33981 - Integrated Processing Systems M

Learning outcomes

Despite the official language of the course being Italian, the teacher can speak Spanish and English fluently to help visiting students during their first weeks of lectures.

The course is delivered in Italian. Please, refer to the Italian version.

A translation of the Learning outcomes is reported below:

The course deals with the problems of the choice of alternative technological processes in the product engineering phase and the development of machining cycles, both in the traditional way and with CAPP techniques, integrated into the CAD-CAM environment for the use of CNC machine tools and flexible machining systems

Course contents

Despite the official language of the course being Italian, the teacher can speak Spanish and English fluently to help visiting students during their first weeks of lectures.

The course is delivered in Italian. Please, refer to the Italian version.

A translation of the Course contents is reported below:

The student who accesses this course knows the basics of the main production processes and design. This knowledge is usually acquired by passing the Manufacturing Studies exam. Lessons will be held in Italian. An understanding of the Italian language is therefore necessary to profitably follow the course. Some teaching materials are provided, and some technical terms are introduced in English in order to encourage students to read and study international specialised publications. The course is presented according to the following schedule: Inaugural lecture, Theory, Exercises, Interdisciplinary projects, Group work, Thematic seminars and Company visits.

Opening session:

• Timetable of lectures and exercises; description of the course contents:
• Theory,
• Classroom exercises and computer lab exercises,
• Thematic seminars, interdisciplinary projects and group work.
• Bibliographic texts adopted.
• Examination methods.

 

Block 1: On Machining and Automation Architecture.

Introduction to the concept of Industry 4.0.

Introduction to the concepts of Sustainability declined for the manufacture of industrial products.

PRODUCTION BY SUBTRACTION OF MATERIAL (MACHINING) AND THE MACHINE TOOL (MT) SYSTEM.

On the main machine tool architectures: the conventional lathe, the conventional milling machine, and lathe and milling machine machining; Reminders of the parameters of the cutting process.

Architecture of the MTs: rules for identifying the axes of motion in the lathe and milling machine, materials, main structures and components (beds, columns, guides, worm screws), drives (actuators and transducers).

Sensors and transducers. General characteristics of a transducer. Analogic position transducers: linear and rotary resolvers and inductosyns. Digital position transducers: linear encoders (optical scales) and rotary encoders. Position transducers in the MTs.

Evolution of MTs thanks to Computer Numerical Control (CNC). The unity of Government. The functionality of the CNC and the Programmable Logic Controller (PLC). Direct and indirect measurement; CNC with closed structure, closed loop, and CNC with semi-closed structure, semi-closed loop. 2, 2.5, 3, 4 and 5-axis controlled CNC MTs. Innovative MTs for hybrid machining.

 

Block 2: On the Programming of Machining-Paths-Direct programming of CNC Machine Tools.

Introduction to the Automatically Programmed Tool (APT) system. The Processor-Post-processor structure. The EIA/ISO language, structure of a machining program, preparatory "G" functions, auxiliary or miscellaneous "M" functions. Modal and non-modal functions. Macro instructions.

Advanced programming of CNC MUs using Computer Aided Manufacturing (CAM). Integrated and parametric CAM and CAD-CAM: structure; generation of machining paths in the process phase and the Cutter Location Data File (CL Data File); Generation of machine language programs in the post-process phase: the G-Code.

 

Block 3: LASER Systems and Additive Manufacturing

3.1. LASERS AND PROCESSING SYSTEMS USING LASERS

The generation of LASER (Light Amplified by Stimulated Emission of Radiation) Notes on electromagnetic radiation and the electromagnetic spectrum. The stimulated emission of electromagnetic radiation: the population inversion in the lasering medium obtained through the pumping of energy, the resonance condition in laser sources.

Example of an architecture of a laser source. Properties of Laser emission. Main characteristics of the laser beam: efficiency, fluence and irradiance. The distribution of energy in the laser beam. The polarisation, divergence and quality of the laser beam. Continuous and pulsed laser sources. Safety in laser systems.

