The course is aimed at developing the knowledge of production methods typical of mechanical industry. Description is than given of plastic deformation processes of metals, welding processes, foundry techniques and material removal processes, analyzing the relationships among them and the product requirements (i. e. performances and costs).

The knowledge of production processes utilized by the mechanical industry is necessary as the student must be capable of : - choosing process technologies, - choosing and, if required, collaborating in the design of production means; - preparing the manufacturing cycle of the part. At the end of the course the student must: - know and apply the relationships between materials and processes; - know and apply manufacturing techniques; - know and apply basic performances of production means (machines, tools/moulds/dies, fixtures and measurement/testing instruments); - know and apply process variables and their interactions with part requirements (quality, tolerances, surface roughness etc.) - know and apply the right actions in order to minimize the part cost; - know and apply the regulations concerning the industrial safety. As to judgement independence and communication cleverness, the student must: - write technical reports, also in English, with a high level of professionalism - evaluate production problems and find quickly their solutions as he knows the interactions among the various players in the production process and he has a sufficient experience in the evaluation of the magnitude order of involved variables; - get easily into touch with people, using English too.

Ability in technical drawing, as every production process starts from the detailed drawing of the component; extensive knowledge of materials, especially metal. The mastery of English, spoken and written is essential.

The course is aimed at developing the basic knowledge on manufacturing processes. Through lectures, demonstrations, and practical applications, the students will be introduced to the different types of manufacturing processes with the aim of making them able to select the most economic process which best meets the design requirements. The principal topics are: Mechanical fundamentals: ˑ Elastic and plastic behavior ˑ Stress and strain ˑ Stress and strain relationship for elastic behavior ˑ Element of the theory of plasticity Application to material testing ˑ Tensile test. Bridgman correction. Effect of temperature and strain rate. ˑ Compression test. W&F theory. ˑ Hardness test Fundamental of metalworking Bulk deformation Process ˑ Forging: open die forging process. ˑ Forging: closed die forging. ˑ Closed die design ˑ Extrusions. Material removal processes ˑ Orthogonal cutting. ˑ Chip types and chip removal mechanism. ˑ Velocity relationship. ˑ Cutting forces. Ernst & Merchant theory. ˑ Cutting pressure. Cutting power. ˑ Temperatures in cutting. ˑ Oblique cutting. Machining operations and machine tolls ˑ Turning. Engine lathe, CNC lathes, fixtures, tools geometry, characteristic angles, forces, powers. Surface roughness ˑ Milling: peripheral milling. Chip thickness. Cutting force. MRR. Helical milling cutter. Surface finish in milling. Working time. ˑ Milling: face milling. Chip thickness. Cutting force, Working time. ˑ Drilling: drill press e work holding. Cutting force and power. Drilling time Cutting tool technology ˑ Toll wear. Toll life . Taylor and Kronenberg equations. Economic and product design ˑ Optimization of cutting condition. Cutting speed for maximum production and minimum cost. Solidification processes ˑ Fundamental of metal casting. ˑ Sand Casting: from the draw to the pattern. Feeding system, gating system design, metallostatic force. ˑ Casting manufacturing processes: discussion of several expandable and permanent mold processes. ˑ Casting quality. Welding processes. Manufacturing system ˑ Computer Numerical Control. Programming (G-code, APT). ˑ Program structure. CNC milling.

During the course, the students will solve different practical exercises using numerical tools, such as excel, Q_Form and CNC simulator, and will visit a laboratory of the Polytechnic of Turin.

Manufacturin Engineering and Technology S. Kalpakjian, S.R. Schmid Pearson Fundamentals od Modern Manufacturing Mikell P. Groover John Wiley & sons, inc. Mechanical Metallurgy George E. Dieter Mc Graw - Hill Book Company Slides and exercices available on the Didactic Portal at the end of each lesson.

Modalità di esame: Prova orale facoltativa; Prova scritta tramite PC con l'utilizzo della piattaforma di ateneo; Elaborato progettuale in gruppo;

