Metal Casting Workshop Sparks Interest of Area High School Students

Dr. Sam Ramrattan explains the metal casting process to high school students enrolled in the 2006 summer metal casting workshop

Last month, IME professor Dr. Sam Ramrattan hosted a weeklong metal-casting workshop for 10 high school students from Kalamazoo, Coldwater, Saginaw, Grand Rapids, Detroit, and Toledo, Ohio. He has been offering similar hands-on workshops for up to 15 area tenth-through-twelfth-grade high school students during each of the last seven summers.

During the students’ five-day campus visit, Ramrattan, a technical advisor to the American Foundrymen's Society and a Key Professor for the Foundry Educational Foundation, directs activities in the College of Engineering and Applied Sciences, Parkview Campus Metal Casting Laboratory.

Workshop topics include metal casting history, trends, and the relationship of manufacturing (molding, melting, filling, and finishing), engineering, quality, purchasing, marketing, and sales of castings. The students explore the use of computers, math, and science in metal casting.

In addition to their lab and course work, the students meet with WMU administrators to discuss university entrance requirements and expectations and with professionals from the foundry industry to review career opportunities in metal casting.

Field trips to metal casting industries provide students with opportunities to see real-world technology and to meet with professionals. This year’s attendees toured A.C. Foundry in Battle Creek, MI, Metal Technologies’ Three Rivers Gray Iron Plant, and SPX Contech’s die casting facilities in Dowagiac, MI. They also enjoyed activities in the Kalamazoo / Portage metro area.

Students who attend the program are sponsored by various chapters of the American Foundry Society (AFS) and the North American Die Casting Association (NADCA). Students are selected on the basis of an aptitude for math and science. There is no cost to the students who stay in WMU dorms and enjoy campus life.

Dr. Sam Ramrattan and Adil Abdelwahab, an IME graduate student, demonstrate how to pour molten aluminum into sand castings. After the demo, the high school students, who are seated behind the protective barrier, donned safety apparel and made their own sand castings.

WMU has had a casting metal program in various engineering curricula since the college opened over 100 years ago. Its most recent accreditation began in 1992 when Ramrattan joined the faculty. “Our goal is to produce hands-on engineers as an integral part of what we do in manufacturing engineering programs,” he said.

Metal casting is currently a program option in the industrial, manufacturing, graphics, and engineering management programs.

Dr. Sam Ramrattan demonstrates the mold making process

IME Advisory Boards Meet; Local SME Adds $20,000 to Roscoe Douglas Fund

This spring, the IME’s four advisory boards met to discuss the future education of engineers. The boards, which include representatives from several corporations and organizations and IME faculty, discussed future trends in the workplace and assessed how to meet the changing educational and experiential needs of IME.

Groups re-presenting IME’s four under-grad-uate programs – manufacturing (MFT), engineer-ing graphics (EGR), engineering management (UEM), and industrial engineering (IE) – held meetings following the 38^th Conference on Senior Engineering Design Projects (SEDP).

According to Dr. Mitchel Keil, the IME professor who chairs the EGR board, many members of the boards are WMU alums of the programs for which they now serve as advisors.

The boards considered current changes being suggested to the core curriculum to provide a common first-year program for all incoming freshmen engineering students and to organize them into cohorts. Under consideration also were the need for co-op experiences and international internships and potential changes in foreign language and calculus requirements.

Members also weighed the pros and cons of minors and options, the call to limit programs to 124 credit hours, and the inclusion of a 4 +1 program to allow a student to earn bachelor’s and master’s degrees in five years. They also reviewed enhancing the curriculum with topics such as product data management (PDM) and failure mode effects and analysis (FMEA).

IME professor Fred Sitkins said the MFT board agreed that the goal of education is changing from those proficient in manufacturing engineering to those proficient in manufacturing processes. “They want to hire those who understand the broad processes,” he said

Referencing the SEDP Conference that preceded the advisory meetings, IME professor Dr. Bob White said the IE Board agreed that “the IE projects were the best group of IE projects they’d seen at SEDP.”

