The subject aims to introduce the student to the design of mechanical and automotive structure with the particular target of lightweight. Lightweight targets can be pursued by using recently developed steels of the families of HSS and UHSS, by using light weight metallic alloys such as Aluminum or by using Fiber Reinforced Plastic such as Composite materials. Some times multi-material structures are considered, taking advantage from the particular properties and manufacturing technologies adopted to make mechanical components. The subject will in particular concentrate on the design with composite materials. Further some basic on the joining technique for multi-material structure will be introduced, with particular attention to adhesive joining. It is expected to develop some experimental lab activities. It is expected to have application testimonials from relevant industries.

To understand the need of lightweight, with particular reference to vehicles To compare the different properties of the materials, the related design procedure and manufacturing process To understand the mechanics of orthotropic materials To experimentally characterize composite materials

Machine Design.

1 – introductory notes on lightweight design and of different types of materials that can be adopted from HS steel and UHS stell, to light alloys to reinforced plastics 2 - classification of composite materials, typical matrix and typical reinforcing fibers 3 – micro-mechanical behaviour of the fiber reinforced composite material 4 – mechanical behaviour of composite lamina – orthotropy, stiffness and strength 5 – mechanical behaviour of composite laminate – constitutive equations, stiffness and interlaminar stress 6 – analysis of the material strength under complex loading conditions 7 – numerical modeling methodologies (FEM) 8 – design methodologies, joining of composite parts 9 – experimental test 10 – fatigue behaviour and impact behaviour of composite materials

Class hours will be equally subdivided in lectures and tutorials. During tutorials It is expected to develop some experimental lab activities. Results of the class exercises and of the Lab test are to be collected by each student in reports to be presented and discussed during the final exam.

1 – Tsai S. – Theory of Composite Design 2 – Halpin J.C. (1992) - Primer on composite materials analysis, Technomic 3 – Gay D., Hoa S.V. (2007) - Composite materials : design and applications - CRC 4 – Belingardi G. – notes and slides

Modalità di esame: Prova orale obbligatoria; Elaborato scritto individuale;

Exam: Compulsory oral exam; Individual essay. The final exam is finalized to assess the knowledge gained by each of the students on the subjects developed during lectures, tutorials and Labs. Final exam will consist in an oral exam dealing with the subjects developed during lectures and tutorials. Results of the class exercises and of the Lab test, collected by each student in reports, will be discussed and evaluated during the final exam in order to get a comprehensive assessment with respect to the said subject targets. The oral exam is devoted to verify the level of knowledge of the “Design of Lightweight and composite structures” topics that have been taught during the lectures. The ability of the student to explain from the theoretical point of view the asked questions, making use of formulas, diagrams and sketches, is of particular importance. Booking through the portal is mandatory. The final exam will take place, according to the general procedures defined by the Politecnico, through the PoliTo portal connection. The oral exam will take place either through the Exam platform or a different connection mode (e.g TEAMS). Detailed explanation of the rules and specific advices will be given through documents shared on the subject portal.

Modalità di esame: Prova orale obbligatoria; Elaborato progettuale individuale;

Compulsory oral exam; Individual essay. The final exam is finalized to assess the knowledge gained by each of the students on the subjects developed during lectures, tutorials and Labs. Final exam will consist in an oral exam dealing with the subjects developed during lectures and tutorials. Results of the class exercises and of the Lab test, collected by each student in reports, will be discussed and evaluated during the final exam in order to get a comprehensive assessment with respect to the said course targets. The oral exam is devoted to verify the level of knowledge of the “Design of Lightweight and composite structures” topics that have been taught during the lectures. The ability of the student to explain from the theoretical point of view the asked questions, making use of formulas, diagrams and sketches, is of particular importance. Booking through the portal is mandatory. The final exam will take place, according to the general procedures defined by the Politecnico. Depending on the general situation and according to the decision of the Politecnico, the oral exam could take place in a mixed mode: students that will be allowed to enter the Politecnico rooms could take the exam in the traditional mode, all the other students will take the exam through the PoliTo portal connection. Naturally, students will be informed in advance in a detailed way of this mix mode type. The oral exam that will take place in the remote mode, will be performed either through the Exam platform or a different connection mode (e.g TEAMS). Detailed explanation of the rules and specific advices will be given through documents shared on the subject portal.