The student is expected to learn a basics knowledge of main industrial processes for metal sheet parts and plastic components manufacturing. The application of time compression techniques in product/process design. The ability to design, by means of a CAD/CAM software, a simple mold/die for the fabrication of a metal sheet part and an injection molding product.

The student who follows the subject should have knowledge of Mechanical Drawing, Technology of Metallic Materials and Manufacturing Technology. Students must be familiar with the use of the Personal Computer.

Introduction (6h) - Resume of car body frames, structures and body components - Brief history of plastics - Resume of the properties of plastic materials Injection moulding process (24h) - Process description - Rheological behaviour of plastics - Analysis of the flow of the plastic melt during mould filling - Characteristics and components of an injection moulding machine - Design principles of a mould for injection moulding - 'The role of simulation in mould design - Optimization of moulding parameters - Photoetching and other finishing processes - Co-injection and multimaterial moulding - Gas assisted injection moulding Manufacturing processes for sheet metal parts (6h) - General considerations - Blanking and piercing operations - Bending operations - Forming operations - Forming Limit Diagram - Hydroforming operations - Concepts of lightweight design and innovative technologies/materials Training about the optimization of the injection moulding process and its parameters for the production of an automotive plastic part (24h).

Training at the Technological Lab of Mirafiori Campus about process simulation and optimization of molding conditions by means of a specific CAE software for injection moulding of plastic components. Training is aimed at developing a work in small groups and at preparing a technical report that will be evaluated during the final exam.

PowerPoint slides presented during the lectures will be provided on the course website. The following books are suggested, but not strictly required: -J. Lerma Valero, "Plastics Injection Molding", Hanser. -R. Dangel, "Injection Moulds for Beginners", Hanser. -H. Zhou, "Computer Modeling for Injection Molding: Simulation, Optimization, and Control", Wiley. -I. Suchy, "Handbook of die design", McGraw-Hill. -H. Gastrow, "130 proven mold design", 4th Edition, Peter Unger Ed.

Lecture slides; Lecture notes;

You can take this exam before attending the course

Exam: Written test; Group project;

The aim of the final exam is to verify the student’s knowledge about manufacturing processes of car body components. The final exam is composed of two parts: - a written exam about the topics covered during the lectures; - the evaluation of the technical report of the training. The written exam consists of five or six open questions and it is closed books and closed slides or notes. The duration of the written exam is about 2 hours. The written exam is aimed at the evaluation of student's knowledge about: 1) Polymers and their main properties; 2) Injection moulding process and design principles; 3) Injection moulding machine and its working cycle; 4) Manufacturing processes for sheet metal parts; 5) Concepts of lightweight design and innovative technologies/materials. The technical report about the project that was developed in group during the training is compulsory and it must be delivered at least a week before the beginning of the exam session. The technical report is aimed at the evaluation of student expertise through team working in the design and optimization of the injection moulding process for the production of an automotive component. The written exam contributes to the definition of the final grade for a maximum of 24 points out of 30. The grade is integrated by the evaluation of the technical report for a maximum of 6 additional points. In case of maximum grade (30 over 30), the honor is attributed at the discretion of the professor.

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.