Dimitrios G. Maltezos, P.E.
Professor of Mechanical and
 Manufacturing Engineering Technology

MET 117 -
Manufacturing
Processes

MET 127 -
Advanced
Manufacturing
Processes

MET 210 -
Applied
Thermodynamics

MET 405 -
Dynamics

MET 411 -
Applied
Heat
Transfer

 

Contact:
Voice:  (631) 420-2004
Fax:  (631) 420-2194

Office:
Room 180 - Lupton Hall
SUNY Farmingdale
Farmingdale, NY 11735

Email:
 maltezdg@farmingdale.edu

 

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MET127 - Manufacturing Processes

Course Description

The main purpose of this course is to familiarize the mechanical / manufacturing engineering technology student with the principles and operation of manual and numerically controlled milling machines. Additional topics covered are the gear shaper, indexing head, and grinding machines. Measuring instruments, as well as additional manufacturing processes are also covered. Laboratory projects will be assigned to reinforce the topics covered in the theory. Prerequisite: MET 117 (1,3) 2 credits


Textbook


Goals/Objectives

To give students hands-on experience in the use of milling machines, NC programming, etc
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Course Topics

  • Milling Machines, Types and Accessories / Maintenance.
  • Milling Cutters, classification, types etc.
  • Cutting Speeds, Feeds, and Depth of Cut.
  • Introduction to CNC
  • CNC Programming.
  • COMPUMILL 2500 3-Axis CNC Milling Operations.
  • Midterm test.
  • Milling Machine Setups, Milling Operations.
  • Indexing, index ratio, direct indexing, simple indexing, Dividing Head.
  • Gear Cutting.
  • Special Milling Operations.
  • Gear Shaper and Surface Grinder.
  • Final Test.
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Laboratory Projects

  • Mill two (2) aluminum plates to size using the Bridgeport vertical milling machine.
  • Prepare AutoCAD drawing to be used in writing NC program to machine students’ initials on aluminum plate using CNC Compumill milling machine.
  • Prepare AutoCAD drawing to be used in writing NC program to machine the number 43 on aluminum plate using CNC Compumill milling machine.
  • Prepare AutoCAD drawing to be used in writing NC program to machine pockets on aluminum plate using CNC Compumill milling machine.
  • Cut a gear with indexing head, using the Cincinnati Universal Milling machine.
  • Cut a spur gear, using the Gear Shaper machine.
  • Open assignment (for extra credits).
  • Grinding a parallel steel plate on a plane-grinding machine.
Note: Drawings and manufacturing instructions can be found in the Advanced Machine Tool Laboratory Manual.
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Lab Report Format

Lab report should include the following as a minimum:
  • Cover page that includes:
    • The cover page of the report should include:
    • Student's name
    • Lab instructor's name
    • Project name
    • Name of the course (MET-127 Advanced Manufacturing Processes)
    • Date the report is due
  • Table of Contents
  • Objective of the project (a short paragraph)
  • Route sheet with the description of the manufacturing steps and tools used.
  • AutoCAD drawing of the part.
  • The written G-Code for machining the part
  • Calculations for RPM, tool feed, and time required for machining the part.
  • Conclusions.
Note: The report must be typed (Handwritten reports will not be accepted).

Sample report #1

Sample report #2

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Demonstrations

The following pictorial demonstrations were developed by Mr. Kevin Carmody, a student of Professor Maltezos. The purpose of these presentations is to demonstrate the use of equipment and the steps required to machine the assigned projects.

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