81889 - Processes and System for Product Design

Learning outcomes

The course deals with the traditional and innovative production process within the designer's skills. In particular, at the end of the course the student knows: to evaluate and choose the suitable materials for the production processes; primary and secondary forming processes of metals and polymers; the most common processing systems, and heat treatments.

Course contents

Module 1, 3CFU:

Introduction to production processes and the influence of materials and geometries.

Classification and properties of materials.Characterization of materials, tests and links with workability.

Solidification of metals and “castability”.Metal casting processes: sand casting; permanent casting; technological and economic considerations in the choice of casting processes.

Cutting processes: turning; drilling; milling; the grinding; cutting tools and tool life; economic and performance considerations.

Advanced manufacturing processes: ultrasound; chemical and electrochemical processes; EDM; laser processing; electron beam processing; water and abrasive jet cutting.

Polymers, composites and their industrial processes: chemical-physical properties and characterization; extrusion; printing; thermoforming, casting; cutting processes.

Ceramic materials: characteristics and properties. Production and processing technology. Sintering.

 

Module 2, 2 CFU:

Additive Manufacturing (AM):
- Introduction and general considerations
- Classification of AM technologies
- Stereolithography (SLA)
- Digital Light Processing (DLP), Liquid Crystal Display (LCD) e Digital Light Synthesis (DLS)
- Drop-On-Demand (DOD)
- Material Jetting (MJ), Nano Particle Jetting (NPJ)
- Selective Laser Sintering (SLS)
- Selective Heat Sintering (SHS), High-Speed Sintering (HSS), Selective Inhibition Sintering (SIS), Multi Jet Fusion (MJF)
- Binder Jetting (BJ)
- Fused Deposition Modeling (FDM), Fused Filament Fabrication (FFF), Fused Granulate Fabrication (FGF), Plastic Freeforming (PF), Material Extrusion (MEX)
- Wire and Arc Additive Manufacturing (WAAM)
- Laminated Object Manufacturing (LOM), Ultrasonic Additive Manufacturing (UAM)

Forming and shearing:
- Introduction and general considerations
- Plastic deformation and main characterisation tests
- Constitutive equations of hot and cold forming
- Rolling, Drawing, Extrusion
- Blanking, Piercing, Shaving, Fine Blanking
- Forging: Open-die forging, Closed-die forging, Coining
- Sheet metal drawing
- Deep-drawing capability of sheet metals and characterisation tests
- Rubber pad forming, Hydroforming of sheet metal and pipes
- Single-point incremental forming, Spinning, Stretching
- Sheet metal bending

Readings/Bibliography

Notes of the teacher in the form of lecture notes and slides.

Tecnologie Additive. Introduzione ai processi e alle strategie produttive". Mele M. e Campana G., Ed. Esculapio, 2021, ISBN 13: 9791220262323

Textbook: Mechanical Technology, second edition. Kalpakjian-Schmidt

Teaching methods

Powerpoint presentations, slides and insights on the blackboard.

Exercises and discussion of industrial cases

Assessment methods

Written test with open questions and quiz

Teaching tools

Slides and textbooks.

 

Office hours

See the website of Alessandro Fortunato

See the website of Mattia Mele