30365 - Manufacturing Processes B

Learning outcomes

The student will learn the basic principles of manufacturing processes based on cutting by means of machine tools and casting techniques. He will be able also to organize simple production sequences (including tooling geometry, machine tool selection) basing on product geometry, batch number and dimensional requirements.

Course contents

1. MACHINING PROCESSES:

1.1. Fundamentals of machining:

• Mechanics of cutting

• Principal results of theories of Pijspanen, Ernst Merchant and Merchant Merchant

• Cutting temperatures and power

1.2. Cutting tools:

• Geometries and materials

• Tool wear and integrity, the Taylor’s law

1.3. Machining operations:

• The turning process: lathes and lathe operations

• Milling: mill and milling machine

• Drilling: drills, and drilling Machines

• Hole making: reaming and reamers

• Broaching and Slotting

• Gear manufacturing

• Grinding: grind and grinding wheels

1.4. Numerical control

1.5. Exercises

 

2. CASTING TECNOLOGIES:

2.1. Generalities, metal solidification, micro/macro segregation, related issues.

2.2. Sand casting,

2.3. Shell casting,

2.4. High pressure die casting,

2.5. Investment casting.

Readings/Bibliography

For the machining part (in italian): A.Fortunato, A. Ascari, E. Liverani "Tecnologia Meccanica. Introduzione alle lavorazioni per asportazione di truciolo", Esculapio editore, Bologna, 2016

For the casting part (in italian): F. Gabrielli, R. Ippolito, F. Micari “Analisi e tecnologia delle lavorazioni meccaniche” McGraw-Hill

Suggested book in English:

S. Kalpakjian "Manufacturing Engineering and technology", Addison-Wesley

As integration for in-depth knowledge:

A. Zompi, R Levi "Tecnologia Meccanica-Lavorazioni ad asportazione di truciolo" UTET

Teaching methods

Lectures based on powerpoint slides with in-depth analysis at the blackboard; exercises and analysis of industrial cases.

Attendance is not compulsory but strongly suggested in relation to complexity and interconnections of the course topics.

Assessment methods

Final test in written form with 2 questions about the cutting principle and one test about the definition of a machining cycle of a component. Design of a foundery cycle and open/closed questions on casting theory.

Tests list and results are managed through Almaesami website:

https://almaesami.unibo.it/

It's mandatory to sign in on the website in order to attend the exam, the lists are closed 2 days before the exam.

Teaching tools

Updated slides can be downloaded from Insegnamenti on Line (IOL).

Login with the @studio.unibo.it account.

Office hours

See the website of Lorenzo Donati

See the website of Erica Liverani