Learning objectives
This course provides the knowledge and ability necessary for analysis of manufacturing processes, production systems and assembly methods for industrial components and products. The primary objective of this course is to develop a level of proficiency sufficient such that students can understand mechanical production processes within an industrial context based on information provided within mechanical and detail drawings.
To this end, acquisition 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;
- Machining processes utilising machine tools;
- Reversible and irreversible joining techniques.
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 component;
- Identification of the sequence of operations necessary to create the surfaces making up the component;
- Referencing of the component with respect to machine tools utilising appropriate equipment;
- Calculation of the forces acting throughout the cutting process and the power absorbed by machine tools.
The final 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.
Prerequisites
Physics, Chemistry, Mathematical Analysis, Design
Course unit content
The aim of this course is to study manufacturing processes, production systems and assembly methods for industrial components and products. A systematic approach aligned with process modelling is adopted for understanding the principles and mechanisms on which the manufacturing processes are based, and for understanding their capabilities and limitations in terms of achievable functional performance for specific manufactured products, systematic design and planning of the manufacturing process, and integration of the design and production processes. Modelling will be aimed at predicting the influence of process parameters on the resulting outcomes. The course content will be sufficiently analytical for an elementary university course and adequately descriptive for students that have no specific prior knowledge relating to manufacturing processes. 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 transformations taking place during manufacturing processes, including material, energy and information flow. Relationships between product and manufacturing process; product design and process planning. Manufacturing process selection criteria. Introduction to the analysis of the properties and behaviour of engineering materials. Tests for determining material properties, stress-strain curves. Materials. Structure and classification of ferrous and non-ferrous metals, polymers, ceramics and composite materials.
Primary manufacturing processes
Foundry processes. Basics of solidification and cooling of metals; types and classification of casting processes: sand casting, lost wax, die casting, investment casting. Casting process design; problems and principles relating to sizing of risers and the sprue. Forming processes. Types and classification of forming processes: rolling, extrusion, forging, blanking, bending, deep drawing. The main systems used for forming processes: types, function and use.
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:
- TECNOLOGIA MECCANICA
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.
- Carlo Gaggia, Sergio Gaggia, Tecnologia meccanica vol. 3, (1982), Zanichelli.
- Serope Kalpakjian, Steven R. Schmid, Tecnologia Meccanica, (2008) quinta edizione, Pearson Ed.
Teaching methods
The course is assigned 9 CFU for a total of 72 hours, with 58 hours assigned to lessons and 14 hours to tutorials. Lessons are distributed over the follow principal topics of the course:
- Technical drawing, tolerances and metrology: 6 hours
- Materials: 6 hours
- Foundry: 10 hours
- Plastic deformation: 10 hours
- Machining and machine tools: 22 hours
- Welding: 4 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 that will be verified during exams. To fully understand material covered in tutorials, students must attend lessons or independently study the course supporting material.
Assessment methods and criteria
The final exam will verify acquisition of the required knowledge and ability with a 2-hour written exam and an optional oral 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.
To attend the oral exam, it is necessary to achieve a minimum of 18 points in the written exam. 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. The maximum variation in grade with respect to the written exam is +/- 3 points.
All students who do not pass the written exam can view their marked submission on appointment with the lecturer.
There are no intermediate assessments.
Other information
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2030 agenda goals for sustainable development
This course contributes to realization of the UN 2030 Agenda for Sustainable Development objectives.
