30364 - Manufacturing Processes A

Learning outcomes

At the end of the module, the student acquires the knowledge on the designation of the metals (steels, aluminium, etc) and of the characterization methods (tension, compression, torsion, impact, toughness, hardness, etc). The student knows the effect of the heat treatment on the mechanical and technological proprieties of the steels and of the aluminum alloys. The student becomes familar with the metal forming processes (forging, rolling, drawing and extrusion) including metal forming theory, analytical computantion of process loads and final product proprieties. The student will be able to evaluate if a process is adequate to obtain specific requirements on the final product.

Course contents

1-Manufacturing processes (2 hrs).

2-Materials (2 hrs): classification, material proprieities. Steels: alloyng elements, designations, special steels, steel production. Aluminum alloys: designation, heat treatments, proprieties. Other light alloys.

3-Characterization of materials (6 hrs): tensile test (nominal stress, real stress, strain hardening), compression tests, torsion tests. Hardness tests (Brinell, Vickers, Rockwell and microhardness). Impact tests and wear tests.

 4-Heat treatment of steels (10 hrs): Iron structures, Alloyng elements, Fe-C diagram, Influence of quenching rate, TTT and CCT diagrams, Jominy test, Hardening and Tempering, Annealing, Normalizing, Surface hardening, Casehardening, Nitriding.

 5- Heat treatment of aluminum alloys (2 hrs)

6-Metal forming (25 hrs): Theory of plasticity (Stress and strain; Plasticity criteria, effective stress and strain, effect of temperature), material characterization, strain hardening, plastic flow curves, tension test, compression test, torsion test, friction tests. Solution methods: uniform deformation, plane sections, FEM. Forging, rolling, drawing, extrusion. 

 

Readings/Bibliography

Powerpoint slides available on UniBo repository (see specific section below).

Suggested for Italian students not attending lectures:

1. Alberto Cigada, Tommaso Pastore “Struttura e proprietà dei materiali metallici” McGraw-Hill ISBN: 9788838667336
2. Filippo Gabrielli, Rosolino Ippolito, Fabrizio Micari “Analisi e tecnologia delle lavorazioni meccaniche 2/ed”McGraw-Hill ISBN: 9788838667596

As integration for in-depth knowledge:
1.Zompi' A., Levi R, “Tecnologia meccanica lavorazioni per deformazione plastica”, UTET (ita), 2005, ISBN: 9788877509666
2.F. Giusti, M. Santochi “Tecnologia Meccanica e Studi di Fabbricazione”, Casa ed. Ambrosiana, Milano, 2001

In english:
1. DeGarmo , J. T. Black, Ronald A. Kohser “DeGarmo's Materials and Processes in Manufacturing, 11th Edition”, Wiley, ISBN
2. Serope Kalpakjian, Steven Schmid, “Manufacturing Engineering & Technology, 6/E”, 2010, Prentice Hall, ISBN-10: 0136081681
3. John A. Schey, Introduction to Manufacturing Processes, 3rd Edition, ISBN-13 9780070311367
4. T. Altan “Metal Forming” American Society for Metals

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, 3 hours time. Score will be computed over a 0-30 range with a maximum score of 35/30. 

Test is composed of two parts, provided together at the beginning of the 3 hours:

-A first part with exercises on metal forming and on heat treatment of steels; it provides a partial score in the range 0-30, with 35/30 maximum achievable score; a minium score of 15/30 is compulsory for final positive evaluation;

-A second part with questions (open questions or true/false selection);it provides a partial score in the range 0-30, with 35/30 maximum achievable score; a minium score of 15/30 is compulsory for final positive evaluation; in the true/false question a wrong answer penalizes the score respect a blank answer;

Final score of the module A is obtain as average of the scores of the two parts, the maximum achievable score is 35/30.

Final score of the Manufacturing Tecnology CI is obtain as average of the scores of module A and B (both in 0-30 range, maximum score as 35/30), scores over 31 will be registered as 30 cum laude.

In the provided slides, as examples, exams from previous years are available with proposed solution.

During the test, the use of supporting material such as textbooks, notes, computer supports is not allowed (with the exception of scientific calculator) but it s possible to use the provided formulary handouts (without any type of annotation).

As required by the teaching regulations, 3 tests are scheduled in the months of June-July, 1 in September and 2 in January-February.

To register to the exam you need to register via the Almaesami website (https://almaesami.unibo.it/), in compliance with the deadlines provided for. Those who fail to register by the scheduled date, are required to promptly communicate (and in any case before the official closing of the registration list) the problem to the teaching secretariat. The teacher will have the right to admit them or not to take the test.

The verbalization of the final score takes place only after the achievement of a positive result both in module A and in module B of the integrated course and upon specific request for verbalization by the student.

It is possible to check the elaborate after correction and ask for clarifications in the specific 'correction session' or during teacher reception time. The possibility of using hours of reception to view the task is to be agreed in advance with the teacher via email.

The verbalization can take place in the absence of the student.

The vote obtained is valid for 12 months, after this deadline the written elaborates will be destroyed and it will not be no longer possible to request any further verification of the elaborates. The single vote can be extended beyond 12 months by means of a specific request to the teacher.

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