Materials forming (Non metallic materials forming Technologies)

One of the paradigms of the so-called fourth industrial revolution (Industry 4.0) concerns the production of semi-finished and finished products with sustainable materials and processing technologies. Knowledge of the operating principles of both conventional and emerging forming technologies is essential for the correct selection and processing of materials for optimized and sustainable production activities. Based on these considerations, the course provides an introduction to the main processing technologies of non-metallic materials for the production of semi-finished and finished products. In particular, after an introduction to the rheological behavior of materials, conventional and emerging technologies for polymeric and composite materials will be described together with innovative forming technologies for ceramic materials. The criteria for selecting materials and technologies based on specific applications will also be discussed. The acquired knowledge will finally be used for the development of a group project on the selection of materials and transformation technologies suitable for the production of semi-finished or finished products.

Metal forming technologies

The course is aimed at deepening the knowledge related to the metal forming processes and technologies. After an introduction of the fundamental principles related to the different techniques, processes and the equipment used in metal forming will be examined. In particular, the manufacturing of finished parts, made of metal alloys and composites is studied and analyzed especially in terms of the applications of technology in different industrial sectors

Materials forming (Non metallic materials forming Technologies)

Knowledge and understanding on: - Rheology of polymeric fluids - Viscoelastic behavior of polymeric fluids - Fundamentals of conventional and emerging processing technologies for plastics and polymer-matrix and ceramic-matrix composites - Fundamentals of emerging ceramic processing technologies Apply knowledge and understanding and make judgments about: - Ability to select appropriate materials and processes for the production of a specific object/part (material selection in terms of physical-mechanical and functional properties, cost and sustainability; process selection in terms of geometry / size, productivity, cost and sustainability) Communication skills on: - Ability to draw up a technical report - Ability to present Learning skills on: - Ability to use professional databases for the selection of materials / processes

Metal forming technologies

A fundamental aspect of the course deals with the evaluation of characteristics and properties of the finished product, also as function of the adopted technology. A particular analysis will be devoted to the evaluation of the technical/economic aspects, also in terms of the results deriving from quality control. The close contact with the more relevant industries, by means of targeted visits, provides a practical content for the course, and promotes a continuous updating on evolution and technological innovation.

Materials forming (Non metallic materials forming Technologies)

- Fundamentals of science and technology of polymeric and ceramic materials (see contents of "Scienza e tecnologia dei materiali polimerici" and "Scienza e tecnologia dei materiali ceramici" - CL Ingegneria dei materiali) - Introduction to materials for advanced manufacturing (see contents of "Materials for Advanced Manufacturing" CLM Ingegneria dei materiali per l'industria 4.0)

Metal forming technologies

Knowledge related to the properties of metals and their alloys and on their plastic deformation, acquired during the BSc.

Materials forming (Non metallic materials forming Technologies)

I - Rheology of thermoplastic polymers. Chemo-rheology of thermoset polymers. II - Processing technologies for thermoplastic and thermoset polymers: compounding, extrusion, injection molding, blow molding and other technologies, additive manufacturing III - Processing technologies for polymer-matrix and ceramic-matrix composites: hand lay-up and spray lay-up, autoclave vacuum bagging, resin transfer molding, compression molding, filament winding IV - Advanced processing for ceramic materials: additive manufacturing V - Teamwork: Students' teams (max 5 students/team) - Material and process selection for the production of a specific object/part/component - Resources: Granta EduPack - Output: written technical report and related presentation

Metal forming technologies

FOUNDRY Principles of solidification of the alloys. Flow diagram and processing cycle typical of a foundry. Models, shapes and dies, traditional and special forming methods. Gravity casting, centrifugal casting and die casting. Investment Casting. Squeezecasting, Rheocasting, Thixomolding. Finishing operations and quality control; typical alloys and their fields of application, quality assurance. PLASTIC DEFORMATION Mold Casting and continuous casting. Recall of the theory of plasticity and of the theoretical fundamentals of the plastic deformation. Hot, semi-hot and cold deformation. Primary and secondary rolling. Forging, pressing, direct and inverse extrusion, drawing, blanking and forming of thin sheets. Residual stresses and analysis of the most common defects. Alloys for plastic deformation, properties and characteristics of the pieces obtained, quality control. POWDER METALLURGY Production Techniques and characterization of the product Pressing in molds: obtainable shapes and limits. Special compaction processes, cold and hot isostatic pressing. Sintering in furnaces: thermodynamic aspects of the process, furnaces and sintering atmospheres. Metal Injection Molding: characteristics and applications, raw materials and production cycle. FAST Techniques: SPS, EDS, CDS Free-form processes and 3D printing. Additive Manufacturing: main techniques and typical products DESIGN CRITERIA AND COST ANALYSIS Technical/economic comparison among the different alternative technologies and selection criteria for process optimization. Cost indexes. Design of a forming process, tools and form factors. In the laboratories, the characteristics of formability, properties and microstructural characteristics of the materials will be examined as function of the different technologies adopted, with the observation and analysis of finished pieces.

