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Politecnico di Torino
Academic Year 2017/18
01NLEJM
Manufacturing processes
1st degree and Bachelor-level of the Bologna process in Mechanical Engineering - Torino
Teacher Status SSD Les Ex Lab Tut Years teaching
De Maddis Manuela ORARIO RICEVIMENTO RC ING-IND/16 59 21 0 0 8
SSD CFU Activities Area context
ING-IND/16 8 B - Caratterizzanti Ingegneria meccanica
Subject fundamentals
The course is aimed at developing the knowledge of production methods typical of mechanical industry. Description is than given of plastic deformation processes of metals, of foundry techniques and of material removal processes, analyzing the relationships among them and the product requirements (i. e. performances and costs).
Expected learning outcomes
The knowledge of production processes utilized by the mechanical industry is necessary as the student must be capable of :
- choosing process technologies,
- choosing and, if required, collaborating in the design of production means;
- preparing the manufacturing cycle of the part, both in metal or polymeric materials.
At the end of the course the student must:
- know and apply the relationships between materials and processes;
- know and apply manufacturing techniques;
- know and apply basic performances of production means (machines, tools/moulds/dies, fixtures and measurement/testing instruments);
- know and apply process variables and their interactions with part requirements (quality, tolerances, surface roughness etc.)
- know and apply the right actions in order to minimize the part cost;
- know and apply the regulations concerning the industrial safety.
As to judgement independence and communication cleverness, the student must:
- write technical reports, also in English, with a high level of professionalism
- evaluate production problems and find quickly their solutions as he knows the interactions among the various players in the production process and he has a sufficient experience in the evaluation of the magnitude order of involved variables;
- get easily into touch with people, using English too.
Prerequisites / Assumed knowledge
Ability in technical drawing, as every production process starts from the detailed drawing of the component; extensive knowledge of materials, especially metal. The mastery of English, spoken and written is essential.
Contents
The course is aimed at developing the basic knowledge on manufacturing processes.
Through lectures, demonstrations, and practical applications, the students will be introduced to the different types of manufacturing processes with the aim of making them able to select the most economic process which best meets the design requirements.

The principal topics are:

Mechanical fundamentals:
ˑ Elastic and plastic behavior
ˑ Stress and strain
ˑ Stress and strain relationship for elastic behavior
ˑ Element of the theory of plasticity
Application to material testing
ˑ Tensile test. Bridgman correction. Effect of temperature and strain rate.
ˑ Compression test. W&F theory.
ˑ Hardness test
Fundamental of metalworking
Bulk deformation Process
ˑ Forging: open die forging process.
ˑ Forging: closed die forging.
ˑ Closed die design
ˑ Extrusions.
Material removal processes
ˑ Orthogonal cutting.
ˑ Chip types and chip removal mechanism.
ˑ Velocity relationship.
ˑ Cutting forces. Ernst & Merchant theory.
ˑ Cutting pressure. Cutting power.
ˑ Temperatures in cutting.
ˑ Oblique cutting.
Machining operations and machine tolls
ˑ Turning. Engine lathe, CNC lathes, fixtures, tools geometry, characteristic angles, forces, powers. Surface roughness
ˑ Milling: peripheral milling. Chip thickness. Cutting force. MRR. Helical milling cutter. Surface finish in milling. Working time.
ˑ Milling: face milling. Chip thickness. Cutting force, Working time.
ˑ Drilling: drill press e work holding. Cutting force and power. Drilling time Cutting tool technology
ˑ Toll wear. Toll life . Taylor and Kronenberg equations.
Economic and product design
ˑ Optimization of cutting condition. Cutting speed for maximum production and minimum cost.
Solidification processes
ˑ Fundamental of metal casting.
ˑ Sand Casting: from the draw to the pattern. Feeding system, gating system design, metallostatic force.
ˑ Casting manufacturing processes: discussion of several expandable and permanent mold processes.
ˑ Casting quality.
Manufacturing system
ˑ Computer Numerical Control. Programming (G-code, APT).
ˑ Program structure. CNC milling.
Delivery modes
During the course, the students will solve different practical exercises using numerical tools, such as excel, Q_Form and CNC simulator, and will visit the LATEC laboratory of the Polytechnic of Turin.
Texts, readings, handouts and other learning resources
Manufacturin Engineering and Technology
S. Kalpakjian, S.R. Schmid
Pearson

Fundamentals od Modern Manufacturing
Mikell P. Groover
John Wiley & sons, inc.

Mechanical Metallurgy
George E. Dieter
Mc Graw - Hill Book Company

Slides and exercices available on the Didactic Portal at the end of each lesson.
Assessment and grading criteria
The overall exam consists of two compulsory parts:

1) A written examination concerning the whole program and including theoretical questions (max 4 points) and practical exercises (max 20 points).
Score range is 0-24.
Time exam is 1,5 hours.
Students are allowed to use a personal formula sheet (a single A4 page) and a simple calculator (i.e. not scientific). Students cannot use any material, such as books or electronic devices (i.e. mobile phones/notebooks).

2) A homework on plastic deformation of metals and relative manufacturing processes.
Score range is 0-6.
The homework is developed in a team composed of 4-5 students.
Members of the teams are announced within the two-third of the lectures.
Each team is charged to face and analyze a case study using the tools and the methods introduced during the lectures and, at the end of their task, deliver a report on the performed activity and the obtained results.
The final report must be uploaded on the didactical portal using the tab "elaborati", one week before the first official session exam.
The report on the assigned case study must be presented and discussed by the team during the official exam session.
The personal evaluation of the homework is based on the report and the individual presentation and discussion of the case study.
Homework score will be valid only in the current A.Y.

The final exam score will be the sum of the marks obtained in the two parts. Students pass the exam if the sum ranges between 18 and 30 marks.
The student who does not upload the report within the deadline or doesn’t get a "pass" mark in the oral discussion can achieve a final exam score limited to the written exam evaluation.

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