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Politecnico di Torino
Academic Year 2014/15
01OFNLO
Production technologies for body components
Master of science-level of the Bologna process in Automotive Engineering - Torino
Teacher Status SSD Les Ex Lab Tut Years teaching
Minetola Paolo ORARIO RICEVIMENTO A2 ING-IND/16 30 30 0 0 10
SSD CFU Activities Area context
ING-IND/16 6 D - A scelta dello studente A scelta dello studente
Subject fundamentals
The module aims at providing the basic knowledge of the manufacturing processes for metal sheet parts and plastic components. Starting from the 3D CAD model of the part, all the steps that lead to the design and fabrication of production tooling are analysed by a Concurrent Engineering approach integrating modern CAD/CAM/CAE techniques.
Expected learning outcomes
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.
Prerequisites / Assumed knowledge
It is considered necessary the knowledge of Mechanical Drawing, Technology of Metallic Materials and Manufacturing Technology. Students must be familiar with the use of the Personal Computer.
Contents
Introduction
- Resume of car body frames, structures and body components
- Brief history of plastics
- Resume of the properties of plastic materials

Injection moulding process
- 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

Other manufacturing processes for plastic components
- Extrusion
- Blow moulding
- Thermoforming
- Compression moulding and transfer moulding
- Rotational moulding
Manufacturing processes for sheet metal parts
- General considerations
- Blanking and piercing operations
- Bending operations
- Forming operations
- Forming Limit Diagram
- Hydroforming operations
- Concepts of lightweight design and innovative technologies/materials.
Delivery modes
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.
Texts, readings, handouts and other learning resources
PowerPoint slides presented during the lectures will be provided on the course website.
The following books are suggested, but not strictly required:
-S. Kalpakjian, S.R. Schmid, Manufacturing Engineering & Technology (7th Edition), Prentice Hall.
-Suchy, 'Handbook of die design', McGraw-Hill.
-H. Gastrow, '130 proven mold design', 4th Edition, Peter Unger Ed.
Assessment and grading criteria
The aim of the final exam is to verify the studentís knowledge about manufacturing processes of car body components.
The final exam is composed by a written part and an oral part:
-the written exam will consist of open questions on topics covered during the lectures;
-the oral exam will consist in the discussion of the technical report.
The technical report must be submitted at least one week before the beginning of the exams session.

Programma definitivo per l'A.A.2014/15
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