30364 - Manufacturing Processes A

Learning outcomes

At the end of the module, the student acquires the knowledge of the foundry practice, of the deformation processes and of the main welding technologies. The main material characterization methods (tension, torsion, impact toughness) are also considered. The student will be able to evaluate if a process is adequate to obtain specific requirements on the final product.

Course contents

1-Manufacturing processes.
2-Materials: classification, material proprieities. Steels: alloyng elements, designations, special steels, steel production. Aluminum alloys: designation, heat treatments, proprieties. Other light alloys.
3-Characterization of materials: tensile test (nominal stress, real stress, strain hardening), compression tests, torsion tests. Hardness tests (Brinell, Vickers, Rockwell and microhardness). Impact tests and wear tests.
4-Heat treatments of steels: Iron structures, Alloyng elements, Fe-C diagram, Influence of quenching rate, TTT and CCT diagrams, Jominy test, Hardening and Tempering, Annealing, Normalizing, Surface hardening, Casehardening, Nitriding.
5-Casting processes: Basic knowledge of casting of light alloys and steel. Sand casting (sand types, models, cores, forming sequence, Manual and automatic operations), Shell mold, Expanable pattern, Plaster mold, Ceramic mold, Investment, Permanent mold, Die casting, Centrifugal casting. Shrinkage, defects, porosity. Casting design, casting economics.
6-Metal forming: Theory of plasticity (Stress and strain; Plasticity criteria, effective stress and strain, effect of temperature), material characterization, strain hardening, plastic flow curves, tension test, compression test, torsion test, friction tests. Solution methods: uniform deformation, plane sections, FEM. Forging, rolling, drawing, extrusion. 
7-Welding processes: Arc-welding processes, shielded metal arc welding, submerged arc welding, gas metal arc welding, fluxed cored arc metal, electrogas welding, electrodes. Non consumable electrode, Gas tungsten arc welding, plasma arc welding, basics of Laser welding. Other processes: Spot welding, Brazing and soldering (filler metals, fluxes, brazing methods), Friction Stir Welding Weld design, weld quality, porosity, slag inclusion, weld profile, surface damage, residual stresses, weldability. Testing welded joints: destructive and non destructive testing.

Readings/Bibliography

Mandatory:
A. Fortunato, A. Ascari "Tecnologie di giunzione mediante saldatura vol.1", Ed. Esculapio

Suggested:
D. Veschi, "L'acciaio ed il suo impiego", Ed. Patron

As integration:
A. Zompi, R. Levi "Tecnologia Meccanica - Lavorazioni per deformazioni plastiche", UTET
F. Giusti, M. Santochi "Tecnologia Meccanica e Studi di Fabbricazione", Casa ed. Ambrosiana, Milano, 2001
F. Chiazzo, V. Sergi “Tecnologie generali dei Materiali” Ed. UTET

In english:
DeGarmo "Materials and processes in Manufacturing" Prentice Hall
S. Kalpakjian "Manufacturing Engineering and technology", Addison-Wesley
T. Altan “Metal Forming” American Society for Metals
J.A. Shey "Introduction to Manufacturing Processes" McGraw-Hill, 1987

Teaching methods

Lectures based on powerpoint slides or at the blackboard; exercises and analysis of industrial cases.

Assessment methods

Final test in written form, exercises, multiple choice questions and open questions on all the discussed topics.

Tests list and results are managed trough 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

Course material and lessons slides are available at the Faculty copy-center.
Slides can be downloaded at the following link: http://campus.cib.unibo.it/ .
Login with the account setting of the @studio.unibo.it account.

Office hours

See the website of Lorenzo Donati