Intended Learning Outcomes (ILOs) Knowledge and understanding: 1. know and understand the main mechanical components and their functions; 2. acquire knowledge and understanding of the most important manufacturing and assembly processes in the mechanical industry; 3. understand the relationships among materials, manufacturing processes, and product requirements; 4. identify the advantages and limitations of primary industrial manufacturing and assembly processes; 5. recognize the potential of unconventional processes compared to traditional processes in industrial production. Applying knowledge and understanding: 6. develop the ability to solve medium complexity problems in the core fields of automotive engineering; 7. evaluate which manufacturing and assembly processes are most suitable to meet specific product requirements. Making judgements: 8) critically identify and select the information necessary for the proper selection of the manufacturing and assembly process; 9) objectively asses results obtained from analytical processing, numerical simulations, or experimental laboratory tests; 10) develop a proactive approach to solving medium complexity problems related to manufacturing and assembly technologies; 11) use technical and scientific literature. Communication skills: 12) develop the ability to structure and prepare scientific and technical documentation inherent to the main manufacturing processes used in the mechanical industry; 13) enhance the ability to present, communicate, discuss, and argue the topics covered in the course. Ability to learn: 14) develop learning skills through the individual study of the topics covered during the course. In addition, the analysis of different manufacturing and assembly process problems may also be addressed by group discussions; 15) enhance knowledge of manufacturing and assembly processes by consulting scientific literature, specialized texts, and technical and international standards provided by the professor during the course.

Students are expected to have a basic understanding of mathematical analysis, technical drawing, physics, and materials science. Competence in basic computer applications is also required, particularly Microsoft Excel and SolidWorks or equivalent CAD software. To help students prepare for the course content, a preparatory document on the fundamental mechanical properties of metals will be provided at the beginning of the course. Reviewing this material, which builds on topics covered in previous courses, is essential for successful engagement with some of the subjects addressed.

The course covers the following topics: MANUFACTURING PROCESSES o Classification of manufacturing processes o Fundamentals of metal plasticity o Bulk deformation processes: - Rolling - Drawing - Extrusion - Forging o Sheet metal forming o Fundamentals of material removal processes o Machining processes - Turning - Drilling - Milling - Grinding - Other machining operations o Tool materials o Tool wear o Casting processes - Solidification of metals and mold design - Expendable mold casting processes - Permanent mold casting processes o Manufacturing of plastic components ASSEMBLY TECHNOLOGIES o Welding processes - arc welding - laser welding - resistance welding - other fusion welding processes - solid-state welding o Mechanical joining o Brazing and soldering o Joint quality, testing, and inspection o Taylor welded blanks o Painting in the automotive sector o Assembly line analysis

The course combines lectures with classroom-based exercises and may include visits to manufacturing companies and/or exhibitions. The course is divided into two parts, providing the fundamentals of manufacturing processes and assembly technologies for the automotive industry. Self-assessment forms (i.e., review quiz and questions) will be provided at the end of each teaching unit to enable students to critically reflect on the course topics, identify any areas of difficulty, and monitor their learning progress.

PowerPoint slides presented during lectures will be provided as lecture notes (.pdf files) and uploaded to the Moodle platform of the course. In addition, professors may also provide supplementary materials, such as research papers, web links, and videos related to the course topics. Students can mainly refer to the following textbooks: 1) S. Kalpakjian, S. Schmid: "Manufacturing engineering and technology", ed. Pearson. 2) M.P. Groover, "Fundamentals of modern manufacturing", ed. John Wiley & Sons Inc.

Lecture slides; Text book; Multimedia materials;

Exam: Computer-based written test in class using POLITO platform;

