|Politecnico di Torino|
|Academic Year 2015/16|
Forming Processes and mould design
Master of science-level of the Bologna process in Mechanical Engineering - Torino
The main goal of the subject is the description and the analysis of the design phase and the fabrication of molds and dies for metal sheet parts and plastic components manufacturing. Lectures and laboratories provide a basic knowledge for the design of a mold/die and the selection of the materials for its production. All the steps leading to the design and fabrication of production tooling are analysed by a Concurrent Engineering approach through the integration of modern CAD/CAM/CAE techniques.
Expected learning outcomes
The knowledge of main issues related to design and fabrication of molds and dies for metal sheet parts and plastic components manufacturing. 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.
Prerequisites / Assumed knowledge
Assumed knowledge from the subjects of Mechanical Drawing, Technology of Materials and Treatments and Manufacturing Technology is considered necessary.
Students must be familiar with the use of the personal computer.
- Resume of the injection moulding process
- Resume on the characteristics of injection moulding machines
- Co-injection and multimaterial moulding
- Gas assisted injection moulding
Moulds for injection moulding
- Types of moulds and classification
- Preliminary analysis of the component to be moulded
- Feeding system of the mould
- Standard components
- Ejection systems
- Cooling system
- Mould venting
- Action moulds and inserts for part ejection
- Mould materials for plastics
- Finishing processes and photo-etching
- Mould design and cost estimation
- Examples of mould design
Other manufacturing processes for plastic components
- Blow moulding
- Compression moulding and transfer moulding
- Rotational moulding
Processing of metals by plastic deformation
- Introduction to plastic deformation
- Theory of plasticity
- Wire Drawing
- Forging and stamping
Manufacturing operations for sheet metal parts
- Piercing and blanking
- Forming Limit Diagram
Training at the RMLab of DIGEP Department about:
- Design by means of a CAD/CAM software of an injection mould;
- Process simulation and optimization of forming conditions for sheet metal parts by means of a specific CAE software.
Training is aimed at developing a work in small groups and at preparing a technical report that will be evaluated during the final exam.
Texts, readings, handouts and other learning resources
PowerPoint slides presented during the lectures will be provided on the subject website.
The following books are suggested, but not strictly required:
- S. Kalpakjian, S.R. Schmid, Manufacturing Engineering & Technology (7th Edition), Prentice Hall.
- H. Gastrow, '130 proven mold design', 4th Edition, Peter Unger Ed.
- J. Lubliner, 'Plasticity theory', Dover Publications.
- Suchy, 'Handbook of die design', McGraw-Hill.
Assessment and grading criteria
The aim of the final exam is to verify the studentís knowledge about injection moulds for plastic parts and forming processes of sheet metal parts.
The final exam is composed by two parts:
- an oral exam about the topics covered during the lectures;
- a discussion with evaluation of the technical report of the training.
The technical report must be submitted at least one week before the beginning of the exams session.
Programma definitivo per l'A.A.2015/16