheme

GRADING POLICY
Evaluation Tool Weight
Midterm 20%
Final * 55%
Project Report+ Oral Presentation: Attendance is mandatory in Tutorials 10%
Assignments 10%
Surprise Quizes 5%
Total 100%
Passing Criteria:
• If your total score before the final exam is less than 40% and you decide to defer the final exam, you will
receive an R grade which prevents you from deferring the final exam.
• In order to pass the class, both your cumulative score and the final examination must be above 50%

Tentative Course Schedule

Ref. Ref. Ref Ref
Week Lecture Topic Chapter Chapter Chapter Chapter
(Ed10) (Ed11) (Ed12) (Ed13)
1 Process Capability and Quality Control, 10, 36 35,43,36 10,11,12 10,11,12
Metrology, Inspection
2 Metal Cutting, Chip Type, Cutting Tools 20, 21 20, 21 21,22 21,22
3 Shaping, Planing, Drilling, Reaming 27, 23 25, 23 27,25 27,25
4 Turning and Boring 22 22 23 23
5 Milling 24 24 24 24
6 Sawing, Broaching, Filing, Nontraditional 27, 19 25, 28 27,30 27,30
Processes
7 Thread Cutting and Forming, 29 42 31 31
8 Abrasive Processes, Grinding, Honing, 28 26 28 28
Lapping, MIDTERM
9 Metal Forming, Hot and Cold Working 15,16,17 15,16,17 17,18,19 17,18,19
Process
10 Casting Processes 11,12,13 11,12,13 13,14,15 13,14,15
11 Plastics Production 8 9 8 8
12 Joining Processes, Gas Flame, Arc 30,31, 32,33 30,31, 35,36, 35,36,
Process, Resistance Welding, Brazing and 32,33 37,38 37,38
Soldering
Lab Details
Please refer the course MIAE312
Engineering Tools
Insert engineering tools introduced/utilized in the course here.
Details on assessment tools:
Assignments: 3-5 assignments will be given
Quizzes: Surprise quizzes 5-8
Midterm: The midterm exam will be held on October 27, 2023 – (please mark it in your agenda).
Project description: Student will do power point oral presentation and submit a report on the same research
topic.
Final exam: Covers all course material.

Other information
Formal Report:

Each student must prepare and present a formal report on a selected topic as a part of one of the six main
topics. The presentations are scheduled as follows:

No. Title of the main topic Date of presentation

1 Aerospace industry related processes Week of Oct 23
2 Automotive industry related topics Week of Oct 30
3 Computers and computers peripheral industry related Week of Nov 06
topics
4 Engines and power generator industry Week of Nov 13
5 Materials and manufacturing – general field Week of Nov 20
6 Health care industry Week of Nov 27

Each main topic will be briefly presented during a full tutorial period for presentations. Equal number of topics
will be allocated to each main topic. The attendance to the presentation is strongly encouraged since questions
out of the presented topics may be asked in the final exam. Topics will be assigned on a first come - first served
basis and must be registered with the tutors. You will be unable to change your topic once you have made the
selection, so think judiciously before you select your future topic. You have to select your topic within one week
time. In case a topic is not selected, the topic, he or she will be designated ex officio to one of the six themes
among the above remaining topics. Sample of topics assigned from previous years are available on the web
site. Each theme will consist of individual presentations that are grouped together to represent that particular
topic. Consequently, it is advisable to keep in touch with the members of your general manufacturing topic to
decide upon the way you will present the set of reports. Presentations account for 5% of the final grade! Students
will work on the presentation tools (Power Point presentation is recommended), the order of presentation, the
content. However, each report will be presented as a self-standing work while the presentation will be a
harmonious synthesis of all the topics. The presentation will be assessed by the instructor/tutors and by the
classmates. The best presentations will gain a place on the web site of the course and will be used as a sample
for the next year students.

