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Politecnico di Torino
Academic Year 2017/18
01NINNE
Forming Processes and mould design
Master of science-level of the Bologna process in Mechanical Engineering - Torino
Teacher Status SSD Les Ex Lab Tut Years teaching
Minetola Paolo ORARIO RICEVIMENTO A2 ING-IND/16 58 42 0 0 10
SSD CFU Activities Area context
ING-IND/16 10 B - Caratterizzanti Ingegneria meccanica
Subject fundamentals
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.
Contents
Introduction
- 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
- Extrusion
- Blow moulding
- Thermoforming
- Compression moulding and transfer moulding
- Rotational moulding

Processing of metals by plastic deformation
- Introduction to plastic deformation
- Theory of plasticity
- Rolling
- Wire Drawing
- Forging and stamping

Manufacturing operations for sheet metal parts
- Introduction
- Piercing and blanking
- Bending
- Drawing
- Forming Limit Diagram
Delivery modes
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 manufacturing processes for polymeric components and forming processes of sheet metal parts.
The final exam is composed by two parts:
- a written exam about the topics covered during the lectures;
- a discussion with 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 technical report about the project that was developed in group during the practice hours must be delivered at least a week before the beginning of the exam session.

The written exam contributes to the definition of the final grade for a maximum of 24 points out of 30.
The oral 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.

Programma definitivo per l'A.A.2017/18
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