65896 - Complementary Mechanical Manufacturing Processes

Learning outcomes

The student is informed about the main manufacturing processes available for shaping metals in the fields of metal forming, foundry and welding. Some basic concepts on the theory of plasticity is also provided.

Course contents

Metal forming processes

theory of plasticity, stress state, criteria of plasticity, effective stress and effective strain, axisymmetric strain and plain strain. cold and hot working.

Material characterization: tensile test, Compression test, torsion test, flow stress laws at room and high temperature, friction tests.

Solution methods: methods of uniform energy of deformation, method of plane sections. Processes: Upsetting, Rolling, Wire drawing, Extrusion.

Foundry processes

Production of cast iron and steels, cast iron refining, continuous casting. Foundry technology: models, patterns, moulds, cores.

Solidification: nucleation, omogeneous and etherogeneous, microstructures of solidification, grains, Segregation of castings, solidification defects, porosity, shrinkage. Moulding methods permanent and transitory

Welding theory: electric arc, principles, regimes, characteristics. Manual welding, TIG, MIG/MAG, Plasma, submerged arc. Assistance gas, electrode types, current types, application fields.

Structures of welding joints, thermal cycles, thermal affected zones, distortions, defects, hot and cold cracks.

Pressure welding, point welding, brazing, principles, parameters, brazing alloys and application fields

Readings/Bibliography

"Appunti di Sistemi di Lavorazione" by L.Tomesani, available at the photocopy shop of the school of engineering of Via Risorgimento

“Introduzione ai processi di saldatura” di Ascari-Fortunato, Società editrice Esculapio.

"Appunti di processi di Fonderia" available at the site www.diemtech.ing.unibo.it

Teaching methods

theory lectures and exercices

Assessment methods

written examination with exercices and questions on course arguments

Office hours

See the website of Luca Tomesani

See the website of Alessandro Ascari