Course # Course Title Term Year
MECH421 Mechanical Shaping of Metals and Plastics Winter 2022-2023
MECH6511 Mechanical Forming of Metals Winter 2022-2023
Course Instructor Office Email Office Hours
Dr. Tsz Ho Kwok EV 4.231
[email protected] By appointments
CLASS, LAB, AND TUTORIAL SCHEDULE
Section Day Time Location Instructor E-mail
Lecture MO 11:45-14:30 H507 Dr. Tsz Ho Kwok
[email protected]Labs Sessions Peter Sakaris
[email protected] H1059
(421) Shima Akhondi
[email protected]COURSE CALENDAR DESCRIPTION
Metal forming: extrusion, forging, rolling, drawing, pressing, compacting; shear line theory, sheet forming
limits. Metal cutting, machinability, tooling. Plastics shaping: extrusion, moulding, vacuum forming.
Consideration of the mechanical parameters critical for process control and computer applications.
Interaction of materials characteristics with processing to define product properties: cold working,
annealing, hot working, super plasticity, thermomechanical treatment. Energy conservation, safety,
product quality, and liability. Lectures: 3 hours per week. Laboratory: 2 hours per week, alternate weeks.
PREREQUISITE
MECH 221
TEXTBOOK AND ADDITIONAL COURSE MATERIALS
Note: This course website is on Moodle, where you can find all course notes. You will need to submit
your assignments and projects on Moodle too.
Textbooks
1. Degarmo’s Materials and Processes in Manufacturing, J.T. Black and R.A. Kohser, Wiley, 13th
edition, 2019. (Other editions would also be fine).
2. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Mikell P. Groover,
Wiley, 7th edition, 2019 (Other editions would also be fine).
KNOWLEDGE BASE FOR ENGINEERING PREREQUISITES:
This course requires a good knowledge in:
• Design methodology (design iteration, generative design)
• Calculus (differentiation, integration)
• Linear algebra (vector, matrix, linear systems, geometry)
• Mechanical property of material (stress-strain relationship, stiffness matrix)
• Also, for 6511: algorithms, data structures, programming
GRADING POLICY
MECH 421 MECH 6511
Final Exam 50% Final Exam 50%
Design Project 20% Project with coding 45%
Assignments (2) 5% Assignments (2) 5%
Paper Presentation 10%
Lab 15%
Passing Criteria:
• If your total score is less than 40% and you do not take the final exam, you will receive an R grade
which prevents you from deferring the final exam. You will need to retake the course.
• All exams: Closed book. Closed notes.
• To pass the class, both your cumulative score and the exams must be above 50%.
• In case of online exams, the instructor reserves the right to conduct an individual oral examination
after the exam to verify the student's response to specific questions.
Assessments and reports must be submitted to Moodle before the deadlines. NO DELAYS/EXTENSIONS.
Deadline for submission for laboratory work is available in the Lab Manual. Good presentation, including
legibility, spelling, and grammar, is expected for all work.
Course Learning Outcomes (CLOs)
This is a course aimed at Mechanical Engineering Students who will need to know how
components (whether big or small, simple or complex) are made and the effect that this shaping
has on the properties of the material. A car door, a wing spar, and a cell phone casing are all made
from materials and must all be shaped in some way. How this shaping is carried out affects many
factors; the cost, the complexity available, the mechanical properties such as strength and ductility
and other less obvious properties such as corrosion resistance and toughness. Any engineer who
is designing components need to know not just how to make things but the effect that this has on
the final product. By the end of this course, you are expected to know:
1. the material properties and selection of metals/alloys and plastics;
2. how to measure, interpret and calculate the mechanical properties of metals and plastics;
3. the main processes by which metals and plastics can be formed;
4. the foundation of process modeling for these processes;
5. the hot and cold (working) manufacturing processes to create metallic and plastic products;
6. the effect of these processes has on material properties;
7. the advanced manufacturing techniques and their applications.
This course should be seen as part of the whole process of Design and Production in that the
shaping of a component will influence the designs possible, the mechanics of the system, the ease
of manufacture, and finally the performance of the product.
Note: This course does not cover welding and casting of metals as these topics are covered in Mech 423.
