Teacher

prof. aggr. Marco SORTINO

Credits

6 CFU

Language

Italian

Objectives

The course illustrates the main manufacturing technologies. In particular, metal casting processes, forming and shaping processes, joining processes, machining processes and non-conventional processes. It also discusses the main aspects of machine tools and automated production systems.

Acquired skills

- Knowledge about composition, microstructure and elastic-plastic behavior of metal alloys.
- Knowledge of advanced materials applied in manufacturing.
- Knowledge about statistical process control, metrology and non-destructive inspection techniques.
- Knowledge about organization and economics of manufacturing production.
- Knowledge of the production stages.
- Knowledge of manufacturing techniques and of their application.
- Basic Knowledge about machine tools and manufacturing systems.

Lectures and exercises (topics and specific content)

Composition, microstructure and elastic-plastic behavior of metal alloys. Advanced materials for tools: composition, microstructure and elastic-plastic behavior of metal alloys; advanced materials for tools; tests for measuring mechanical properties of materials; classification, characteristics and applications of the main materials and coatings for tools and mechanical components (12 hours).
Statistical process control, metrology and non-destructive testing: tools and indexes of quality and statistical process control; methodologies and tools for dimensional measurements of mechanical parts and for the characterization of surface; non-destructive inspection techniques of metal components (6 hours).
Metal casting processes: classification of casting processes; casting of shapes; expendable mold casting and permanent mold casting (6 hours).
Forming and shaping processes: classification; rolling; forging; drawing; extrusion; sheet metalworking processes (4 hours).
Joining and parting processes: classification; fusion welding; resistance welding; electric arc welding; friction welding; brazing; parting processes (4 hours).
Material-removal processes and machines: cutting principles in orthogonal cutting; tool geometry; basics of tool wear; circular motion machining operations, classification, kinematics, tools, cutting parameters and dedicated machine tools; linear motion machining operations (10 hours).
Abrasive machining and finishing operations: grinding operations, classification, kinematics, tools, process parameters and machines; deburring;: polishing; lapping; honing and other finishing operations (4 hours).
Chemical and physical processes: chemical and electrochemical machining; electrical Discharge Machining; ultrasound machining; waterjet machining; plasma and laser-assisted machining (2 hours).
Additive manufacturing and rapid prototyping: litography; selective Laser Melting; other rapid prototyping techniques (2 hours).
Automation: introduction to modern CNC machine tools and to CAD/CAM/CNC programming; Flexible Manufaturing Systems – FMS (2 hours).
Machining processes: organization of industrial production; the manufacturing cycle, basic concepts and technical reports; economic analysis of the production cycle, estimate of production times and costs (8 hours).
Exercises: exercise on statistical process control techniques; exercise about metal forming and shaping processes; exercise about machining operations; exercise about production cycle and economics of production cycle.

References

- S. Kalpakjian, S. Schmid, Tecnologia Meccanica, 6^a edizione, Pearson Prentice-Hall (oppure l’originale in inglese, ovvero: S. Kalpakjian, S. Schmid, Manufacturing Engineering and Technology, 7^th edition, Pearson Ed Asia)
- F. Micari, R. Ippolito, F. Gabrielli, Analisi e tecnologia delle lavorazioni meccaniche, 2a edizione, 2012, McGraw-Hill Companies
- Zompì, R. Levi, Tecnologia Meccanica, Lavorazioni ad asportazione di truciolo, UTET
- M. Santochi, F. Giusti, Tecnologia Meccanica e Studi di Fabbricazione, Ambrosiana

Type of exam

Written and oral

Other information and didactic material available on the website