29719 - Mechanical Manufacturing Processes

Learning outcomes

At the end of the course, students will understand the fundamental principles of machining processes based on material removal using machine tools. They will acquire knowledge of cutting mechanics, cutting tool geometry and materials, cutting forces, tool life, and the operating principles of conventional and CNC machine tools. Students will be able to select appropriate machining processes, cutting tools, machine tools, and workholding systems according to component geometry, dimensional and quality requirements, and production volume. They will also be able to develop and optimize simple manufacturing process plans, including machining sequences, process parameters, and machining time estimation.

Course contents

Fundamentals of machining with geometrically defined cutting tools

• Physical principles of metal cutting.
• Mechanics of metal cutting and fundamental physical aspects of the cutting process.
• Simplified cutting models.
• Piispanen's model.
• Ernst and Merchant cutting models.
• Cutting forces and cutting power.
• Thermodynamics of the cutting process.

Cutting tools: geometry and properties

• Cutting tool geometries and materials.
• Tool wear and tool life.
• Taylor's tool life equation.

Conventional machining processes and machine tools

• Machining operations: cutting motions and machine tools.
• Turning: cutting tools, machine tools, cutting forces, and machining time.
• Drilling: cutting tools, machine tools, cutting forces, and machining time.
• Hole machining operations (reaming, boring, etc.): cutting tools, machine tools, cutting forces, and machining time.
• Broaching and slotting.
• Grinding: grinding machines and abrasive tools.
• Gear manufacturing processes: machine tools and cutting tools.
• Workholding and fixturing systems.

Computer Numerical Control (CNC) machine tools

• Fundamentals of Computer Numerical Control (CNC) and programming languages.
• General principles of CNC machine architectures.
• CNC lathes.
• CNC milling machines and machining centres.

Practical session

• Workshop on machining process planning and the development of manufacturing process plans.

Readings/Bibliography

A.Fortunato, A. Ascari, E. Liverani "Tecnologia Meccanica. Introduzione alle lavorazioni per asportazione di truciolo", Esculapio editore, Bologna, 2016

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

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

Teaching methods

Powerpoint presentation; Exercices and discussion of industrial problems

Assessment methods

Assessment methods

The examination is designed to assess whether students have achieved the intended learning outcomes of the course, with particular reference to:

• knowledge of machining processes based on material removal;
• understanding of conventional and CNC machine tools and their fields of application;
• ability to design and organize simple machining process plans, selecting appropriate manufacturing operations, machine tools, cutting tools, and process parameters in accordance with component geometry, dimensional tolerances, and production requirements.

The examination consists of a written test followed immediately by an oral examination.

The written test, graded on a 30-point scale, requires students to develop a complete machining process plan for a mechanical component, including the selection and sequencing of manufacturing operations and the justification of the proposed solutions.

The oral examination begins with the discussion and correction of the written test and continues with two or more theoretical questions covering the topics addressed during the course. The oral assessment evaluates the student's understanding of machining principles, cutting mechanics, machine tools, cutting tools, and process planning, as well as the ability to apply theoretical knowledge to engineering problems.

The final grade is calculated as the arithmetic average of the written and oral examination marks.

Grading criteria

• 18–21: Basic knowledge of the main machining processes and limited ability to apply manufacturing concepts.
• 22–25: Good understanding of machining technologies and satisfactory ability to develop simple process plans with appropriate technical terminology.
• 26–29: Very good knowledge of machining principles, sound analytical skills, and the ability to justify process planning decisions autonomously.
• 30–30L: Excellent and comprehensive understanding of machining technologies, outstanding ability to develop and optimize manufacturing process plans, critical reasoning, and precise use of technical terminology.

 

WORKING STUDENTS

For each examination session, students who have obtained working student status may request an alternative examination date in place of one of the regular examination dates scheduled for that session. Students must contact the lecturer at least 14 days before the first examination date of the session so that a common alternative date can be arranged for all eligible requests.

STUDENTS WITH SPECIFIC LEARNING DISABILITIES (SLD) OR TEMPORARY OR PERMANENT DISABILITIES

Students with Specific Learning Disabilities (SLD) or temporary or permanent disabilities are encouraged to contact the University's dedicated support service well in advance: https://site.unibo.it/studenti-con-disabilita-e-dsa/it . The service will propose any appropriate accommodations, which must be submitted to the course lecturer at least 15 days before the examination for approval. The lecturer will assess the appropriateness of the requested accommodations in relation to the learning outcomes of the course.

Teaching tools

Book and slides.

Office hours

See the website of Alessandro Fortunato