Weight reduction is a key factor in many engineering applications especially for those ones interacting with the environment where future solutions will strategically require high strength/weight ratios. For this reason, multidisciplinary approaches are needed to satisfy the stringent requirements of reliability, failure prevention, mass reduction and global optimization of performances. The main focus of the course is on lattice structures made with metals from additive manufacturing. The course includes a survey on the main design and fabrication principles of lightweight structures: basic design methods, simulation through commercial tools, experimental methods and testing, manufacturing. Engineering solutions from real applications are explored and analyzed, focusing on their benefits, drawbacks, improvements and technical challenges. Practical experience will be provided by a visit to a metrological laboratory. Many disciplines are involved in the development of the tools usable for designing, validating and producing lightweight structures: structural mechanics, materials and manufacturing engineering, mathematics and others. Similarly, many tools are available to improve the design, such as finite elements methods (FEM), design for experiments (DOE), artificial intelligence (AI) algorithms for topology/shape optimization, etc. The final goal of the course is to provide a global view on lightweight structures and on the skills and tools suitable to their production.

Master degree in industrial, civil, materials engineering or other disciplines involved in the design of structures.

Contents - The course provides a basic and intermediate view on the use of lattice and lightweight design for structural components. - The course includes basics on theory, description of experimental practises and original laboratory results, methods for modeling complex cellular shapes with commercial tools, with special reference to nTopology. - The course also includes a visit to a laboratory and the practical description of metrological methods on real instruments. In summary - Introduction to lightweight structures, strategic role for sustainability, advancements and applications. - Methods for the shape design from the cell-based approach. - Methods for computational design based on numerical methods with different levels of discretization and overview on commercial tools (nTopology). - Visit of a metrological laboratory. - Energy-based methods for performances evaluation of lattice structures. - Additive manufacturing for lightweight structures: metals and polymers at macro and micro scales. - Failure occurrence in lattice structures based on real applications experiences. - Fatigue of lattice structures: theory, models and experimental methods. - Application of lightweight design to industrial cases. Program 1. Introduction 2. Structural optimization process 3. Lattices: basics of structural modeling 4. Lattices: static experimental characterization 5. Lattices: enegetic design methods 6. Lattices: fatigue 7. Numerical modeling tools (nTopology, Ansys) 8. Industrial case studies: aeronautic parking bracket, riveting tool. 9. Visit to metrology laboratory. Exam Short report (about 1 page) responding to one question about the contents of the course. It is possible to use notes and other material, not to use connected devices.

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P.D.1-1 - Gennaio