An integrated teaching methodology for manufacturing processes

Abstract

In this paper, we describe an integrated approach for promoting an effective education methodology for teaching manufacturing processes. In that regard, a three-faceted approach that incorporates providing opportunities for an active learning experience for manufacturing processes has been described. For demonstration cases, the course entitled as ENGR3600 Production Engineering has been chosen as the teaching medium. Three main aspects of the teaching methods include: 1) In-class teaching of lecture material (i.e., casting processes) 2) Hands-on sand casting laboratory where students are engaged in conducting and assisting in various steps of sand casting process (i.e., premixing, mold preparation, actual casting process, trimming sprues, runners, gates etc.) 3) Numerical and graphical analysis of the casting process through simulation. The integrated methodology would be comprised of classroom and lab activities, in which two sessions are conducted in the classroom environment, and one session is conducted in the casting lab. The first classroom lecture incorporates describing the various aspects of the casting processes such as the process description, capabilities, characteristics, design considerations, various types of casting processes with the corresponding variations. In the second classroom lecture, the students through the CastView™ software had the opportunity to analyze a casting process processes both visually and analytically. In the third step, the sand casting process is employed for casting aluminum for obtaining the final product. Students, using insights obtained from the classroom lectures have the opportunity to demonstrate their design skills in an engineering setting which involves mold design and preparation and actively participate in assisting in the subsequent operations. In overall sense, authors conclude that a three-faceted approach that integrates the elements of the theoretical classroom teaching with the computer assisted analysis along with actual laboratory implementation would significantly facilitate reaching the learning objectives associated with various manufacturing processes outlined in the Production Engineering class. It is worth mentioning that the suggested approach is not limited with a particular manufacturing process and might be adopted for different manufacturing processes which span a large spectrum of existing manufacturing technology (e.g., shaping processes for plastics, sheet metal forming and welding processes). As a future research direction, the guidelines that would help increasing the generality of the suggested approach for different manufacturing processes would be further proposed and detailed.