33978 - Processes and Manufacturing Methods for Product Development M

Learning outcomes

Attending students will acquire the methodological approaches and application methods to improve the fundamentals skills addressed in the previous courses on manufacturing processes.
Some of the most important industrial tools and design methods for manufacturing are provided, dealing with economic aspects related to manufacturing processes, such as industrial cost estimations, and more strictly technical aspects related to mechanical tool design and optimization of process parameters using last CAE tools.
Mathematical models and solution methods for numerical simulation of some of the main manufacturing processes are dispensed, explaining the theoretical principles of the analysis on industrial cases.
The course involves students taking part in project-teams that have to develop a specific engineering project aimed at the design of manufacturing tools for production of a mechanical component.

Course contents

• Classification of manufacturing processes
• criteria and strategies of choice for manufacturing processes
• models for manufacturing cost prediction
• Tools for process numerical simulations
• Short introduction to the theoretical principles of the FEM methods and FVM (finite elements and volumes)
• References on finite element method and application examples to structural analysis (displacements, stresses, deformations)
• modeling principles: verification, validation, convergence tests and error checking
• ·non-linearity of the FEM method
• modeling approaches to the motion description: Lagrangian and Euler formulations
• time integration: explicit and implicit formulations
• thermo-structural problems: the formulations coupled
• examples of calculation procedures in structural problems and coupled analysis
• examples of case studies
• introduction to numerical models governing the main multiphysics phenomena involved in manufacturing processes (Navier-Stokes equations, Fourier)

Numerical simulation of casting processes
Main computational aspects involved in the casting processes
Computational methods to simulate the filling phases in sand and shell-casting processes
Numerical analysis of heat exchanges during cooling and solidification phases of casting processes
Basic concepts modeling of solidification phenomena in metal alloys (ferrous and non ferrous)
Criteria for interpretation of results obtained by numerical simulation (prediction of manufacturing defects)
Use of numeric codes in the tool design (molds)
Applications on industrial cases

Numerical simulation of plastic deformation processes
The laws of plastic flow stress: their determination, tests, data analysis, mathematical models;
The models for the friction and other simulation parameters
Interpretation of results and advanced tools of analysis of the process
The thermo-mechanical solicitation of tools: Die stress, elastic, plastic elastic, creep
Applications in industrial cases and Troubleshooting

Readings/Bibliography

Specific reference books are not required.

Teaching methods

Lectures and exercices with commercial finite element codes for process analysis

Assessment methods

Written examination on theoretical aspects.

Detailed analysis and presentation of an industrial process (Fem analysis, cost analysis) by working groups of 4-5 students each.

Teaching tools

FEM analysis of casting and forming processes will be made on commercially available software tools with the help of teachers.

Office hours

See the website of Luca Tomesani

See the website of Rosario Squatrito