Content of the Formal Report:

The topic chosen should be searched in references on magazines and journals as well as on the internet. A
minimum of 15 references must be consulted out of which 6 must be printed information in books, journals or
magazines. All the references must be cited in the text and listed at the end of the report along with the call
number of the library and library name (if other than Concordia). The full web site address must be also provided.
In general, the format of the report shall follow the guidelines given in course ENGR 281, as far as arrangement
of the text, figures and pictures, references, etc. is concerned.
The length of the report must range between 6 and 8 pages (1200 to 1600 words) excluding figures, references,
table of contents, abstract (max 150 words), title page. A list to the recommended order of pages is shown on
the web site.
No verbatim copying or citing from references is permitted! The subject matter contained in references
must be completely rewritten in student's own expressions, on a level understood by second year mechanical
engineering students. All specialized "lingo" and "shop talks" as it often appears in technical articles, must either
be eliminated or explained in text.
The maximum length of 1600 words of text must be strictly adhered to. Any report submitted exceeding the limit
will be devaluated by at least 10%.
While preparing the report, please make sure that you respect all the listed requirements such that you would
avoid losing grades by ignoring the stated rules.

Presentation of the Formal Report:

Each student as part of the team topic will present the topic of the formal report. The order of the presentations
and the method of the presentation (video, compute projector, transparent overheads) will be decided by the
team. Make sure that there is no subject overlapping in the presentations. Each student will present his topic
within a time (5 to 15 minutes depending on the size of the group) such that the entire team will complete the
presentation within the tutorial period.
Timetable
All students must have their topics assigned by September 22. The final project report submission will be on
December 4 before 5:00 p.m. Late submissions will not be considered. Start preparing your report as soon as
possible to avoid such undesirable situation.
The topics for the formal report and the presentation are given in the next page. If a student has a suggestion
on a topic on which he has experience or knowledge, he should contact the class instructor before September
22 to establish a title for that specific MANUFACTURING PROCESSES topic.

Assignments and Reports will be submitted through moodle.

Graduate Attributes:
The following is the list of graduate attributes (skills) that students use, learn and/or apply throughout the term.

GRADUATE ATTRIBUTES:
MIAE311 emphasizes and develops the CEAB (Canadian Engineering Accreditation Board) graduate
attributes and indicators:
ATTRIBUTE INDICATOR LEVEL OF
KNOWLEDGE
A knowledge base for engineering Knowledge-base for INTERMEDIATE
Demonstrated competence in university-level specific engineering field
mathematics, natural sciences, engineering
fundamentals, and specialized engineering
knowledge appropriate to the program.
Design Define the objective INTERMEDIATE
An ability to design solutions for complex,
open-ended engineering problems and to
design systems, components or processes
that meet specified needs with appropriate
attention to health and safety risks, applicable
 standards, and economic, environmental,
cultural and societal considerations.

Use of engineering tools Ability to use appropriate ADVANCED

An ability to create, select, apply, adapt, and engineering tools,
extend appropriate techniques, resources, techniques and
and modern engineering tools to a range of resources
engineering activities, from simple to complex,
with an understanding of the associated
limitations.
Ability to select ADVANCED
appropriate tools,
techniques, and
resources
Communication skills Documentation INTERMEDIATE
An ability to communicate complex
engineering concepts within the profession
and with society at large. Such ability includes
reading, writing, speaking and listening, and
the ability to comprehend and write effective
reports and design documentation, and to
give and effectively respond to clear
instructions.
Oral Presentation INTERMEDIATE
Life-long learning Continuous improvement ADVANCED
An ability to identify and to address their own and self-learning
educational needs in a changing world in
ways sufficient to maintain their competence
and to allow them to contribute to the
advancement of knowledge.

Course Learning Outcomes (CLOs):

By the end of this semester, students are expected to master the following engineering concepts.

The students will be able to

• Define and select the process parameters for required machining operation.
• Recognize and select suitable inspection methods and tools.
• Describe the process sequences required for manufacturing.
• Apply different methods of manufacturing for making a prototype.
• Demonstrate the usage of different inspection and production tools for fabricating a prototype.
• Analyse the inspected measurements for statistical and process capability estimation.
• Understand and apply the fundamentals of manufacturing for making a prototype and solve
manufacturing problems.
• Evaluate the existing manufacturing methods and create mew methods for required situations.
 • Carryout data collection, data analysis, research into manufacturing methods, lab analysis,
report writing and making bill of materials
• Demonstrate selection of appropriate tools and methods for inspection and manufacturing.
• Follow safety rules and procedures.

