B2391 - Advanced and Sustainable Manufacturing

Learning outcomes

The student will acquire the skill to selectadvanced manufacturing technologies for metallic material processing, as well as implementing and comprehending the relationships between process parameters and product characteristics. The student will be able to evaluate the suitability and consistency of technologies in order to obtain specific requirements for the finished product, as well as to evaluate the different processes in terms of sustainability and environmental impact.

Course contents

MODULE 1

 1. JOINING TECHNOLOGIES

Friction welding Technologies: Friction welding, Friction stir welding (FSW), Solid State Bonding. Diffusion Bonding. Adhesive Bonding. Welding of polymers, Ultrasonic Welding.

2. ADVANCED MATERIAL REMOVAL TECHNOLOGIES

Electrical Discharge Machining (EDM) and Wire Electrical Discharge Machining(WEDM). Machines architecture and components. Process parameters. Electrodes: materials and technologies. Examples.
Chemical and electro-chemical machining processes (ECM).
Ultrasonic machining (USM). machining/welding

3. ADVANCED CUTTING TECHNOLOGIES

Mechanical cutting: Shearing technologies: blanking, piercing and punching, cutoff, fine blanking.
Thermal cutting: high energy beam cutting, Oxygen Torch cutting, Plasma cutting.
Others: water jet and abrasive water jet.

4. PROCESSING OF METAL POWDERS

Production of powders, Powder Mixing and Blending, Compacting, Sintering. Secondary and finishing operations. Proprieties of metal powders. Components. Hot isostatic pressing. Powder forming. Metal Injection Molding (MIM) or Powder Injection Molding (PIM). Properties of P/M Products.

 

MODULE 2

5. SUSTAINABILITY OF MANUFACTURING PROCESSES

Introduction to sustainability in manufacturing
Life Cycle Assessment (LCA) of manufacturing processes
Sustainability through advanced manufacturing technologies

6. LASER THEORY PROCESSES

Fundamentals of laser processes
Laser sources, optics, and beam scanning systems
Laser–material interaction
Laser processes: laser heat treatment, laser welding, laser cutting, and laser micromachining

7. MODELING OF LASER PROCESSES

Modeling of laser processes: from analytical models to AI-based models
In-class exercises using CFD simulation software (Flow3D)

8. FUNDAMENTALS OF ADDITIVE MANUFACTURING FOR METALLIC MATERIALS

Introduction to additive manufacturing processes
Laser Powder Bed Fusion (LPBF)
Directed Energy Deposition (DED)

Readings/Bibliography

1. DeGarmo , J. T. Black, Ronald A. Kohser DeGarmo's Materials and Processes in Manufacturing, 11th Edition, Wiley, ISBN

2. Michele Monno, Barbara Previtali, Matteo Strano “Tecnologia meccanica. Le lavorazioni non convenzionali” CittàStudi Edizioni, ISBN: 8825173776

3. E. Capello, Le lavorazioni industriali mediante laser di potenza, 2009, Maggioli Editore, ISBN-10: 8838741816

4. Gholami, H., Abdul-Nour, G., Sharif, S., & Streimikiene, D. (Eds.), Sustainable Manufacturing in Industry 4.0: Pathways and Practices (2023), Springer, ISBN 978-981-19-7217-1.

Teaching methods

Lectures based on powerpoint slides with in-depth analysis at the blackboard; exercises and analysis of industrial cases. Visits to Manufacturing Plants. Team working project on a selected technology.

Assessment methods

The exam aims to verify the achievement of the Learning outcomes:

· knowledge of the meaning of sustainability of manufacturing technologies and measurement metrics;

· knowledge of advanced processing technologies;

· ability to analyze and propose complex technological cycles, in relation to the adequacy and compatibility of the technologies identified to obtain specific requirements on the finished product;

· ability to find specialized bibliography on innovative technologies;

· team working skills in carrying out the study.

Preliminary or after the final test, the students must discuss the team-working project on the selected technology, a score up to 30/30 is given.

The exam is performed in a written form, followed by an optional oral discussion on the same day or on subsequent days. 
The use of supporting materials such as textbooks, notes, or even computer equipment is not permitted during the exam.

The written exam consists of open-ended questions covering all course topics. 
Two questions will be related to Module 1, each worth 8 points. 
During Module 2, software (Flow3D) will be used for some in-class exercises. Students who attend classes (100% attendance during the exercises) will be required to complete three simple laser process modeling exercises in small groups during the lectures and present their results at the beginning of the next lecture. Completion of the exercise will certify successful completion of this part of the course.
Students who do not attend (or attend only partially) the exercises will be required to study supplementary teaching materials that will be provided by the instructor at the beginning of the course via Virtuale. 
The preparatin of the supplementary course material will be assessed through the written exam, along with the other theoretical topics covered in the course. The exact dates and times of the in-class exercises will be communicated at the beginning of the course by the instructor (Prof. Erica Liverani).

Module 2 is assigned a score out of 16, divided as follows: 
-4 points for question 3 
-4 points for question 4 
-8 points for the in-class exercises or for questions 5 and 6 (4 points each) 
P.S. The minimal grade for passing Module 2 is 10/16.

The written exam will therefore be scored as the sum of Module 1 (maximum 16 points) and Module 2 (maximum 16 points), for a total of 32 points. Scores higher than 30 will correspond to a final grade of 30 cum laude.

Any oral exam (to be conducted at the student's request) may cover all course topics and the group study completed. The final grade is the average of the grades obtained in the group discussion, the written exam (Module 1 and Module 2), and the oral exam (if applicable). For written exam grades lower than 24/32, the average will be weighted with greater weight than the written exam grade.

At least, 5 evaluation session will be realized through the accademic year.

Tests list and results are managed through Almaesami website: [https://uniwex.unibo.it/]https:// .unibo.it/ [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.

In accordance with the University Code of Ethics (Codice Etico di Ateneo), students’ attention is drawn to the obligation to adopt conduct based on the highest standards of integrity.
Any activity that may compromise the proper conduct of examinations is prohibited, including but not limited to:

• cheating and plagiarism;
• access to online learning resources;
• use of artificial intelligence tools not expressly authorized;
• use or possession of unauthorized materials or equipment.

It is specified that the mere possession of unauthorized tools or materials during the conduct of any examination results in the immediate invalidation of the submitted work and notification to the competent offices.

Any conduct in violation of the above provisions may result in disciplinary proceedings and, where criminal relevance applies, reports to the competent authorities, with the consequent risk of criminal proceedings being initiated against the students involved.

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