SCHEDULE
Week Topic 421 6511
1 (Jan 9) Introduction of Manufacturing
2 (Jan 16) The Nature of Materials
3 (Jan 23) Properties of Materials Form group
4 (Jan 30) Fundamentals of Metal Forming Present topic Phase 1
5 (Feb 6) Finite Element Method HW #1 due
6 (Feb 13) Paper Presentation Present due Study week
7 (Feb 20) Sheet-Forming Processes I Project topic Phase 2
8 (Mar 6) Sheet-Forming Processes II
9 (Mar 13) Bulk-Forming Processes I
10 (Mar 20) Bulk-Forming Processes II Phase 3
11 (Mar 27) Plastics and Shaping Process for Plastics HW #2 due
12 (Apr 3) Project Presentation Project due Study week
13 (Apr 17) Advanced Manufacturing & Review Phase 4
Disclaimer
In the event of extraordinary circumstances and pursuant to the Academic Regulations the University
may modify the delivery, content, structure, forum, location and/or evaluation scheme. In the event of
such extraordinary circumstances, students will be informed of the changes.
A brief description of the course
This course provides fundamental information on plastic deformation of metals/alloys and plastics.
Based on this, the mechanical shaping processes which are commonly used to manufacture
metallic and plastic products are discussed. Some of the advanced manufacturing techniques
including additive manufacturing technologies are also reviewed.
Note: There is a laboratory for MECH 421 (cold working, roll milling and annealing of brass)
where you can experiment and observe what you have learned in theory. There is an individual
coding project for MECH 6511.
Final Exam:
For true/false and multiple-choice questions (i.e., those answered in the scantron sheet), the
grading method is as follows:
Correct answer 2
Wrong answer 0
Blank answer 1*
*with at least 30% correct answers in the section
For MECH 421
Laboratory:
There is a laboratory component to this course, namely; the cold working and annealing of brass.
The aim of this lab is to illustrate the effects of cold working processes such as rolling on the
mechanical properties of metals and then how these effects may or may not be reversed. Mr. Peter
Sakaris (3153) will be supervising this in the Materials Laboratory (H-1059). A lab manual,
prepared by Mr. Peter Sakaris is available at the COPY CENTER, and the labs commence from
the week of Jan 16. The lab is in H-1059, and the students are expected in the lab with lab coats
and covered shoes.
Presentation:
Each group will select a paper of recent technologies (within last 5 years) related to this course
(approved by the instructor) and will prepare an oral presentation (Week 6) giving an overview of
the technical details of the paper, as well as its major advantages and disadvantages, applications,
possible improvements, etc. Time will be set aside in the lecture sessions for each student to make
the presentation to the rest of the class (see Presentation Schedule). Each talk will be followed by
a short question period. Marks will be awarded for:
• Presentation style – 2% (audibility, structure, clarity, quality of visual aids, pace, teamwork)
• Technical content – 3% (understanding of subject, background and techniques; explanation)
• Reflection – 3% (key concepts, relationship between concepts, to life experiences, questions)
• Report – 2% (structure, content, reflective, visual aids, etc.)
More details can be found in Presentation Details.
Design for Vacuum Forming Project:
There is a design for vacuum forming project in this course. Each group will pick a part of interest,
study its manufacturing history, and re-design the part such that it can be fabricated by plastic
vacuum forming and best suits the requirements and performances. Certain design methodology
like iterative design is expected. You will experience the whole forming process from designing
and making the mold, to forming the part. A plastic vacuum forming machine is the target process
in this project. Each group will give an oral presentation presenting the whole design process and
any concerns with the forming process in Week 12. Marks will be awarded for:
• Presentation and reflection – 4%
• Include everything as in the paper presentation.
• Completeness – 10%
• Design a successful part and apply all the design considerations and modifications.
• Validation and verification.
• Complexity – 4%
• Part, mold, and process complexity.
• Peer evaluation – 2%
More details can be found in Design Project Details.
