73109 - Advanced manufacturing and composite materials technologies (2nd cycle)

Academic Year 2022/2023

  • Docente: Lorenzo Donati
  • Credits: 6
  • SSD: ING-IND/16
  • Language: Italian
  • Teaching Mode: Traditional lectures
  • Campus: Forli
  • Corso: Second cycle degree programme (LM) in Mechanical Engineering (cod. 8771)

Learning outcomes

The student must acquire the competences to select advanced manufacturing technologies for processing of metallic and composites materials and to acquire the knowledge for the preparation of adanced manufacturing cycles, in relation to the suitability and compatibility of the technologies identified in order to obtain specific requirements on finished product.

Course contents

1. ADVANCED MATERIAL REMOVAL TECHNOLOGIES (10 hours)

Electrical Discharge Machining (EDM) and Wire Electrical Discharge Machining(WEDM). Machines architecture and components. Process parameters. Electrodes: materials and technologies. Examples.

Chemical and electro-chemical machining processes (ECM).

Ultrasonic machining (USM). machining/welding

2. ADVANCED CUTTING TECHNOLOGIES (10 hours)

Mechanical cutting: Shearing technologies: blanking, piercing and punching, cutoff, fine blanking.

Thermal cutting: high energy beam cutting, Oxygen Torch cutting, Plasma cutting, Laser cutting.

Others: water jet and abrasive water jet.

3. ADVANCED WELDING TECHNOLOGIES (3 hours)

High power source welding: Laser welding (LW), Electron beam welding (EBW). Friction welding Technologies: Friction welding, Friction stir welding (FSW) , Solid State Bonding. Diffusion Bonding. Welding of polymers, Ultrasonic Welding.

4. PROCESSING OF METAL POWDERS (5 hours)

Production of powders, Powder Mixing and Blending, Compacting, Sintering. Secondary and finishing operations. Proprieties of metal powders. Components. Hot isostatic pressing. Powder forming. Metal Injection Molding (MIM) or Powder Injection Molding (PIM). Properties of P/M Products.

5. RAPID PROTOTYPING TECHNOLOGIES (2 hours)

Selective laser sintering (SLS) of polymers, metals and powders. Fused deposition modeling (FDM). Laminated object manufacturing (LOM).

6. COATINGS AND SURFACE TECHNOLOGIES (5 hours)

Physical vapor deposition (PVD), Chemical vapor deposition (CVD).

7.  TECHNOLOGIES OF THERMOPLASTIC POLYMERS (5 hours)

Polymers, Press molding, injection molding, blow molding, stretch blow molding, thermoforming.

8. TECHNOLOGIES OF THERMOSETTING POLYMERS AND COMPOSITE MATERIALS (20 hours)

Properties of resins and fibers; classification of fabrics, properties of pre-pregs

Hand layup, Liquid Composite Molding (LCM), Resin transfer molding (RTM) and variants (VARTM, VARI, RIFT, etc), Autoclave and pre-preg, Press Molding, Filament winding.



Readings/Bibliography

Powerpoint slides available on UniBo repository (see specific section below).

Suggested for Italian students not attending lectures:

1. Alessandro Fortunato, Alessandro Ascari "Introduzione ai processi di saldatura", Ed. Esculapio ISBN: 9788874886944

2. E. Capello, Le lavorazioni industriali mediante laser di potenza, 2009, Maggioli Editore,  ISBN-10: 8838741816

3. Crivelli Visconti I., Caprino G., Langella A., Materiali compositi, Casa editrice: Hoepli, ISBN: 8820341581

4. Michele Monno, Barbara Previtali, Matteo Strano “Tecnologia meccanica. Le lavorazioni non convenzionali” CittàStudi Edizioni, ISBN: 8825173776

In english:

5. DeGarmo , J. T. Black, Ronald A. Kohser DeGarmo's Materials and Processes in Manufacturing, 11th Edition, Wiley, ISBN

6. Serope Kalpakjian, Steven Schmid, " Manufacturing Engineering & Technology, 6/E ", 2010, Prentice Hall, ISBN-10: 0136081681

7. John A. Schey, Introduction to Manufacturing Processes, 3rd Edition, ISBN-13 9780070311367

Teaching methods

Lectures based on powerpoint slides with in-depth analysis at the blackboard; exercises and analysis of industrial cases. Visits to Manufacturing Plants. Team working project on a selected technology.

Assessment methods

Preliminary or after the final test, the students must discuss the team-working project on the selected technology, a score up to 30/30 is given.

Final test is realized in a written form, it consists in open questions on all the course topics. During the test, the use of any supporting material (such as textbooks, notes, computer supports, etc) is not allowed. Test is compsed by 4 questions to be discussed in open form, a score 0-4 is given to each answer thus realizing a final score on 32 basis. An optional oral session (based on student's request) can also be added, oral session can deal on all course topics and team-working study in order to clarify student's preparation and own contribute to the team working study.  

The final score is an average of team working project score, written test and optional oral discussion. For written test scores below 24/32 a weighted average will be used with an higher weight provided to written test.

At least, 5 evaluation session will be realized through the accademic year.

Tests list and results are managed through Almaesami website:
https://almaesami.unibo.it/
It's mandatory to sign in on the website in order to attend the exam, the lists are closed 2 days before the exam.

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 Lorenzo Donati

SDGs

Industry, innovation and infrastructure Responsible consumption and production

This teaching activity contributes to the achievement of the Sustainable Development Goals of the UN 2030 Agenda.