30365 - Manufacturing Processes B

Learning outcomes

The student will learn the basic principles of manufacturing processes based on cutting by means of machine tools. He will be able also to organize simple production sequences (including tooling geometry, machine tool selection) basing on product geometry, batch number and dimensional requirements.

Course contents

FUNDAMENTALS OF CUTTING: Mechanics of chip formation, types of chips, Cutting forces, stresses and power, theory of Merchant, cutting temperatures, wear and failure. Roughness finishing and surface integrity. Machinability

TOOL MATERIALS: Carbon steels, high speed steels, High strength Alloys, sintered carbides, ceramic tools, diamonds, TiN coated high speed steels, cermets, cubic boron nitrides. Monitoring of tool wear, cutting fluids, cutting fluid management.

MACHINING OPERATIONS: turning, boring, facing, drilling, reaming. Lathe design and terminology, boring machine and boring tools. Workholding in lathes: mandrels, chucks, collets. Drilling Machines and drills. Milling: fundamentals of milling, milling cutters and milling machines.

Broaching, Sawing, Shaping, Planing. Gear manufacturing.

ABRASIVE MACHINING: Abrasive grain size and geometry, grinding, grinding wheels, bonding materials, dressing and truing, honing.

WORKHOLDING DEVICES: design criteria, location principles, clamping consideration, group jigs and fixtures

NUMERICAL CONTROL AND MACHINING CENTERS: CAD-NC, level of automation, types of control, servomotors, ball lead screw, table positioning measure, velocity transducers, part programming, turning centers and milling centers.

FOUNDRY PROCESSES: permanent and transient mold processes, patterns and cores. the solidification process, the cast structure, molten metal problems, gating systems, solidification shrinkage, risers and riser design. Gravity sand casting, shell molding, ceramic mold casting, investment casting, lost foam casting. Permanent mold casting. Casting defects: gas and shrinkage porosity.

Readings/Bibliography

L. Tomesani, Dispense del corso, reperibili presso la segreteria;

A. Zompi, R Levi "Tecnologia Meccanica-Lavorazioni ad asportazione di truciolo" UTET

F. Giusti, M. Santochi "Tecnologia Meccanica e Studi di Fabbricazione", Casa ed. Ambrosiana, Milano, 1992

DeGarmo "Materials and processes in Manufacturing" Prentice Hall

S. Kalpakjian "Manufacturing Engineering and technology", Addison-Wesley

J.A. Shey "Introduction to Manufacturing Processes" McGraw-Hill, 1987

R.H. Todd, D.K. Allen, L. Alting "Manufacturing Processes Reference Guide, Industrial Press inc., NY, 1994

J.G. Bralla "Handbook of product design for manufacturing", McGraw-Hill, 1986

M. M. Farag "Materials Selection for Engineering Design, Prentice Hall, 1997

Teaching methods

Powerpoint presentation; Exercices and discussion of industrial problems

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 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

The lectures arguments are fully described in "Appunti di Macchine Utensili" and "Appunti di Fonderia", which are available online.

Office hours

See the website of Alessandro Fortunato