30365 - Manufacturing Processes B

Learning outcomes

The student will learn the basic principles of manufacturing processes based on machining by means of simple or CNC controlled machines. Principles and practice of metals welding and casting techniques will also be provided. The student will be able to organize simple production sequences (including tooling geometry, machine tool selection, etc) 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. FOUNDRY PROCESSES:

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.

3. WELDING PROCESSES

3.1 Definitions, classification of processes.

3.2 Arc processes: SMAW, GMAW, GTAW, SAW.

3.3 Resistance welding.

3.4 Brazing and soldering.

3.5 Metallurgy and defects in welding.

Readings/Bibliography

• A.Fortunato, A. Ascari, E. Liverani "Tecnologia Meccanica. Introduzione alle Macchine Utensili", III Edizione, Esculapio, Bologna, 2019, ISBN: 9788893851695
• per eventuali approfondimenti: A. Zompi, R Levi "Tecnologia Meccanica-Lavorazioni ad asportazione di truciolo" UTET

Foundry processes:

• dispense e slides fornite dal docente su IOL.

• per eventuali approfondimenti: F. Gabrielli, R. Ippolito, F. Micari “Analisi e tecnologia delle lavorazioni meccaniche” McGraw-Hill
  

Welding processes:

• A. Ascari, A.Fortunato "Introduzione ai Processi di Saldatura", II Edizione, Esculapio, Bologna, 2014, ISBN: 9788874886944

In English:

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

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

The exam consists of a written test lasting 3 hours, structured as follows:

• Machining process planning: 13+2 points

• Theoretical questions machining processes – 8 points

• Theoretical questions related to welding – 5 points

• Questions related to foundry processes – 5 points

During the exam, students must bring the tool manual provided, which is essential for completing the first exercise. The manual must not contain any notes or equation. 

To pass the exam, all parts must be sufficient and the final grade must be ≥ 18/30.

Students who achieve a grade ≥ 18/30 may take an optional oral exam, which can potentially adjust the written exam grade by ±3 points.

The oral exam must be taken shortly after the written exam correction (typically within 4 to 7 days from the written exam), on the date indicated by the instructor and, when possible, in agreement with the interested students. 

Three exam sessions are scheduled for June–July, one in September, and two in January–February.

To take the exam, registration via Almaesami website, https://almaesami.unibo.it/ is mandatory and must be completed strictly within the deadlines. 

The exam can be reviewed within 12 months of the exam date. The grade does not expire, but students must ensure that there are no programme variations between different academic years.

Office hours

See the website of Erica Liverani