Learning objectives
This course provides knowledge and ability necessary for analysis of manufacturing processes and production systems 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;
- Reversible and irreversible joining techniques;
- Machining processes utilising machine tools;
The final goal of this course is for students to obtain skills relating to manufacturing of a mechanical component and development of a correct (rational and economical) machining sequence plan that comprises all necessary steps for production.
To this end, development of skills relating to the following points is necessary:
- Choice of the raw material (in terms of dimensions, material and primary production process) for machining of a component;
- Identification of the sequence of operations necessary for production of the component;
- Positioning and reference of the component with respect to the machine tool with appropriate fixtures;
- Calculation of the forces acting throughout the cutting process and the power absorbed by machine tools.
Prerequisites
General physics, Mathematical analysis A, Design and Manufacturing Technology
Course unit content
The aim of this course is to study manufacturing processes and systems for industrial parts and products. A systematic approach aligned with process modelling is adopted for understanding the basic principles and mechanisms on which the manufacturing processes are based, and for understanding their capabilities and limitations in terms of functional performance achievable for manufactured products, and in terms of production requirements and constraints. The course addresses some of the topics introduced in the Manufacturing Technology module and completes fundamental training for Management Engineers specialised in manufacturing. The course will consist of lectures and tutorials where exercises will be completed together with the lecturer and discussion of industrial applications will take place.
Full programme
Introduction
Basics and classification of manufacturing processes. Modelling shape transformation in manufacturing processes. Relationships between product and manufacturing process; product design and process planning. Manufacturing process selection criteria. Recap of mechanical design, tolerances and materials.
Secondary manufacturing processes
Machining processes. Fundamentals of metal cutting mechanics and chip formation. Tool 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, slotting, broaching, grinding. Types and classification of machine tools: structure, form and functionality. Process planning: Study of process cycles. Joining processes based on welding: types and methods of welding.
Tutorials
Tutorials will see application of methods and techniques for selecting parameters and planning the main manufacturing process, including the study and discussion of industrial applications.
Bibliography
Slides used throughout the course will be available to students in PDF format via the Elly online platform, together with all teaching material and practical exercises covered during lessons. To download this material, students must log on to Elly and register for:
- STUDI DI FABBRICAZIONE
Further to material provided within the course, students can expand upon covered topics by studying from the following texts (in Italian):
- Marco Santochi, Francesco Giusti, Tecnologia meccanica e studi di fabbricazione, (2000) seconda edizione, Casa Editrice Ambrosiana.
- Serope Kalpakjian, Steven R. Schmid, Tecnologia Meccanica, (2008) quinta edizione, Pearson Ed.
Teaching methods
The course is assigned 6 CFU for a total of 48 hours, with 34 hours assigned to lessons and 14 hours to workshop tutorials. Lessons are distributed over the follow principle themes during course:
- Recap of mechanical design, tolerances and materials: 6 hours
- Machine tools: 10 hours
- CNC machine tools: 4 hours
- Welding: 4 hours
- Machining sequence planning: 4 hours
- Introduction to industrial robotics and automated measurement systems: 4 hours
- Flexible production systems: 2 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).
Assessment methods and criteria
The final exam will verify acquisition of the required knowledge and ability with a 2-hour written exam.
The written exam comprises 3 exercises: 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 relating to the explanation of a machine or production process, including schematics, definitions and demonstrations, etc.;
- One calculation-based exercise aimed at verifying the candidate’s aptitude in determining quantitative results for the posed question;
- A technical/practical exercise 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.
All students who do not pass the written exam can view their marked submission on appointment with the lecturer.
Other information
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