Main industrial laser sources and architecture of processing systems using CO2, Nd:YAG, diode, Yb:YAG, and fibre laser sources. Comparison of laser sources. The optical path: mirrors, lenses and systems for focusing laser radiation. Principles of cutting and welding processes with LASER sources. The interaction of the laser with the material: absorptivity, transmissivity and reflection of electromagnetic radiation. The process parameters related to the laser-material interaction. Plasma formation in laser processing.

Classification of processes with laser sources according to irradiance.

Laser cutting: cutting mechanisms, characteristics of laser cutting heads. Process parameters and processing quality: defects and possible causes.

Laser welding: welding mechanisms, characteristics of laser welding heads. Process parameters and processing quality: defects and possible causes.

 

3.2. ADDITIVE MANUFACTURING

The main systems and technologies for Additive Manufacturing Introduction to the main processes and systems for the production by addition of material: photopolymerization and stereolithography or photolithography (Stereolithography, SLA); Laser Selective Sintering (SLS); Fused Deposition Moulding (FDM); Direct Metal Deposition (DMD); Multi Jet Modelling (MJD); Object; Laminated Object Manufacuring, LOM.

Description of the processes and their constraints.

 

Tutorials: Implementations of the Routing Language.

In the classroom: reminders for the reading of the technical drawing. Examples of direct programming of a CNC MU using the EIA/ISO Standard language.

In Lab6. Module 1: Drawing of solid geometries and drafting. Integrated CAD-CAM systems. Parametric and nonparametric systems.

In Lab6. Module 2: Structure of a CAM software and advanced programming of CNC MU machining paths. Tools. Realisation of machining paths of mechanical parts in the case of CNC MU with three controlled axes.

In Lab6. Module 3: Search for the optimal process parameters for the realisation of the CAM machining of a mechanical part.

 

Interdisciplinary projects and group work.

During the course, optional participation in projects to be carried out in interdisciplinary groups may be proposed.

During the course, exercises related to the topics covered (direct programming, evaluation of the performance of production systems, CAM exercise) may be assigned. The exercises can be carried out optionally in groups.

Students who will follow the course and carry out the optional exercises may be assigned a student license for the use of the Cimatron CAM software, offered by 3D Systems.

Free exercises - outside class hours - in Lab6 are possible after notifying the laboratory technicians, according to the methods of service delivery.

 

Compulsory thematic seminars.

The seminars provided during the course are an integral part of the subject and, therefore, attendance is mandatory. Some seminars delivered in previous years had the following topics:

· "The integrated CAD-CAM system Cimatron E", by CAMBRIO.

· "Projects and sizing of plants in IMA", by IMA.

· "Creo CAD and Windchill PLM", by PTC.

· "The digitisation of industrial information in Proterm", by Proterm.

· "Advanced machining of mechanical parts with CNC MU", by HPE COXA.

· "Structure and technical characteristics of a modern CNC", by HEIDENHAIN.

 

Visits to enterprises

Due to the large number of students, visits to the company may be offered to a selected number of interested students.

Readings/Bibliography

Books and teacher's note (in Italian)

SISTEMI INTEGRATI DI LAVORAZIONE, Giampaolo Campana, Mattia Mele, ESCULAPIO EDITORE, 2^ EDIZIONE, 2021.

TECNOLOGIE ADDITIVE. INTRODUZIONE AI PROCESSI E ALLE STRATEGIE PRODUTTIVE, Mattia Mele, Giampaolo Campana, ESCULAPIO EDITORE, 1^ EDIZIONE, 2021.

- DISPENSE A CURA DEL DOCENTE.

Suggested didactical materials (to be consulted in the University Library)

- AUTOMATION, PRODUCTION SYSTEM AND COMPUTER-INTEGRATED MANUFACTURING, M. P. Groover, 3rd Edition, Pearson Int. Edition.

- MANUALE DELLE MACCHINE UTENSILI A CONTROLLO NUMERICO, F. Grimaldi, Hoepli, 2007. - Zompì e Levi, Tecnologia meccanica, Edizioni Città Studi.
- Giusti e Santochi, Tecnologia Meccanica e studi di fabbricazione, Casa Editrice Ambrosiana. Testi facoltativi per l'approfondimento in lingua italiana

- Manuale di Programmazione per la fresatura SINUMERIK, 2009, Siemens.

- Manuale di Programmazione per la tornitura SINUMERIK, 2009, Siemens.

