Teacher

prof. aggr. Giovanni TOTIS

Credits

6 CFU

Language

Italian

Objectives

The course aims to deepen the manufacturing technologies introduced in the first module and to provide students with methodologies for the design of machining processes. The main types of machine tools and automated production systems mechanics are introduced. Specific educational objectives of the course are the ability to engineer a manufacturing cycle with respect to economic parameters, the knowledge of NC programming and knowledge of equipment and specific procedures.

Acquired skills

- Knowledge about the physics of manufacturing processes and about main issues and defects affecting manufactured products.
- Capability to design tools and tooling systems, workpiece fixtures and to select process parameters.
- Knowledge about architecture and functioning principles of modern CNC machine tools.
- Knowledge about CNC programming and fundamentals of CAM programming.
- Knowledge about gear manufacturing and other advanced manufacturing processes.
- Basic knowledge for innovation, optimization and continuous improvement of manufacturing processes.

Lectures and exercises (topics and specific content)

Metal casting processes: physics of metal alloys solidification; defects of metal castings; techniques for molds and dies design (6 hours).
Forming and shaping processes: theory of plasticity; defects of products obtained by plastic deformation; analytical and numerical techniques for the analysis of forming and shaping processes; preliminary design of molds and equipment (8 hours).
Material-removal processes: tool geometry; tool wear mechanisms and effects; advanced modeling of cutting forces; mechanics of turning, milling and other machining operations; insights on grinding processes (10 hours).
Additive manufacturing: insights on Selective Laser Melting and other additive manufacturing techniques (2 hours).
Gear shaping: basic methods, Milling, Hobbing, Fellows shaping, Sunderland, Maag; procedures for manufacturing bevel gears with straight teeth; procedures for manufacturing bevel gears with spiral teeth; procedures for finishing and grinding of gears, shaving, grinding and lapping (4 hours).
CNC machine tools: architecture and components of modern CNC machine tools, structural parts, guideways, engines, transmission systems; control of CNC axes and spindles; toolholder system and tool change; pallet; control unit; general procedures for machine tool set-up, tool offset measurement, identification of workpiece reference system, etc.; classification of modern CNC machine tools (5 hours).
Automation and CNC/CAM programming: generation of basic part programs - CNC; programming language ISO standard (G&M); elements of Computer Assisted Manufacturing - CAM (7 hours).
Manufacturing cycle: start-up information; choice of manufacturing processes and the sequence of steps, phases, and operations; choice of tools, of tooling systems and equipment for clamping; selection of cutting parameters; examples and case studies (9 hours).
Process Innovation: litography; selective Laser Melting; other rapid prototyping techniques (6 hours).
Exercises: numerical exercises on casting processes and design of a sand casting form; design of mold for closed-die forging; introduction to numerical simulation (by means of FEM software) of forming operations; exercise about CNC programming; practice with CAM software; exercise about production cycle planning; exercise on process optimization and innovation (22 hours).
Guided tours (3 hours).

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, 2^a edizione, 2012, McGraw-Hill Companies
- Zompì, R. Levi, Tecnologia Meccanica, Lavorazioni ad asportazione di truciolo, UTET
- Y. Altintas, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, 2^nd Edition, 2012, Cambridge University Press
- D.C. Montgomery, Progettazione ed analisi degli esperimenti, 2005, McGraw-Hill (oppure l’originale in inglese:D.C. Montgomery, Design and Analysis of Experiments, 8^th Edition, 2012, John Wiley & Sons)
-  M. Santochi, F. Giusti, Tecnologia Meccanica e Studi di Fabbricazione, Ambrosiana

Type of exam

Written and oral

Other information and didactic material available at the website