1. FORMATIVE ASSESSMENT Classroom exercises and discussions with the professor during lectures will provide opportunities to assess students’ ability to apply their knowledge and understanding of the topics covered in the course. The expected ILOs assessed during the formative assessment are as follows, with reference to the list of “expected learning outcomes”: - ILOs assessed through discussions with the professor: 2, 11, 13, 14. - ILOs assessed through classroom exercises and laboratory activities: 1, 3, 6, 9, 10, 12, 14. 2. CRITERIA, RULES, AND PROCEDURES FOR THE FINAL EXAMINATION The final examination consists of two distinct written parts, which students must take consecutively on the same day: a) Manufacturing part, aimed at assessing the content related to manufacturing processes; b) Assembly part, aimed at assessing the content related to assembly technologies. a) Manufacturing part The Manufacturing part lasts 70 min. with a maximum grade of 30/30 points and consists of two tasks related to the topics addressed during the course: - Computer-based multiple-choice quiz on manufacturing topics (30 min. for a maximum score of 20/30 points). The quiz consists of 8 questions. For each question, the student must select 1 or 2 correct answers from 5 proposed alternatives. Each question answered correctly is awarded 2.5/30 points, while a penalty ranging from -0.5/30 to -1/30 points is applied for each wrong answer, depending on the difficulty of the question. Unanswered questions receive no penalty. The score for this task is calculated as the arithmetic sum of the points awarded and any penalties applied. - Two exercises on manufacturing topics (40 min. for a maximum score of 10/30 points). Each exercise can be awarded a maximum of 5/30 points. The score for this task is calculated as the arithmetic sum of the points awarded. The grade for the Manufacturing part (max 30/30) is calculated as the sum of the scores obtained in the multiple-choice quiz and in the exercises. This part is successfully passed if the student achieves a minimum grade of 18/30. b) Assembly part The Assembly part lasts 70 min. with a maximum grade of 30/30 points and consists of two tasks related to the topics addressed during the course: - Computer-based multiple-choice quiz on assembly topics (30 min. for a maximum score of 20/30 points). The quiz consists of 8 questions. For each question, the student must select 1 or 2 correct answers from 5 proposed alternatives. Each question answered correctly is awarded 2.5/30 points, while a penalty ranging from -0.5/30 to -1/30 points is applied for each wrong answer, depending on the difficulty of the question. Unanswered questions receive no penalty. The score for this task is calculated as the arithmetic sum of the points awarded and any penalties applied. - Two open-ended questions on assembly topics (40 min. for a maximum score of 10/30 points). Each open-ended question can be awarded a maximum of 5/30 points. The score for this task is calculated as the arithmetic sum of the points awarded. The grade for the Assembly part (max 30/30) is calculated as the sum of the scores obtained in the multiple-choice quiz and in the open-ended questions. This part is successfully passed if the student achieves a minimum grade of 18/30. Both the Manufacturing and Assembly parts must be passed in order to pass the whole exam; otherwise, the exam is failed. If a student passes only one of the two parts, for example the Manufacturing part, but fails the other, for example the Assembly part, the overall exam is failed. However, the student may keep the passing grade for the following exam sessions and retake only the failed part. Student enrolment in the exam session remains mandatory in all cases. Once both parts have been successfully passed, the overall exam can be registered. This opportunity is valid only until the beginning of the course in the next academic year (the end of February). After that date, any previously earned grade for a single part will expire. In both the Manufacturing and Assembly parts, students are not allowed to use textbooks, notes, blank sheets, or electronic devices, such as tablets, smartphones, smartwatches, etc. Only calculators, pencils, pens, and erasers are permitted. Blank sheets are provided by the professor. The expected ILOs assessed during the final exam are, with reference to the list of “expected learning outcomes”: 1–8, 10, 13. 3. EVALUATION CRITERIA AND CRITERIA FOR AWARDING MARKS The evaluation criteria are based on the correctness of the answers to the multiple-choice questions; the correctness of the solutions to the exercises; the relevance and clarity of the answers to the open-ended questions. Final grade The final grade is calculated as the arithmetic mean of the grades obtained in the Manufacturing and Assembly parts. Both parts must have been passed with a minimum grade of 18/30. Students may also complete all the homework assigned during the course in order to increase their final grade by an additional 2/30 points. This optional activity consists of solving exercises related to the topics covered in the course. The exercises will be provided by the professor, as Excel or Word files. Students must complete the exercises and submit them on the Moodle platform during the course by the deadlines communicated by the professor. An additional 2/30 points will be awarded only to students who submit all the homework assigned. This activity is optional and not compulsory. In summary: final grade = [grade of manufacturing part + grade of assembly part] /2 + homework grade The final grade is rounded to the nearest integer: it is rounded down if the first decimal digit is less than 5 and rounded up if the first decimal digit is 5 or greater. Exam results are communicated to students through the didactic portal, generally within 4–5 working days. Students may review their graded exams during a meeting with the professor. The meeting date will be communicated to students through a notice on the didactic portal before each exam session. Examples of previous exam formats and exercise solutions are available on the course portal.

In addition to the message sent by the online system, students with disabilities or Specific Learning Disorders (SLD) are invited to directly inform the professor in charge of the course about the special arrangements for the exam that have been agreed with the Special Needs Unit. The professor has to be informed at least one week before the beginning of the examination session in order to provide students with the most suitable arrangements for each specific type of exam.