Optional didactical materials

- COMPUTER-AIDED MANUFACTURING, T. C. Chang, R. A. Wysk, H. P. Wang, 3rd Edition, Prentice-Hall.

- PRINCIPLES, PRACTICE AND MANUFACTURING MANAGEMENT, C. McMahon e J. Browne, 2nd Edition, Pearson Int. Edition.

- TNC 640 (Contouring Control for Machining Centers and Milling/Turning Machines), 2014, Heidenhain.

- GENERAL CATALOG (Linear Encoders, Length Gauges, Angle Encoders, Rotary Encoders, Contouring Controls Touch Probes, Evaluation Electronics Digital Readouts), 2014, Heidenhain.

Teaching methods

Despite the official language of the course being Italian, the teacher can speak Spanish and English fluently to help visiting students during their first weeks of lectures.

The course is delivered in Italian. Please, refer to the Italian version.

A translation of the Teaching methods is reported below:

Face-to-face lessons in the classroom with the help of a blackboard, projector.

When necessary due to some issues, lessons can be held remotely through the MsTeam platform. Exercises in the classroom on the topics of the course and in the computer lab in order to introduce the use of a professional system for the programming of machining by chip removal. The integrated CAD-CAM system Cimatron E, courtesy of 3D System, will be used for this purpose. The exercises in the computer lab will be carried out through an introduction to stand-alone CAM systems and integrated CAD-CAM systems. Subsequently, through the development of programming examples for the machining of complex geometries using CAM.

Assessment methods

Despite the official language of the course being Italian, the teacher can speak Spanish and English fluently to help visiting students during their first weeks of lectures.

The course is delivered in Italian. Please, refer to the Italian version.

A translation of the Assessment methods is reported below:

The assessment of learning takes place through a final written exam that ascertains the acquisition of the knowledge imparted and the expected skills.

The dates of the summer session sessions (June and July) will be established during the lessons. The lists will be published on Almaesami and, possibly, on the notices page of the teacher's website.

The exams of the autumn (September) and winter (January and February) sessions will be communicated through the lists published on Almaesami and, possibly, on the notices page of the teacher's website.

The written exam consists of open and closed questions on all the theoretical topics covered in class and in the writing of a work program using the EIA/ISO Standard language. The written test will last about two hours. The use of notes or books is not allowed. The final exam is registered through the Almaesami system.

The written exam will be followed by the correction, which is mandatory to attend, with the assignment of the grade and registration. The date for the correction of the written test will be communicated through Almaesami and published on the notices page of the teacher's website.

The oral exam is not scheduled.

The grade obtained remains valid for the entire academic year of attendance (from September to March of the following year).

The passing of the exam will be guaranteed to students who demonstrate mastery and operational ability in relation to the key concepts illustrated in the course. In particular, knowledge of the main machine tool architectures and the habit regarding the units of measurement and the composition of the main process parameters is considered fundamental. A higher score will be awarded to students who demonstrate that they have understood and are able to write and comment on a short machining path using the EIA/ISO language based on a proposed geometry.

Failure to pass the exam may be due to insufficient knowledge of key concepts, lack of mastery and adequacy of technical language.

 

Admission to the exams of the Integrated Machining Systems course M

The final grade, if lower than expected, can be rejected once. It is allowed that the student repeats the written exam at the following session. Upon entering the classroom/laboratory, any grade obtained in the previous exam session will be cancelled. In case of withdrawal from the exam, any grade obtained in the previous session will be cancelled, and therefore it will be necessary to repeat the test. The grade obtained in one of the sessions remains valid for the entire academic year or until March of the following year of enrolment, unless the rule described above is met.

Teaching tools

Despite the official language of the course being Italian, the teacher can speak Spanish and English fluently to help visiting students during their first weeks of lectures.

The course is delivered in Italian. Please, refer to the Italian version.

A translation of the Teaching tools is reported below:

Lectures and classroom exercises are carried out with the help of audiovisual means (projector), overhead projector and blackboard. The exercises in the Computer Science Laboratory are aimed at introducing the use of a professional system for drawing (Computer Aided Design, CAD) and for programming computer-aided machining (CAM).

 

Office hours

See the website of Giampaolo Campana