Upon successful completion of MIAE311, the students will develop a feel for manufacturing, which means,
they will be able to understand and apply the fundamentals of manufacturing for industrial problems and
implement the same through design, analysis, and demonstration of acquired knowledge

Health and Safety Guidelines

All health and safety rules specific to this course can be found in the lab manual. General health
and safety instructions and available health and safety trainings can be found at:
Safety Programs - Concordia University (https://www.concordia.ca/campus-life/safety/general-
safety.html)

On Campus Resources
Please visit Student services at Concordia University for the services available Gina Cody
School students.
 APPENDIX

ADDENDUM TO THE COURSE OUTLINE

ACADEMIC CONDUCT ISSUES

The basic ten rules that make you a good engineer

The B. Eng. program is set to satisfy most of the requirements for your education and prepares
you for a professional engineering career that requires dedication and knowledge. What you
learn, and how you learn, will be used extensively in your engineering profession for the next 30
to 40 years. Therefore, the four years spent in the engineering program are crucial towards your
professional formation. The first step is for you to learn to “think like an engineer” which means:

• accept responsibility for your own learning

• follow up on lecture material and homework
• learn problem-solving skills, not just how to solve each specific homework problem
• build a body of knowledge integrated throughout your program
• behave responsibly, ethically and professionally

One of the mainstays of being a professional engineer is a professional code of conduct and as
an engineering student this starts with the Academic Code of Conduct (Article 16.3.14 of the
undergraduate calendar). However, you may encounter situations that fall outside the norm and in
such cases, you use your common sense.

Further, the following issues should be given serious consideration:

1) Attendance at lectures and tutorials are major learning opportunities and should not be missed.
The labs represent a unique opportunity for you to acquire practical knowledge that you will need
in your career. Class and tutorial attendance is important for you to comprehend the discipline
and make the connections between engineering skills. You are strongly encouraged to participate
in the class, ask questions and answer the instructor’s questions. Tutorials are just extensions of
the classes in which application of the concepts presented during the lectures are presented and
problems are practically solved.

2) The decision to write tests that are not mandatory is entirely yours. For example, midterm test are
often stated in many courses as optional. However, one the objectives of midterms is to check on
your comprehension of the material and allow time for whatever action is necessary (from more
study time to discontinuing a course). Plan to attend the class tests even if they are not
mandatory. If you pay attention in the lectures, it will take you significantly shorter time to
comprehend the material. Note also that if you are in the unfortunate position of being unable to
write a final exam due to medical reasons and seek a deferral, this may not be possible if the
instructor has no information indicating that you have been attending the course and assimilating
the material (ie through midterms, quizzes, assignments etc).

3) Homework is usually mandatory and it has some weight in the final grade (such information is
given in the course outline). Homework may also be conceived as training material for the class
tests. Under all circumstances, it is highly recommended to carry out the home work on time and
submit it on the prescribed date. Late submissions are not granted to individual cases regardless
 of the reason. This is part of the training for being in the workforce where deadlines have to be
met. Please, plan your work such that you submit all the assignments and lab reports on time and
in the correct place (not in the corridor or on the street!).

4) Office hours with tutors, lab instructors or class instructors are listed in the course
outline/website/office doors. Please respect these office hours and in case you have a serious
conflict, contact the instructor asking for a special time arrangement.

5) Class tests (midterms, quizzes) are not returned to the student. The final exams also are not. If
you wish to see your exam paper, be aware that most instructors allow only a narrow window of
time for that purpose. For the fall term, exams may usually be reviewed in January and May for
the spring term.

6) When you see your marked work (assignments, midterms, final exam etc), be aware that you are
supposed to review your material and see the type of errors you made and if marks have been
added incorrectly. This is not an opportunity to try and “negotiate” a higher grade with the
instructor. If you believe that your grade is not right, you may apply for a formal Course
Reevaluation through the Birks Student Centre.

7) Writing tests and exams represents a major component of your course work. These tests and
exams have rigorous requirements such as:
• No cell phone or other communication enabling tool is allowed on the student during the
examination period.
• Only specified faculty calculators [ SHARP EL-531 or CASIO FX-300MS ] are allowed during
tests and exams unless otherwise indicated by the instructor.
• Usually, no materials are allowed in the exam unless otherwise announced.
Get used to signing in and out of your exam. Make sure that you leave your exam papers with the
invigilator. There are rules concerning general exam issues in the UG Calendar. These
requirements are there to eliminate any possible misunderstanding and you are asked to respect
the rules. Disciplinary measures are taken when the rules are not followed.

