Learning objectives
This module 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;
- Foundry and plastic deformation as primary forming processes;
- Machining processes utilising machine tools;
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;
- Calculation of the forces acting throughout the cutting process and the power absorbed by machine tools.
Prerequisites
General physics, Mathematical analysis A
Course unit content
The course consists of 2 modules, “Design” and “Manufacturing Technology”, each of which are 6 CFU.
The aim of the Manufacturing Technology module 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. Process 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 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 behaviour of engineering materials. Tests for determining material properties, stress-strain curves. Structure and classification of metallic, polymeric, ceramic 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. Casting process design; problems and principles relating to sizing of risers and the sprue. Forming processes. Types and classification of forming processes: rolling, extrusion, blanking, bending, deep drawing. The main systems used for forming processes: types, function and use.
Secondary manufacturing processes
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. Types and classification of machine tools.
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:
- DISEGNO E TECNOLOGIE DI PRODUZIONE – Module 1
Further to material provided within the course, students can expand upon covered topics by studying from the following texts (in Italian):
1. Marco Santochi, Francesco Giusti, Tecnologia meccanica e studi di fabbricazione, (2000) seconda edizione, Casa Editrice Ambrosiana.
2. Carlo Gaggia, Sergio Gaggia, Tecnologia meccanica vol. 3, (1982), Zanichelli.
3. 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 42 hours assigned to lessons and 6 hours to workshop tutorials. Lessons are distributed over the follow principle themes to provide the knowledge conveyed during course:
- Tolerances, metrology and fundamentals of mechanics: 8 hours
- Materials: 6 hours
- Foundry: 8 hours
- Forming processes: 8 hours
- Machining and machine tools: 12 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
Common rules for both modules of the course:
- The exam in its entirety consists of a written assessment comprising both modules of the Design and Manufacturing Technology course and an optional oral exam comprising one or both modules.
- The two modules of the Design and Manufacturing Technology course are not separable.
- The written and oral exams are not separable and therefore must be undertaken in the same round.
- To pass the written exam, a minimum grade of 16/30 is required in both modules.
- There will be no mid-term assessments.
- All students that do not achieve a pass grade can view their marked exam through appointment with the course coordinator.
Specific rules for the two modules:
The written exam for the Manufacturing Technology module is 2 hours in length and comprises:
- 10 short answer or multiple choice questions worth a total of 15 points.
- One calculation and/or technical/practical exercise worth a total of 15 points aimed at verifying the candidate’s aptitude in determining quantitative results for the posed question.
The oral exam, which will begin with a discussion of the written exam, aims to verify the candidate’s ability to discuss and reason in relation to any of the themes addressed during the course and, where required, to provide an appropriate graphical representation. 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.
Other information
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