Learning objectives
This course provides knowledge and ability (capacity to apply knowledge) necessary for analysis of manufacturing processes, production systems and assembly methods for industrial components and products.
The primary objective of this course is to development a level of proficiency sufficient such that students can understand mechanical component production processes within an industrial context based on information provided within mechanical and detail drawings.
To this end, development of knowledge relating to the following points is necessary:
- Information contained within a technical drawing in terms of component geometry, materials, surface finish and dimensional and positioning tolerances;
- Issues relating to fulfilment of specific precision requirements during the production cycle and knowledge of measurement tools necessary for quantification;
- Foundry and plastic deformation as primary forming processes;
- Reversible and irreversible joining techniques;
- Machining processes utilising machine tools;
The ultimate objective of this course is for students to develop the ability to correctly plan, from a manufacturing point of view (rational and inexpensive), the process cycles necessary for production of a mechanical component that includes all phases necessary for its creation.
To this end, development of the following abilities is necessary:
- Study of the primary forming processes of a component;
- Determination of the raw material (in terms of dimensions, material and primary production process) for subsequent machining of a mechanical component;
- Identification of the sequence of operations necessary to create the surfaces making up the component;
- Referencing of the component with respect to the machine tools utilising appropriate equipment;
- Calculation of the forces acting throughout the cutting process and the power absorbed by machine tools.
Prerequisites
Physics, Math I & II, Chemistry, Technical drawing
Course unit content
Aim of the class is the study of manufacturing processes and systems for industrial parts and products. A systematic approach is adopted for understanding the basic principles and mechanisms of manufacturing processes, and for understanding their capabilities and limitations in terms of functional performance achievable for manufactured products, and in terms of production requirements and constraints. Manufacturing process design and manufacturing process planning are introduced, as well as their integration with product design in computer-aided environments. Theoretical modeling of manufacturing processes is aimed towards the analysis and prediction of the effects of process variables and towards the automation of manufacturing process execution. Traditional manufacturing processes are covered, as long as some innovative processes. Design for manufacturing and concurrent engineering is also covered. The class will consist in lectures and applicative sessions. Team projects will be developed involving the discussion of industrial case studies.
Full programme
Aim of the class is the study of manufacturing processes and systems for industrial parts and products. A systematic approach is adopted for understanding the basic principles and mechanisms of manufacturing processes, and for understanding their capabilities and limitations in terms of functional performance achievable for manufactured products, and in terms of production requirements and constraints. Manufacturing process design and manufacturing process planning are introduced, as well as their integration with product design in computer-aided environments.
Theoretical modeling of manufacturing processes is aimed towards the analysis and prediction of the effects of process variables and towards the automation of manufacturing process execution. Traditional manufacturing processes are covered, as long as some innovative processes. Design for manufacturing and concurrent engineering is also covered.
The class will consist in lectures and applicative sessions. Team projects will be developed involving the discussion of industrial case studies.
Program
Part A
Basics and classification of manufacturing processes. Modeling shape transformation in manufacturing processes. Relationships between product and manufacturing process; product design and process planning. Manufacturing process selection criteria.
Introduction to the analysis of the properties and behavior of engineering materials. Tests for determining material properties, stress-strain curves. Structure and classification of metallic, polymeric, ceramic and composite materials.
Manufacturing processes based on mass conservation. Casting processes. Basics of solidification and cooling of metals; types and classification of casting processes: sand casting, die casting, etc. Casting process design. Forming processes: rolling, extrusion, forging, sheet metal bending, deep drawing, etc. Forming systems. Powder metallurgy.
Part B
Manufacturing processes based on mass reduction. Machining processes. Fundamentals of cutting mechanics and chip formation. Cutter geometry. Machining process variables: cutting velocity, wear and tool life. Cutting force and power evaluation. Machinability of metals. Optimal cutting conditions. Turning, milling, drilling, boring, finishing. Types and classification of machine tools: structure, shape and functionality. Material removal process planning: machining cycles. Sheet metal cutting and punching. Hydro-Abrasive Machining and Water Jet Machining. Laser cutting.
Manufacturing processes based on mass increase. Joining processes: welding, adhesive bonding, mechanical fastening. Assembly processes: basics and principles. Assembly operations and systems: feeding, orienting and inserting parts. Design for assembly.
Manufacturing processes for polymeric and composite materials. Manufacture of fiber reinforced plastics, injection molding.
Laboratory activities
The applicative sessions will be concerned with the applications of methodologies and techniques for manufacturing process selection and planning. A team project will involve the design and analysis of manufacturing processes for industrial case studies. In particular, the team project will be divided into two main parts:
Part A
Analysis of the geometry and functional role of an industrial part and design of a casting process to manufacture it .
Part B
Machining process planning for producing the finished part from the casting.
Bibliography
M. Santochi, F. Giusti, Tecnologia Meccanica e Studi di Fabbricazione 2ed., Casa Editrice Ambrosiana, 2000.
S. Kalpakjian e S. Schmid, Tecnologia meccanica 5 Ed., Pearson, Milano, 2008.
Slides of the lessons are available on ELLY. Be careful that due to brevity slides alone are not enough to understand the concepts commented during the lessons.
Teaching methods
The course is assigned 9 CFU for a total of 63 hours, with 54 hours assigned to lessons and 9 hours to workshop tutorials. Lessons are distributed over the follow principle themes to provide the knowledge conveyed during course:
- Technical drawing review: 3 hours
- Metrology: 3 hours
- Metals and their characterisation: 6 hours
- Foundry: 12 hours
- Plastic deformation: 12 hours
- Welding: 3 hours
- Machining: 12 hours
- Process cycles: 3 hours
Lessons will follow the chronology necessary for execution of operations exactly as they would be performed in a real production cycle. This practical approach has the function of providing guidelines for exam preparation to focus study on creating the abilities necessary for achieving the educational objectives.
Tutorials will provide supporting material for lessons through practical experience, viewing and direct participation, so that students can develop the abilities to be verified during exams. To fully understand material covered in tutorials, students must attend lessons or independently study the course supporting material (slides and textbook).
The total study load of this course is no less than 250 hours; between 25 and 30 hours per credit, including lessons, workshop technical/practical tutorials and independent study.
Assessment methods and criteria
The final exam will verify acquisition of the required knowledge and ability (the capacity to apply knowledge) through a 3 hour written exam, without use of notes or texts, and subsequent oral exam.
The written and oral exams are weighted 75 % and 25 % of the final grade, respectively.
The exam comprises 3 exercises, including 2 questions relating to acquired knowledge throughout the course and 1 exercise relating to the student’s ability. Specifically, candidates will be required to answer:
- One theoretical question worth 7 points relating to the explanation of a machine or production process, including schematics, definitions and demonstrations, etc.;
- One calculation-based exercise worth 8 points aimed at verifying the candidate’s aptitude in dealing with different orders of magnitude in SI units (with particular attention to unit conversion) and determining quantitative results for the posed question;
- A technical/practical exercise worth 15 points relating to formulation of the production cycle for a simple mechanical component based on a quoted technical drawing. The objective of this exercise is to verify the ability of the candidate to choose the most effective and least costly production cycle.
To attend the oral exam it is necessary to achieve a minimum of 16 points in the written exam. Those who achieve at least 25 points in the written exam can choose not to sit the oral exam and take the written exam score as final (100 % weighting).
The oral exam, which begins with correction of the candidate’s submitted written exam, verifies the competency of the candidate relating to reasoning and discussing of any of the themes covered in the course with the correct terminology and graphical representations.
There are no intermediate assessments.
Other information
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