Materials forming (Non metallic materials forming Technologies)

Self-assessment sessions will be provided along with the course using an online based platform after each main topic of the course is completed.

Metal forming technologies

Self-assessment sessions will be provided along with the course using an online based platform after each main topic of the course is completed.

Materials forming (Non metallic materials forming Technologies)

The course is organized as follows: - theoretical lessons in the classroom (20-25 hours) - classroom exercises for the group project (analysis, discussion and review, 10-15 hours) - presentation and discussion of the technical reports of the group projects (about 5 hours)

Metal forming technologies

Analysis of a set of functional components, with the investigation of the different component parts, examination of the most proper materials for the manufacturing, choice of the molding process and design of the production cycle.

Materials forming (Non metallic materials forming Technologies)

- Slides and notes provide by the professor. - C. Bonten, Plastics technology, Hanser, 2019 (ISBN 978-1-56990-767-2; E-Book ISBN 978-1-56990-769-9)

Metal forming technologies

Kalpakjian, Mechanical Technology, Pearson, 2014 J. Beddoes, Principles of Metals Manuafcturing Processes, Elsevier, 2006 A. Salak, Ferrous Powder Metallurgy, Cambridge International Science Pub., 1995 G. Dieter, Mechanical Metallurgy, McGraw.Hill, Tokio, 1988. M.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Wiley, 2012 Slides used during classes are uploaded on the course portal web. Exercise lessons: the topic of the final project, practical exercises, materials and plants datasheet, parts of international standards and handbooks are given during front lessons and uploaded on the portal web.

Materials forming (Non metallic materials forming Technologies)

Slides; Libro di testo; Strumenti di collaborazione tra studenti;

Metal forming technologies

Dispense; Libro di testo; Strumenti di auto-valutazione;

Materials forming (Non metallic materials forming Technologies)

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

Metal forming technologies

Modalità di esame: Prova scritta (in aula);

Materials forming (Non metallic materials forming Technologies)

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

Metal forming technologies

Exam: Written test;

...

Materials forming (Non metallic materials forming Technologies)

The final grade of the "Materials forming" course (10 CFU) is given by the weighted average of the grades obtained in the modules "Metal forming technologies" (6 CFU) and "Non metallic materials forming technologies" (4 CFU). With regard to the "Non metallic materials forming technologies" module, the assessment is carried out with the following methods and criteria: - Test A: final written test (maximum grade 20 points). - Test B: written technical report and oral presentation of the group project (maximum grade 10 points). Test A consists of multiple choice questions (from 5 to 10) and open questions (from 3 to 5) on the topics illustrated during classroom lessons. Test A is carried out in the classroom using the student's personal PC and has a maximum duration of 60 minutes. Test B (delivery of the written technical report and oral presentation) is carried out in the classroom in the last week of the lesson. Alternatively, the test can be carried out on subsequent dates to be agreed. In the attribution of the final scores, the level of theoretical knowledge acquired and the ability to apply the knowledge acquired (Tests A and B) are predominantly assessed. The level of independent judgment and communication skills will also be taken into consideration (Test B).

Metal forming technologies

The verification of learning takes place through the final examination, which certifies the acquisition of knowledge and skill expectations. In particular, the examination consists of an oral test in which the analysis of the specific characteristics of the different manufacturing processes are considered and discussed. Students, divided in groups made of 2, will also be required to produce and illustrate into details a report on the proper manufacturing technique/s (at an industrial scale) of a given component, assigned during the course. Templates for the correct preparation and writing of the report will be shown during the course and made available on the portal. The final mark will take into account the level of knowledge of the topics of the exam, as well as the critical analysis and communication skills of the student.

Gli studenti e le studentesse con disabilità o con Disturbi Specifici di Apprendimento (DSA), oltre alla segnalazione tramite procedura informatizzata, sono invitati a comunicare anche direttamente al/la docente titolare dell'insegnamento, con un preavviso non inferiore ad una settimana dall'avvio della sessione d'esame, gli strumenti compensativi concordati con l'Unità Special Needs, al fine di permettere al/la docente la declinazione più idonea in riferimento alla specifica tipologia di esame.