30365 - Manufacturing Processes B

Course Unit Page

  • Teacher Erica Liverani

  • Credits 6

  • SSD ING-IND/16

  • Teaching Mode Traditional lectures

  • Language Italian

  • Campus of Forli

  • Degree Programme First cycle degree programme (L) in Mechanical Engineering (cod. 0949)

Academic Year 2022/2023

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

Final test in written form with 2 questions about the cutting principle and one test about the definition of a machining cycle of a component. Design of a foundry cycle and open/closed questions on casting and welding theory. Duration 3 hours time. Score will be computed over a 0-30L range with a maximum score of 35/30.

Tests list and results are managed through Almaesami website:

https://almaesami.unibo.it/

It's mandatory to sign in on the course list in order to attend the exam, the lists are closed 2 days before the exam.

Final score of the Manufacturing Tecnology CI is obtain as average of the scores of module A and B (both in 0-30 range, maximum score as 35/30), scores over 31 will be registered as 30 cum laude.

In the provided slides, as examples, exams from previous years are available with proposed solution.

During the test, the use of supporting material such as textbooks, notes, computer supports is not allowed (with the exception of scientific calculator) but it s possible to use the provided cutting tools catalogue (without any type of annotation).

As required by the teaching regulations, 3 tests are scheduled in the months of June-July, 1 in September and 2 in January-February.

To register to the exam you need to register via the Almaesami website (https://almaesami.unibo.it/), in compliance with the deadlines provided for. Those who fail to register by the scheduled date, are required to promptly communicate (and in any case before the official closing of the registration list) the problem to the teaching secretariat. The teacher will have the right to admit them or not to take the test.

The verbalization of the final score takes place only after the achievement of a positive result both in module A and in module B of the integrated course and upon specific request for verbalization by the student.

It is possible to check the elaborate after correction and ask for clarifications in the specific 'correction session' or during teacher reception time. The possibility of using hours of reception to view the task is to be agreed in advance with the teacher via email.

The verbalization can take place in the absence of the student.

The vote obtained is valid for 12 months, after this deadline the written elaborates will be destroyed and it will not be no longer possible to request any further verification of the elaborates. The single vote can be extended beyond 12 months by means of a specific request to the teacher.

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 Erica Liverani