SME Scholarship Funds Presented to Foundation

SME members pose with a $20,000 check donated to SME Foundation for scholarships. Left to right are Ron Jones, Dave Steffans, Bruce Burrows, Mitchel Keil, Erik Korbecki, Brian Cervin, Ryan Miller, SME Foundation Representative Bart Aslon, and IME Chair Paul Engelmann

Kalamazoo Chapter 116 of the Society of Manufacturing Engineers (SME) presented a check for $20,000 to the SME Foundation for Roscoe Douglas Scholarships (RDS). Ron Aslon, representing the SME Foundation, accepted the check and thanked the local organization.

In the past, Chapter 116 has supported RDS, which have been awarded by SME to full-time students who maintained a 3.0 GPA in either a manufacturing engineering or a technology program and who attended one of six approved Michigan institutions.

WMU’s most recent RDS recipients are Brian Cervin, Eric Korbecki, and Joshua Weise.

Next year, the IME department’s scholarship and publicity committee will determine how the RDS funds are distributed. Also all future RDS recipients must be WMU students.

The next official advisory board meetings are set for April 2007.

IE senior earns IME’s Presidential and Dean’s scholar awards

Pamela S. Apotheker earned top senior awards as IME faculty’s choice as both the 2006 WMU Presidential Scholar and the 2006 CEAS Scholar. Her nomination was based on a combination of academic excellence and extracurricular involvement.

The Presidential award was presented at the 26^th Annual Presidential Scholars Convocation, which was hosted by WMU President Judith Bailey, and the Dean’s award was given at a special luncheon given by CEAS Dean Tim Greene. A faculty member of her choice celebrated with Apotheker at each celebration. Dr. Bob White was selected for the Presidential event, and Dr. Azim Houshyar, for the Dean’s event.

“Dr. White and Dr. Houshyar are the dynamic duo of the IME department,” Apotheker said. “They teach well and maintain high standards, and they have the respect of their students.”

Apotheker, who maintained a 3.88 GPA, graduated with a BS in Engineering – Industrial with a minor in mathematics, was one of 47 WMU students from the university’s 48 departments honored as a Presidential Scholar, an award that has been given since 1981.

Before graduating, Apotheker passed the Fundamentals of Engineering Exam, the first of two tests that lead to her becoming a credentialed professional engineer. After working four years in the field, she will be eligible to take the final exam for her PE credential.

For her senior design project, Apotheker and two other seniors completed an analysis of the security checkpoint at the Kalamazoo/Battle Creek International Airport. This project helped the airport determine the additional resources needed to decrease the wait time experienced by passengers.

Apotheker’s memberships include two engineering honor societies: Tau Beta Pi, the engineering honor society, and Alpha Pi Mu, the IE honor society. As a new member to Tau Beta Pi, she won an award and $50 for the “shiniest bent,” which is a small replica of the Tau Beta Pi symbol.

She also chaired WMU’s chapter of the Society of Women Engineers (SWE), served as vice-president of the Institute of Industrial Engineers (IIE), and mentored the Kalamazoo area’s first FIRST competitive robotics team, which won a rookie award.

Left to right: CEAS Dean Dr. Tim Greene, 2006 Presidential and Dean Scholar Pam Apotheker, IME Professor Dr. Bob White, and IME Chair Dr. Paul Engelmann

The Kalamazoo native and a graduate of Kalamazoo Christian High School came to WMU as an undecided engineering major. She selected IE because “it’s people related” and because an IE career would enable her to use her math skills without requiring her to teach. “I knew I wanted to be an engineer, and industrial engineering offered the most,” she said.

As an undergraduate, Apotheker had a summer internship at Cook Nuclear Power Co that she described as “fun.”

Apotheker officially changed her name to Pamela Tkachuk on May 6, when she married Dan Tkachuk, a WMU aviation administration alumnus who works as an operations technician at the Kalamazoo / Battle Creek Airport.

Pam Tkachuk recently began working as a production engineer at Perrigo Company in Allegan. “I deal with and support the day-to-day operations,” she said.