8) Respect your colleagues and those that you meet during the class: tutors, instructors, lab
instructors, technical personnel, assistants, etc. Use appropriate communication means and
language. Be considerate for all human beings. This includes small things such as turning off cell-
phones before a class begins. Concordia University is a very diverse group of people and a very
large multicultural community.

9) Communication is part of your future profession. Learn how to communicate effectively and
efficiently in the shortest time possible. Write short but meaningful e-mails, make effective phone
calls, etc. If your instructor accepts emails make sure that your request is clear with the course
number and your name in the Subject line. Do not ask for special treatment as instructors have to
treat all students equitably.

Respect all the above and you will get closer to your future profession.
 LIST OF PROJECTS

1. Aerospace Industry Related Processes

1 Turbine blade manufacturing
2 Aluminum sheet shaping for airplane fuselage
3 Composite materials - an alternative solution for airplane construction
4 Riveting process in aerospace industry
5 High precision bore measurement in aerospace industry
6 Rapid prototyping - efficient path from design to manufacturing
7 Technology of physical measurement in flight control
8 Efficient de-icing process in air transportation industry
9 Assembly technology of airplanes
10 Maintenance program in airplane service industry
11 Inspection and calibration of shop and tool-room measuring instruments.
12 Assembly technology for Gas Turbine Engines
13 Technology of more electric Gas Turbine Engines
14 Fabrication technology for avionics
2. Automotive Industry Related Processes
1 Hybrid vehicles, an alternative for the future cars
2 Ceramic materials in car engine fabrication
3 Composite material, an alternative for the body parts of a car
4 Efficient casting methods for the engine block
5 Milling process in engine fabrication
6 Plastic injection in car manufacturing
7 Foam car seat manufacturing
8 Windshield manufacturing
9 Control and tests in automotive industry
10 Car tire manufacturing process
11 Low emission engine technologies
12 Car engine fabrication technology
13 Spot welding in car manufacturing
14 Advanced fabrication technologies for the braking system

3. Computers and Computer Peripheral Industry

1 Manufacturing processes in Integrated Circuits (IC) production
2 Hard Disk manufacturing processes
3 High precision coatings for hard disk media manufacturing
4 Laser printing principles and manufacturing
5 Ink jet printing head manufacturing
6 Display technologies in computer peripheral industry
7 High resolution display technologies
8 Compact Disc (CD) manufacturing technology
9 Recording technology on WCD and RWCD
10 Manufacturing technology of floppy disks
11 PCB’s fabrication technology
12 Fabrication processes for MEMS
13 Non-conventional technologies in computer applications
14 Packaging technologies for MEMS

4. Engines and Power Generating Industry

1 Casting vs. Forging in engine fabrication
2 Ball and roller bearing technology
3 Deep hole boring technology
4 Gear manufacturing technology
5 Control principles and technology of the large size gears
6 High precision measurement of large features
7 Non-destructive test principles and methods in engine manufacturing
8 High precision alignment of bores in large housings
9 Fabrication technology of engine valves
10 Assembly technology of power station turbines
11 Process capability assessment in mass production
12 Diagnostic and maintenance of power generating turbines
13 Health and Usage Monitoring Systems for power generating systems
14 Ultra-fast metal cutting technologies
5. Materials and Manufacturing
1 Composite materials vs. metal sheet technology
2 Powder technology: applications in cutting tool manufacturing
3 Ceramics technology; applications and potential
4 Rapid prototyping principle, methods and applications
5 Fatigue resistant advance materials used in industry
6 Non-conventional manufacturing technologies for mechanical systems
7 Miniaturization and MEMS; a trend for the future microsystems
8 Advanced alloys for special application
9 Advanced CNC for high precision flexible manufacturing
10 Fabrication technology and codes for pressure vessels
11 Precision molds for high efficiency casting
12 Die-casting of small components in non-ferrous alloys
13 Technology of ceramic and metallic composites
14 Technology of nano-composite materials