Exam: The overall exam consists of two parts: A written exam which take place remotely via pc using the university Exam platform and the Respondus Lockdown Browser integrated with proctoring tools. The examination concern the whole program and including theoretical questions on the principal topics covered during the course and practical exercises similar to those carried out during the practical lessons. The number of theoretical and exercise questions is at the discretion of professors. The score range is 0-24. The written exam will consist in three session of 35 minutes, each session in e different typ of manufacturing processes. Between sessions the student has 10 min to start the next session. The student can only use a pen, a calculator, blank sheets, formula sheet. Nothing else! In each session the student has the option to skip a question and to resume it later, therefore without the need to answer. The student can modify the answers already selected at any time, however, always within the time available. Within 35 minutes, the student must deliver the exam results by clicking on the button indicated on the Exam platform. If this is not done, the software will automatically conclude the exam, collecting all the answers (both those provided and not). The total sum of the marks assigned to the 3 sessions is 24, each session is evaluated with a maximum of 8 marks. B) Oral presentation on project on plastic deformation of metals and relative manufacturing processes. Score range is 0-6. The homework is developed in a team composed of 3 students. Members of the teams are announced within the two-third of the lectures. Each team is charged to face and analyze a case study using the tools and the methods introduced during the lectures and, at the end of their task, deliver a report on the performed activity and the obtained results. The report on the assigned case study must be presented and discussed by the team during the official exam session. The personal evaluation of the homework is based on the report and the individual presentation and discussion of the case study. Homework score will be valid only in the current A.Y. The score of the final exam will be the sum of the marks obtained in the two parts (A,B). Students pass the exam if the sum ranges between 18 and 30 marks. The student who does not upload the report within the deadline or doesn’t get a “pass” mark for the own contribution on the team work can achieve a final exam score limited to the written exam evaluation (max 24 points). The knowledge of production processes utilized by the mechanical industry is necessary as the student must be capable of : - choosing process technologies, - choosing and, if required, collaborating in the design of production means; - preparing the manufacturing cycle of the part. At the end of the course the student must: - know and apply the relationships between materials and processes; - know and apply manufacturing techniques; - know and apply basic performances of production means (machines, tools/moulds/dies, fixtures and measurement/testing instruments); - know and apply process variables and their interactions with part requirements (quality, tolerances, surface roughness etc.) - know and apply the right actions in order to minimize the part cost; - know and apply the regulations concerning the industrial safety. As to judgement independence and communication cleverness, the student must: - write technical reports, also in English, with a high level of professionalism - evaluate production problems and find quickly their solutions as he knows the interactions among the various players in the production process and he has a sufficient experience in the evaluation of the magnitude order of involved variables; - get easily into touch with people, using English too.

Modalità di esame: Prova orale facoltativa; Elaborato grafico prodotto in gruppo; Prova scritta tramite PC con l'utilizzo della piattaforma di ateneo;

Exam: The overall exam consists of two parts: A written exam which take place remotely via pc using the university Exam platform and the Respondus Lockdown Browser integrated with proctoring tools. The examination concern the whole program and including theoretical questions on the principal topics covered during the course and practical exercises similar to those carried out during the practical lessons. The number of theoretical and exercise questions is at the discretion of professors. The score range is 0-24. The written exam will consist in three session of 35 minutes, each session in e different typ of manufacturing processes. Between sessions the student has 10 min to start the next session. The student can only use a pen, a calculator, blank sheets, formula sheet. Nothing else! In each session the student has the option to skip a question and to resume it later, therefore without the need to answer. The student can modify the answers already selected at any time, however, always within the time available. Within 35 minutes, the student must deliver the exam results by clicking on the button indicated on the Exam platform. If this is not done, the software will automatically conclude the exam, collecting all the answers (both those provided and not). The total sum of the marks assigned to the 3 sessions is 24, each session is evaluated with a maximum of 8 marks. B) Oral presentation on project on plastic deformation of metals and relative manufacturing processes. Score range is 0-6. The homework is developed in a team composed of 3 students. Members of the teams are announced within the two-third of the lectures. Each team is charged to face and analyze a case study using the tools and the methods introduced during the lectures and, at the end of their task, deliver a report on the performed activity and the obtained results. The report on the assigned case study must be presented and discussed by the team during the official exam session. The personal evaluation of the homework is based on the report and the individual presentation and discussion of the case study. Homework score will be valid only in the current A.Y. The score of the final exam will be the sum of the marks obtained in the two parts (A,B). Students pass the exam if the sum ranges between 18 and 30 marks. The student who does not upload the report within the deadline or doesn’t get a “pass” mark for the own contribution on the team work can achieve a final exam score limited to the written exam evaluation (max 24 points). The knowledge of production processes utilized by the mechanical industry is necessary as the student must be capable of : - choosing process technologies, - choosing and, if required, collaborating in the design of production means; - preparing the manufacturing cycle of the part. At the end of the course the student must: - know and apply the relationships between materials and processes; - know and apply manufacturing techniques; - know and apply basic performances of production means (machines, tools/moulds/dies, fixtures and measurement/testing instruments); - know and apply process variables and their interactions with part requirements (quality, tolerances, surface roughness etc.) - know and apply the right actions in order to minimize the part cost; - know and apply the regulations concerning the industrial safety. As to judgement independence and communication cleverness, the student must: - write technical reports, also in English, with a high level of professionalism - evaluate production problems and find quickly their solutions as he knows the interactions among the various players in the production process and he has a sufficient experience in the evaluation of the magnitude order of involved variables; - get easily into touch with people, using English too.