For MECH 6511
Project with coding:
Finite element analysis (FEA) has been developed during the last decades as a very useful tool for
analysis of metal forming processes. Progress in the development of cheap and efficient computer
technology, and the implementation of the finite element method (FEM) into user-friendly,
window-based programs, has brought this technology forward. One can state that this development
has revolutionized the art of mechanical shaping analysis. In this project, you will choose a product
or component with a manufacturing history, and you need to write about the material selection and
the manufacturing technique explaining why they have been used. You must implement and
demonstrate how FEA can be applied for the analysis of a mechanical shaping operation, e.g., cold
forming, drawing, deformation, and stretching. However, FEM can be applied for the
manufacturing process, the usage, or the inspection. The formulation should be for large elastic-
plastic deformation. The output of this project is a simulation program and a report describing all
the implementation details. The assessment is based on the report describing how you realize and
implement the simulation program:
• Problem definition (assumptions and simplification)
• Mathematical formulation of FEM (including isoparametric mapping)
• Read/generate/refine mesh
• Calculate local stiffness/mass matrix
• Assemble stiffness/mass matrix
• Solve the equation system
• Stress recovery
• Triangular v.s. Quadrilateral elements
• 2D v.s. 3D FEA (i.e., tetrahedral/hexahedral elements)
A basic C++ MFC platform with file import/export and mesh operation/visualization is provided
for this project. You can use other language/platform for this project, e.g., Python and MATLAB,
but you will need to implement all the interaction, operations, and visualizations yourself.
More details can be found in Coding Project Details.
ON CAMPUS RESOURCES
HEALTH SERVICES COUNSELLING AND PSYCHOLOGICAL SERVICES
An on-campus health clinic and health promotion center with Counsellors (licensed mental health professionals) work with
nurses and doctors. students to address their mental health and wellbeing needs.
SGW 514-848-2424 ext. 3565 SGW 514-848-2424 ext. 3545
LOY 514-848-2424 ext. 3575 LOY 514 848-2424 ext. 3555
ACCESS CENTRE FOR STUDENTS SEXUAL ASSAULT RESOURCE CENTRE
WITH DISABILITIES Provides confidential and non-judgemental support and services to
Supports students with a variety of disability conditions students, staff and faculty of all genders and orientations affected by
(including temporary disabilities arising from illness or injury). sexual violence and/or harassment.
Students receive academic support for their educational
experience at Concordia. Jennifer Drummond, Coordinator
[email protected][email protected] [email protected]514-848-2424 ext. 3525
514-848-2424 ext. 3353
STUDENT SUCCESS CENTRE DEAN OF STUDENTS
Support network from first-year to graduation. You’ll find one-on- Supports students to enhance their Concordia
one tutors, study groups, workshops as well as learning and experience by engaging in student life outside the
career advisors classroom.
514-848-2424, ext. 3921 Terry Kyle, Manager
[email protected] SGW
514-848-2424 ext. 3517
LOY 514-848-2424 ext. 4239
ABORIGINAL STUDENT RESOURCE CENTRE INTERNATIONAL STUDENTS OFFICE
An on-campus resource for First Nations, Métis and Inuit students Supporting international students with immigration documents, health
that helps them make the most of the many resources available insurance, social events, and workshops.
at the university.
[email protected]Orenda Konwawennotion Boucher-Curotte, Coordinator 514-848-2424 ext. 3515
[email protected]514-848-2424 ext. 7327
STUDENT ADVOCACY OFFICE MULTI-FAITH & SPIRITUALITY CENTRE
Advocating for students facing charges under Provides a home for all those wishing to celebrate the human spirit
the Academic Code of Conduct or the Code of Rights and in the widest sense of the word, through programs, events and a
Responsibilities. quiet space for reflection.
[email protected] Ellie Hummel, Coordinator
514-848-2424, ext. 3992
[email protected] 514-848-2424, ext. 3593
CAMPUS SECURITY CONCORDIA UNIVERSITY STUDENT
Ensures the safety of our members and campus property through PARENTS CENTRE
prevention, surveillance, intervention, training, and education. An accessible space for student parents to study, share
Provides emergency medical services. interests and develop a support network.
[email protected] Sumaiya Gangat, Coordinator
[email protected]514-848-3717
(dial 1 for urgent situations; dial 2 for non-urgent situations) 514-848-2424, ext. 2431
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 can be found in section 17.10 entitled “Academic Integrity and the
Academic Code of Conduct” in the Undergraduate Calendar.
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.
ADDENDUM
ACADEMIC CONDUCT ISSUES THAT APPLY IN GENERAL
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) The exams are not returned to the student. 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 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.
10) Respect all the above and you will get closer to your future profession.