6. Food and Healthcare Industry

1 Specific requirements for the materials of equipment used in food and drug industry
2 Fabrication of single-use surgery supplies
3 Industrial sterilization of single use surgery supplies
4 Fabrication of containers for food industry
5 Fabrication technology of articulation prosthesis
6 Implantable miniature drug dispensers equipped with CPU and sensor
7 Special conditions for materials used for implantable devices
8 Packaging technology for drug industry
9 Fabrication technology of surgical needles
10 Fabrication technology of artery catheters
11 Production of medical tablets
12 Manipulation technologies in bio-engineering industry
13 Fabrication technologies and packaging in the food industry
14 Fabrication technologies for plastics for food and health industry
ON CAMPUS RESOURCES
HEALTH SERVICES
An on-campus health clinic and health promotion
center with nurses and doctors.
SGW 514-848-2424 ext. 3565
LOY 514-848-2424 ext. 3575
ACCESS CENTRE FOR STUDENTS WITH
DISABILITIES
Supports students with a variety of disability
conditions (including temporary disabilities
arising from illness or injury). Students receive
academic support for their educational
experience at Concordia.
acsdinfo@concordia.ca 514-848-2424 ext. 3525
STUDENT SUCCESS CENTRE
Support network from first-year to graduation.
You’ll find one-on-one tutors, study groups,
workshops as well as learning and career
advisors
514-848-2424, ext. 3921
ABORIGINAL STUDENT RESOURCE
CENTRE
An on-campus resource for First Nations, Métis
and Inuit students that helps them make the
most of the many resources available at the
university.
Orenda Konwawennotion Boucher-Curotte,
Coordinator
orenda.boucher@concordia.ca 514-848-2424
ext. 7327
COUNSELLING AND PSYCHOLOGICAL
SERVICES
Counsellors (licensed mental health
professionals) work with students to address their
mental health and wellbeing needs.
SGW 514-848-2424 ext. 3545
LOY 514 848-2424 ext. 3555
SEXUAL ASSAULT RESOURCE CENTRE
Provides confidential and non-judgemental
support and services to students, staff and
faculty of all genders and orientations affected
by sexual violence and/or harassment.
Jennifer Drummond, Coordinator
jennifer.drummond@concordia.ca
sarc@concordia.ca
514-848-2424 ext. 3353
DEAN OF STUDENTS
Supports students to enhance their Concordia
experience by engaging in student life outside
the classroom.
Terry Kyle, Manager
deanofstudents.office@concordia.ca SGW 514-
848-2424 ext. 3517
LOY 514-848-2424 ext. 4239
INTERNATIONAL STUDENTS OFFICE
Supporting international students with
immigration documents, health insurance, social
events, and workshops.
iso@concordia.ca
514-848-2424 ext. 3515
 STUDENT ADVOCACY OFFICE MULTI-FAITH & SPIRITUALITY CENTRE
Advocating for students facing charges under Provides a home for all those wishing to celebrate
the Academic Code of Conduct or the Code of the human spirit in the widest sense of the word,
Rights and Responsibilities. through programs, events and a quiet space for
studentadvocates@concordia.ca 514-848-2424, reflection.
ext. 3992 Ellie Hummel, Coordinator
mfsc@concordia.ca
514-848-2424, ext. 3593
CAMPUS SECURITY CONCORDIA UNIVERSITY STUDENT
Ensures the safety of our members and campus PARENTS CENTRE
property through prevention, surveillance, An accessible space for student parents to study,
intervention, training, and education. Provides share interests and develop a support network.
emergency medical services. Sumaiya Gangat, Coordinator
security@concordia.ca 514-848-3717 cusp@concordia.ca
(dial 1 for urgent situations; dial 2 for non-urgent 514-848-2424, ext. 2431
situations)

ACADEMIC HONESTY AND CODE OF CONDUCT

Violation of the Academic Code of Conduct in any form will be severely dealt with. This includes
copying (even with modifications) of program segments. You must demonstrate independent thought
through your submitted work. The Academic Code of Conduct of Concordia University is available at:
http://www.concordia.ca/students/academic-integrity/offences.html

It is expected that during class discussions and in your written assignments you will communicate
constructively and respectfully. Sexist, racist, homophobic, ageist, and ablest expressions will not be
tolerated.